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© 2001 PTC

TrainingExercises

VERICUT for Pro/ENGINEER

TrainingExercises

VERICUT for Pro/ENGINEER

Machine SimulationMachine Simulation

© 2001 PTC 2

IntroductionIntroduction

Terms ‘MS’ stands for ‘Machine Simulation’ in this exercise

Terms ‘MS’ stands for ‘Machine Simulation’ in this exercise

© 2001 PTC 3

Exercise 1 - OutlineExercise 1 - Outline

Outline 3 axis milling machine

Work in Pro/E Create machine components and assembly in Pro/E Export STL file of each machine component against Machine

Zero CSYS Create tool path file(NCL and TAP) using Pro/NC and G-Post

Work in VERICUT Machine Simulation Build machine kinematics in VERICUT Machine Simulation Load machine components (STL file) to VERICUT MS Load Control file Save MCH, CTL and JOB file in your working directory Test machine with MDI Job, Machine setting Create or load tool library file, tool gauge length setting Load tool path file and simulate tool path


Work in Pro/E Create machine components and assembly in Pro/E Export STL file of each machine component against Machine

Zero CSYS Create tool path file(NCL and TAP) using Pro/NC and G-Post

Work in VERICUT Machine Simulation Build machine kinematics in VERICUT Machine Simulation Load machine components (STL file) to VERICUT MS Load Control file Save MCH, CTL and JOB file in your working directory Test machine with MDI Job, Machine setting Create or load tool library file, tool gauge length setting Load tool path file and simulate tool path

© 2001 PTC 4

Exercise 1 - 3 axis milling machineExercise 1 - 3 axis milling machine

Build 3 axis milling machine and simulate tool path Work in Pro/E

Preparation Copy all the machine simulation exercise folder and files to your

computer, set Pro/E working directory to: …\exercise 1 Machine components and assembly

In Pro/E, Open file ‘3axis-mill.asm’

Build 3 axis milling machine and simulate tool path Work in Pro/E

Preparation Copy all the machine simulation exercise folder and files to your

computer, set Pro/E working directory to: …\exercise 1 Machine components and assembly

In Pro/E, Open file ‘3axis-mill.asm’

base-x-slide

x-axisy-axis

z-axis

stockfixture

z-axis-cylinder

base

base-z-slide

© 2001 PTC 5

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

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


© 2001 PTC 6

Export all of other components in STL format Tips

Choose the right Coordinate System - machine zero (ACSO) for all components, because there is no rotary axis on this machine

Give Chord Height: 0.1 or smaller Change file name 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’

Export all of other components in STL format Tips

Choose the right Coordinate System - machine zero (ACSO) for all components, because there is no rotary axis on this machine

Give Chord Height: 0.1 or smaller Change file name 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

stockfixture

z-axis-cylinder

base

base-y-slide

base-z-slide


© 2001 PTC 7


Work in VERICUT Machine Simulation Access VERICUT Machine Simulation

In command line, type in ‘proems’ then click enter Or click batch file ‘proems.bat’ (‘$PRO_DIRECTORY \bin\

proems.bat’) Choose: File/New

Save JOB file in your working directory (… \exercise 1) In MS, choose: File / Save as, give file name ‘3ax-mill.job’

Build machine kinematics In MS, choose: Machine / Components

Work in VERICUT Machine Simulation Access VERICUT Machine Simulation

In command line, type in ‘proems’ then click enter Or click batch file ‘proems.bat’ (‘$PRO_DIRECTORY \bin\

proems.bat’) Choose: File/New

Save JOB file in your working directory (… \exercise 1) In MS, choose: File / Save as, give file name ‘3ax-mill.job’

Build machine kinematics In MS, choose: Machine / Components

© 2001 PTC 8


Build components tree as following figure shows In components window, click Add Add base component: In Add components window, give type as base, color as cyan, then click

‘Apply’

Build components tree as following figure shows In components window, click Add Add base component: In Add components window, give type as base, color as cyan, then click

‘Apply’

ComponentsTree

© 2001 PTC 9


Using the same method to add other components, make sure ‘Type’, ‘Color’, motion axis, and ‘Connect To’ is right. See following figure for details.

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 PTC 10


Components: X-Linear, Fixture and Stock After finish last component - ‘Stock’, click OK in Add Component window

Components: X-Linear, Fixture and Stock After finish last component - ‘Stock’, click OK in Add Component window

X Linear Fixture Stock

© 2001 PTC 11


Load STL files to VERICUT MS Load base STL files

In Components window, choose ‘Base’ (Base is highlighted), click STL file icon Open file ‘base.stl’, (find this file in …\exercise 1 folder) Using the same method, load STL files: ‘base-y-slide.stl’, ‘base-z-slide.stl’, to component base.

Load STL files to VERICUT MS Load base STL files

In Components window, choose ‘Base’ (Base is highlighted), click STL file icon Open file ‘base.stl’, (find this file in …\exercise 1 folder) Using the same method, load STL files: ‘base-y-slide.stl’, ‘base-z-slide.stl’, to component base.

© 2001 PTC 12


Load STL files to other components Load ‘z-axis.stl’ and ‘z-axis-cylinder.stl’ to component Z Load ‘y-axis.stl’ to component Y Load ‘x-axis.stl’ to component X Load ‘fixture.stl’ to component Fixture Load ‘stock.stl’ to component Stock

Change color of Primitives In Components window, choose ‘base-y-slide.stl’, click ‘Atrib button’,

choose Color: White Using save method, change color of ‘base-z-slide.stl’ to white Change ‘z-axis-cylinder.stl’ to color white

Load STL files to other components Load ‘z-axis.stl’ and ‘z-axis-cylinder.stl’ to component Z Load ‘y-axis.stl’ to component Y Load ‘x-axis.stl’ to component X Load ‘fixture.stl’ to component Fixture Load ‘stock.stl’ to component Stock

Change color of Primitives In Components window, choose ‘base-y-slide.stl’, click ‘Atrib button’,

choose Color: White Using save method, change color of ‘base-z-slide.stl’ to white Change ‘z-axis-cylinder.stl’ to color white

© 2001 PTC 13


Change Tool connect position 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

In VERICUT MS, choose: Machine / Components In Components window, choose: ‘Tool’, then click Modify In Modify window, set Connect position=(0 0 15.2), then click

OK Close Components window

Change Tool connect position 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

In VERICUT MS, choose: Machine / Components In Components window, choose: ‘Tool’, then click Modify In Modify window, set Connect position=(0 0 15.2), then click

OK Close Components window

15.2

Gauge Point

Machine Zero

© 2001 PTC 14


Save machine file in your working directory In VERICUT MS, choose: Machine / Save as, give file name

‘3ax-mill.mch’, make sure you save it in …\exercise 1 folder Load control file

In VERICUT MS, choose: Control / Open, open file ‘generic.ctl’, find this control file in category ‘CGTECH_RP2LIB’

Save control file in your working directory In VERICUT MS, choose: Control / Save as, give file name

‘generic.ctl’, make sure save it in …\exercise 1 folder

Save machine file in your working directory In VERICUT MS, choose: Machine / Save as, give file name

‘3ax-mill.mch’, make sure you save it in …\exercise 1 folder Load control file

In VERICUT MS, choose: Control / Open, open file ‘generic.ctl’, find this control file in category ‘CGTECH_RP2LIB’

Save control file in your working directory In VERICUT MS, choose: Control / Save as, give file name

‘generic.ctl’, make sure save it in …\exercise 1 folder

© 2001 PTC 15


Test your machine with MDI In VERICUT MS, choose: Job / MDI Test X axis, type in ‘x10’ in MDI, click Apply. Notice movement

of X axis Test negative direction of X axis (x-10) Test Y and Z axis (Notes: if axis doesn’t move, check if

you load control file correctly)

Test your machine with MDI In VERICUT MS, choose: Job / MDI Test X axis, type in ‘x10’ in MDI, click Apply. Notice movement

of X axis Test negative direction of X axis (x-10) Test Y and Z axis (Notes: if axis doesn’t move, check if

you load control file correctly)

© 2001 PTC 16


Set machine table 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

In VERICUT MS, choose: Machine / Table 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

(Notes, Machine Table contents can also be defined in Job Table, if a Job Table is defined, it will over write Machine Table)

Set machine table 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

In VERICUT MS, choose: Machine / Table 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

(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 PTC 17


Set Travel Limits In VERICUT MS, choose: Machine / Travel Limits In Travel Limits window, type in Min and Max travel limits of

each axis, then click Modify See following figure for limits value of 3 axis Toggle Overtravel Detection On Click OK

Set Travel Limits In VERICUT MS, choose: Machine / Travel Limits In Travel Limits window, type in Min and Max travel limits of

each axis, then click Modify See following figure for limits value of 3 axis Toggle Overtravel Detection On Click OK

© 2001 PTC 18


Collision setup In VERICUT MS, choose: Job / Collision Set: Component 1=Fixture, Component 2=Tool, Tolerance=0.1 Toggle Collision Detection On Click OK

Collision setup In VERICUT MS, choose: Job / Collision Set: Component 1=Fixture, Component 2=Tool, Tolerance=0.1 Toggle Collision Detection On Click OK

© 2001 PTC 19


Tool library Method 1, retrieve tool library in VERICUT exercise 4a&b folder

copy file ‘cgtpro.tls’ from ‘VERICUT exercise 4a&b folder’, paste it in your current working directory - ‘VERICUT MS exercise 1 folder’

In VERICUT MS, choose: Tools / Tool File, open file ‘cgtpro.tls’, find it in your current working directory

Change tool gauge length. In VERICUT MS, choose: Tools / Tool Manager In Tool Manager window, click Modify

Tool library Method 1, retrieve tool library in VERICUT exercise 4a&b folder

copy file ‘cgtpro.tls’ from ‘VERICUT exercise 4a&b folder’, paste it in your current working directory - ‘VERICUT MS exercise 1 folder’

In VERICUT MS, choose: Tools / Tool File, open file ‘cgtpro.tls’, find it in your current working directory

Change tool gauge length. In VERICUT MS, choose: Tools / Tool Manager In Tool Manager window, click Modify

© 2001 PTC 20


In Tool Modify window, click Properties In Tool Properties window, set Gage Length=4, click OK In Tool Modify window, click OK In Tool Manager window, click Save, then Close

In Tool Modify window, click Properties In Tool Properties window, set Gage Length=4, click OK In Tool Modify window, click OK In Tool Manager window, click Save, then Close

© 2001 PTC 21


Method 2, create tool library in VERICUT MS by yourself In Tool Manager window, click Add In Tool Add window, give: ID=1, Description=‘1 inch FEM’, Choose FEM icon, give: Diameter=1, Length=4, click Add then click OK Save tool library file. In Tool Manager window, choose: File / Save as, give file name ‘3ax-

mill.tls’, save it in exercise 1 folder Close Tool Manager window Click ‘Yes’ in the small question window

Method 2, create tool library in VERICUT MS by yourself In Tool Manager window, click Add In Tool Add window, give: ID=1, Description=‘1 inch FEM’, Choose FEM icon, give: Diameter=1, Length=4, click Add then click OK Save tool library file. In Tool Manager window, choose: File / Save as, give file name ‘3ax-

mill.tls’, save it in exercise 1 folder Close Tool Manager window Click ‘Yes’ in the small question window

© 2001 PTC 22


Load tool path In VERICUT MS, choose Job / Setting In Job Settings window, open Toolpath file ‘tool-com.tap’, find

this file in exercise 1 folder Other settings: see following figure for details

For Log file, give file name: ‘3ax-mill.log’, and select exercise 1 folder In Job Setting window, click OK

Reset Machine Simulation

Run machine simulation

Load tool path In VERICUT MS, choose Job / Setting In Job Settings window, open Toolpath file ‘tool-com.tap’, find

this file in exercise 1 folder Other settings: see following figure for details

For Log file, give file name: ‘3ax-mill.log’, and select exercise 1 folder In Job Setting window, click OK

Reset Machine Simulation

Run machine simulation

© 2001 PTC 23



Build machine kinematics Load STL files Machine Table, Travel Limits, Collision setting Load tool library, set tool gauge length offset Load tool path file, control file Tool path simulation


Build machine kinematics Load STL files Machine Table, Travel Limits, Collision setting Load tool library, set tool gauge length offset Load tool path file, control file Tool path simulation

© 2001 PTC 24


Build 4 axis milling machine Build machine kinematics

See following figures for machine kinematics Make sure component Type, Connect to, Motion axis and

Connect Position is right Notice connect position of rotary axis A is: (0 0 4), Design

is: (0.5 0 0) (Notes: For Multi-Axis machine

uses CSYS on rotary centerline for rotary axis)

Build 4 axis milling machine Build machine kinematics

See following figures for machine kinematics Make sure component Type, Connect to, Motion axis and

Connect Position is right Notice connect position of rotary axis A is: (0 0 4), Design

is: (0.5 0 0) (Notes: For Multi-Axis machine

uses CSYS on rotary centerline for rotary axis)

© 2001 PTC 25


Build machine kinematics Build machine kinematics

© 2001 PTC 28


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

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

© 2001 PTC 29


Set Machine Table See following Machine Table figure for details

Set Travel limits See following Travel Limits figure for details

Save machine file Give file name: ‘prolight.mch’, save it in …\exercise 2 folder

Set Machine Table See following Machine Table figure for details

Set Travel limits See following Travel Limits figure for details

Save machine file Give file name: ‘prolight.mch’, save it in …\exercise 2 folder

© 2001 PTC 30


Job setting Load tool path file: ‘op010.tap’, find this file in …\exercise 2

folder Other settings, see following figure

Collision setup See following Collision Setup figure for details

Job setting Load tool path file: ‘op010.tap’, find this file in …\exercise 2

folder Other settings, see following figure

Collision setup See following Collision Setup figure for details

© 2001 PTC 31


Load tool library and set tool gauge length offset Load tool library file ‘ncmach_gage.tls’, find it in

…\exercise 2 folder Set gauge point at top of each tool

Control file Load control file ‘tmc2000.ctl’, find this file in

…\exercise 2 folder Save Job file

Give JOB file name: ‘prolight.job’, save it in …\exercise 2 folder

Tool path simulation

Load tool library and set tool gauge length offset Load tool library file ‘ncmach_gage.tls’, find it in

…\exercise 2 folder Set gauge point at top of each tool

Control file Load control file ‘tmc2000.ctl’, find this file in

…\exercise 2 folder Save Job file

Give JOB file name: ‘prolight.job’, save it in …\exercise 2 folder

Tool path simulation

Gauge Point

© 2001 PTC 32

Exercise 2a- OutlineExercise 2a- Outline

Outline 5 axis laser machine

In Pro/E, export components in STL format Base and linear axis - Against Machine Zero CSYS Rotary axis - Against CSYS at rotary center

Build machine kinematics, rotary axis and tool connect position calculation

Load STL files to machine Machine Table, initial machine location, RTCP pivot offset

calculation Load tool library and set gauge length offset Load tool path file, control file Tool path simulation

Outline 5 axis laser machine

In Pro/E, export components in STL format Base and linear axis - Against Machine Zero CSYS Rotary axis - Against CSYS at rotary center

Build machine kinematics, rotary axis and tool connect position calculation

Load STL files to machine Machine Table, initial machine location, RTCP pivot offset

calculation Load tool library and set gauge length offset Load tool path file, control file Tool path simulation

© 2001 PTC 33

Exercise 2a - 5 axis laser machineExercise 2a - 5 axis laser machine

Build 5 axis laser machine Preparation

Set Pro/E working directory to …\exercise 2a Open file ‘laserdyne.asm’

Export components in STL format Export base and all linear axis using CSYS

at machine zero

Build 5 axis laser machine Preparation

Set Pro/E working directory to …\exercise 2a Open file ‘laserdyne.asm’

Export components in STL format Export base and all linear axis using CSYS

at machine zero

Base

XAXIS

YAXIS

ZAXIS

Table

CAXIS

DAXIS

© 2001 PTC 34


Export rotary components (C and D axis) using CSYS at centerline of rotary axis

Using ‘ACS0’ for CAXIS, and ‘ACS1’ for DAXIS (Notes: Use same name as Pro/E part for STL files)

Export rotary components (C and D axis) using CSYS at centerline of rotary axis

Using ‘ACS0’ for CAXIS, and ‘ACS1’ for DAXIS (Notes: Use same name as Pro/E part for STL files)

CAXIS DAXIS

© 2001 PTC 35


Build machine kinematics & load STL files Base

Type: Base, Name: Base, Color: Blue , Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

XAXIS 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) Primitives: ‘xaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

ZAXIS 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) Primitives: ‘zaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

YAXIS 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) Primitives: ‘yaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Build machine kinematics & load STL files Base

Type: Base, Name: Base, Color: Blue , Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

XAXIS 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) Primitives: ‘xaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

ZAXIS 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) Primitives: ‘zaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

YAXIS 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) Primitives: ‘yaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC 36


CAXIS 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) Primitives: ‘caxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

DAXIS 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) Primitives: ‘daxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Tool 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) Table

Type: Other, Name: Table, Connect To: Base, Connect Position: (0 0 0) Color: Blue , Mixed Mode: Shade, Angles: (0 0 0)

Primitives: ‘table.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

CAXIS 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) Primitives: ‘caxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

DAXIS 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) Primitives: ‘daxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Tool 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) Table

Type: Other, Name: Table, Connect To: Base, Connect Position: (0 0 0) Color: Blue , Mixed Mode: Shade, Angles: (0 0 0)

Primitives: ‘table.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC 37


Design Type: Design, Name: Design, Connect To: Table, Connect Position: (0 0 0) Color: Green ,

Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘test_laserdyne.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Design Type: Design, Name: Design, Connect To: Table, Connect Position: (0 0 0) Color: Green ,

Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘test_laserdyne.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Components Tree

© 2001 PTC 38


Rotary axis & tool connect position calculation C-axis connect position is measured from Machine Zero to C-axis CSYS D-axis connect position is measured from C-axis CSYS to D-axis CSYS Tool connect position is measured from D-axis CSYS to Gauge Point (in this case it is

Machine Zero)

Rotary axis & tool connect position calculation C-axis connect position is measured from Machine Zero to C-axis CSYS D-axis connect position is measured from C-axis CSYS to D-axis CSYS 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 PTC 39


Set machine table Set Initial Machine Location=(0 0 20) Set RTCP pivot offset=(0 -16.5 15)

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 )

Save machine file

Set machine table Set Initial Machine Location=(0 0 20) Set RTCP pivot offset=(0 -16.5 15)

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 )

Save machine file

-16.5

15

© 2001 PTC 40


Load tool library and set gauge length offset Load file ‘tool.tls’, find it in exercise 2a folder Set gauge offset=8

Load control Load control file ‘laserdyne.ctl’, find it in exercise 2a folder

Load Toolpath file Load file ‘op010.tap’, find it in exercise 2a folder

Save JOB file

Run simulation

Load tool library and set gauge length offset Load file ‘tool.tls’, find it in exercise 2a folder Set gauge offset=8

Load control Load control file ‘laserdyne.ctl’, find it in exercise 2a folder

Load Toolpath file Load file ‘op010.tap’, find it in exercise 2a folder

Save JOB file

Run simulation

© 2001 PTC 41


Outline Build your own machine

Choose one machine from list shown in next 7 slides Build machine components and assembly in Pro-E Export components in STL format against right CSYS Create machine kinematics in VERICUT Machine Simulation Load machine components (STL file) to VERICUT MS Load control file (fan16M, find it in category of

CGTECH_RP2LIB) and save it in your current directory Machine & Job setting Test your machine with MDI Create or load tool library file, set tool gauge length Create Post-Processor (optional), generate TAP file Load a tool path file (TAP file), run simulation

Outline Build your own machine

Choose one machine from list shown in next 7 slides Build machine components and assembly in Pro-E Export components in STL format against right CSYS Create machine kinematics in VERICUT Machine Simulation Load machine components (STL file) to VERICUT MS Load control file (fan16M, find it in category of

CGTECH_RP2LIB) and save it in your current directory Machine & Job setting Test your machine with MDI Create or load tool library file, set tool gauge length Create Post-Processor (optional), generate TAP file Load a tool path file (TAP file), run simulation

© 2001 PTC 42

Exercise 3 - Build your own machineExercise 3 - Build your own machine

3 Axis Vertical Mill3 Axis Vertical Mill 3 Axis Horizontal Mill3 Axis Horizontal Mill

© 2001 PTC 43


4 Axis Vertical Mill Table A4 Axis Vertical Mill Table A

4 Axis Horizontal Mill Table B4 Axis Horizontal Mill Table B

© 2001 PTC 44


5 Axis Vertical MillHead A on B5 Axis Vertical MillHead A on B

5 Axis Vertical MillHead B / Table A5 Axis Vertical MillHead B / Table A

© 2001 PTC 45


5 Axis Vertical Milltables A on C5 Axis Vertical Milltables A on C

5 Axis Horizontal MillHeads A on B5 Axis Horizontal MillHeads A on B

© 2001 PTC 46


5 Axis Horizontal Milltables B on A5 Axis Horizontal Milltables B on A

5 Axis Horizontal MillHead A / Table B5 Axis Horizontal MillHead A / Table B

© 2001 PTC 47


5 Axis Gantry Mill - Heads B on C5 Axis Gantry Mill - Heads B on C

© 2001 PTC 48


5 Axis Gantry Mill - Heads A on B5 Axis Gantry Mill - Heads A on B

© 2001 PTC 49

Exercise 4, 4a, 4bExercise 4, 4a, 4b

Exercise 4 Menu View

Attributes View Select/Store

Exercise 4a Menu Job

Job Setting Job Table Collision

Exercise 4b Menu Machine

Machine Tables Travel Limits

Exercise 4 Menu View

Attributes View Select/Store

Exercise 4a Menu Job

Job Setting Job Table Collision

Exercise 4b Menu Machine

Machine Tables Travel Limits

© 2001 PTC 50

Exercise 4 - Menu/ViewExercise 4 - Menu/View

Menu View Open file ‘prolight.job’ in …\exercise 4 folder

Attributes In VERICUT MS, choose: View / Attributes Show CSYS

Toggle Component Origin, Primitive Origin and Machine Zero On, then click Apply

CSYS appears

Menu View Open file ‘prolight.job’ in …\exercise 4 folder

Attributes In VERICUT MS, choose: View / Attributes Show CSYS

Toggle Component Origin, Primitive Origin and Machine Zero On, then click Apply

CSYS appears

© 2001 PTC 51


Draw Mode Choose Draw Mode=Lines, click Apply, notice the change Choose Draw Mode=Hidden, click Apply, notice the change Change Draw Mode back to ‘Shade’ You can also use the icon show below to switch draw mode Usage of line mode, when simulation, if tool is not shown up,

you can switch to line mode, find where tool is

Draw Mode Choose Draw Mode=Lines, click Apply, notice the change Choose Draw Mode=Hidden, click Apply, notice the change Change Draw Mode back to ‘Shade’ You can also use the icon show below to switch draw mode Usage of line mode, when simulation, if tool is not shown up,

you can switch to line mode, find where tool is

Line Hidden

© 2001 PTC 52


View Select/Store Choose: View / Orient. In Orientation window, click ISO icon Choose: View / Select/Store. In Select/Store View window,

click Add In View Add window, give view name: ‘iso1’, then click OK Using same method, add XY and YZ view You can switch view by clicking view name

View Select/Store Choose: View / Orient. In Orientation window, click ISO icon Choose: View / Select/Store. In Select/Store View window,

click Add In View Add window, give view name: ‘iso1’, then click OK Using same method, add XY and YZ view You can switch view by clicking view name

© 2001 PTC 53

Exercise 4a - Menu/JobExercise 4a - Menu/Job

Menu Job Job Setting

Choose: Job / Setting In Job Setting, click ‘Select (beside output file)’ to specify

output APT file name(ex4a.apt) and directory(…\exercise 4) In Job Setting, click ‘Select (beside Log File)’ to specify

output Log file name(ex4a.apt) and directory(…\exercise 4) In Job Setting window, Click OK Toggle Conversion: On Reset VERICUT MS Run simulation Find file ‘ex4a.apt’ and ‘ex4a.log’

in your …\exercise 4 folder

Menu Job Job Setting

Choose: Job / Setting In Job Setting, click ‘Select (beside output file)’ to specify

output APT file name(ex4a.apt) and directory(…\exercise 4) In Job Setting, click ‘Select (beside Log File)’ to specify

output Log file name(ex4a.apt) and directory(…\exercise 4) In Job Setting window, Click OK Toggle Conversion: On Reset VERICUT MS Run simulation Find file ‘ex4a.apt’ and ‘ex4a.log’

in your …\exercise 4 folder

© 2001 PTC 54


Job Table (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)

Choose: Job / Tables, in Job Table window, select ‘Initial Machine Location’, give Values= (0 0 12), click Add then Close

Reset VERICUT MS, see change of initial machine location Delete Job Table contents

Job Table (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)

Choose: Job / Tables, in Job Table window, select ‘Initial Machine Location’, give Values= (0 0 12), click Add then Close

Reset VERICUT MS, see change of initial machine location Delete Job Table contents

© 2001 PTC 55


Collision Choose: Job / Collision 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’

Reset VERICUT MS, run simulation During simulation, both A axis and tool are in error color-red Change tolerance back to ‘0.1’

Collision Choose: Job / Collision 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’

Reset VERICUT MS, run simulation During simulation, both A axis and tool are in error color-red Change tolerance back to ‘0.1’

© 2001 PTC 56

Exercise 4b - Menu/MachineExercise 4b - Menu/Machine

Menu Machine Tables

Choose: Machine / Tables In Machine Tables, change Initial Machine Location values

to: (0 0 12), click Modify, then close Reset VERICUT MS, notice change of machine initial

location Change it back to (0 0 8) (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 Tables

Choose: Machine / Tables In Machine Tables, change Initial Machine Location values

to: (0 0 12), click Modify, then close Reset VERICUT MS, notice change of machine initial

location Change it back to (0 0 8) (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 PTC 57

Exercise 4b - Menu/MachineExercise 4b - Menu/Machine

Travel Limits Choose: Machine / Travel Limits Change Z limits to: (Min=-1, Max=7), click Modify Toggle Overtravel Detection On, click OK Reset VERICUT MS, run simulation Z axis becomes red (error color) during simulation. An error

message also appears in message line. Open Log file to view error information

Change Z limits back to (-1, 8)

Travel Limits Choose: Machine / Travel Limits Change Z limits to: (Min=-1, Max=7), click Modify Toggle Overtravel Detection On, click OK Reset VERICUT MS, run simulation Z axis becomes red (error color) during simulation. An error

message also appears in message line. Open Log file to view error information

Change Z limits back to (-1, 8)

© 2001 PTC 58


Outline Run VERICUT and Machine Simulation simultaneously

Machine simulation setting Change Fixture and Stock connection position Job Table setting Job Setting Load tool library, set gauge length offset

VERICUT Setting Tool retract setting

Outline Run VERICUT and Machine Simulation simultaneously

Machine simulation setting Change Fixture and Stock connection position Job Table setting Job Setting Load tool library, set gauge length offset

VERICUT Setting Tool retract setting

© 2001 PTC 59

Exercise 5 - Run VERICUT & Machine Simulation simultaneously Exercise 5 - Run VERICUT & Machine Simulation simultaneously

Run VERICUT and Machine Simulation simultaneously Machine Simulation setting

Open file ‘3ax-mill.job’, find it in exercise 5 folder Notes: differences between this job file and the one in exercise

1 are: Fixture and Stock STL files are replaced by those in VERICUT exercise 6 - ‘sub.usr’ Tool library file is replaced by ‘tools.tls’ in VERICUT exercise 6-’sub.usr’

We find fixture and stock are not in right position

Run VERICUT and Machine Simulation simultaneously Machine Simulation setting

Open file ‘3ax-mill.job’, find it in exercise 5 folder Notes: differences between this job file and the one in exercise

1 are: Fixture and Stock STL files are replaced by those in VERICUT exercise 6 - ‘sub.usr’ Tool library file is replaced by ‘tools.tls’ in VERICUT exercise 6-’sub.usr’

We find fixture and stock are not in right position

© 2001 PTC 60

Exercise 5 - Run VERICUT & Machine Simulation simultaneouslyExercise 5 - Run VERICUT & Machine Simulation simultaneously

Move fixture and stock to center of machine table In VERICUT MS, choose: Machine / Components In Components window, choose ‘Fixture’, then click ‘Modify’ In Modify Component window, give connect position (-12.5,

-12.5, 1) Hint: Fixture Dimension is (25x25x1), by setting connect

position, it is moved 12.5 inch left, 12.5 inch back and 1 inch up

Move fixture and stock to center of machine table In VERICUT MS, choose: Machine / Components In Components window, choose ‘Fixture’, then click ‘Modify’ In Modify Component window, give connect position (-12.5,

-12.5, 1) 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 PTC 61


Job table setting Set Input Program Zero

In VERICUT MS, choose: Job / Tables 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 (Notes, distance from gauge point to machine table is: 15.2, fixture thickness is: 1)

Job table setting Set Input Program Zero

In VERICUT MS, choose: Job / Tables 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 (Notes, distance from gauge point to machine table is: 15.2, fixture thickness is: 1)

15.2

X

YZ

© 2001 PTC 62


Set work offset (fixture offset) Refer Job Table figure on last slide, and VERICUT exercise 6 (sub.usr) for details (Notes: Stock thickness is 2)

Job setting Choose: Job / Settings Select tool path file ‘sub.tap’ in exercise 5 folder Give Log file name: ‘3ax-mill.log’, save it in exercise 5 folder 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)

Set work offset (fixture offset) Refer Job Table figure on last slide, and VERICUT exercise 6 (sub.usr) for details (Notes: Stock thickness is 2)

Job setting Choose: Job / Settings Select tool path file ‘sub.tap’ in exercise 5 folder Give Log file name: ‘3ax-mill.log’, save it in exercise 5 folder 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 PTC 63


Test your machine with MDI Give (X0Y0Z0), machine should be at position as following figure shows Rest machine simulation

Test your machine with MDI Give (X0Y0Z0), machine should be at position as following figure shows Rest machine simulation

XZ plane YZ plane

© 2001 PTC 64


Load tools and Set gauge length offset In VERICUT MS, choose: Tools / Tool File, open file ‘tools.tls’,

find it in exercise 5 folder Tool gauge length setting

Choose: Tools / Tool Manager In Tool Manager window, choose a tool then click ‘Modify’ In Tool Modify window, choose Tool Properties In Tool Properties window, give tool gauge length value Change gauge point of all five tools to the most top point of each tool

Load tools and Set gauge length offset In VERICUT MS, choose: Tools / Tool File, open file ‘tools.tls’,

find it in exercise 5 folder Tool gauge length setting

Choose: Tools / Tool Manager In Tool Manager window, choose a tool then click ‘Modify’ In Tool Modify window, choose Tool Properties In Tool Properties window, give tool gauge length value Change gauge point of all five tools to the most top point of each tool

Gauge point

© 2001 PTC 65


Save machine file, save job file Set Layout to 3 views Run simulation

Save machine file, save job file Set Layout to 3 views Run simulation

© 2001 PTC 66


VERICUT Setting Open user file ‘sub.usr’, find it in exercise 5 folder

Machine simulation window is opened too (Notes: this user file is same as the one in VERICUT exercise

6) Change user file setting

In VERICUT, choose: Toolpath / Toolpath Control In toolpath control window, choose toolpath file ‘sub.tap’(it’s in VERICUT MS exercise 5 folder)

VERICUT Setting Open user file ‘sub.usr’, find it in exercise 5 folder

Machine simulation window is opened too (Notes: this user file is same as the one in VERICUT exercise

6) Change user file setting

In VERICUT, choose: Toolpath / Toolpath Control In toolpath control window, choose toolpath file ‘sub.tap’(it’s in VERICUT MS exercise 5 folder)

© 2001 PTC 67


G-Code setting In G-Code Setting window, open Job file ‘3ax-mill.job’, find this file in VERICUT MS exercise 5

folder. Close window Right after successfully change Job file, machine appears in VERICUT MS window.

Save User file Resize VERICUT, and Machine Simulation window Run simulation (Hint: you can control simulation in both

window)

G-Code setting In G-Code Setting window, open Job file ‘3ax-mill.job’, find this file in VERICUT MS exercise 5

folder. Close window Right after successfully change Job file, machine appears in VERICUT MS window.

Save User file Resize VERICUT, and Machine Simulation window Run simulation (Hint: you can control simulation in both

window)

© 2001 PTC 68


Tool retract setting We find there is a gouge in both fixture and stock, it because

that there is no tool retract when tool changing Set tool retract

In VERICUT MS, choose: Modals / Tooling In Tooling window, change Tool Change Retract Method to ‘Retract (Z-Axis only)’,then click

OK (Notes: this can also be set in VERICUT / Toolpath / Toolpath Control / G-Code setting) Save Job file, reset VERICUT Run simulation, now everything is running well

Tool retract setting We find there is a gouge in both fixture and stock, it because

that there is no tool retract when tool changing Set tool retract

In VERICUT MS, choose: Modals / Tooling In Tooling window, change Tool Change Retract Method to ‘Retract (Z-Axis only)’,then click

OK (Notes: this can also be set in VERICUT / Toolpath / Toolpath Control / G-Code setting) Save Job file, reset VERICUT Run simulation, now everything is running well

© 2001 PTC 69

Exercise 6, 6a - OutlineExercise 6, 6a - Outline

Exercise 6 Menu Control

Use Control/Subroutine Create main program and subroutine Load subroutine to control Load new toolpath file (main program)

Exercise 6a Menu Modals

Control simulation Slow down machine simulation Stop simulation when error occurs

Exercise 6 Menu Control

Use Control/Subroutine Create main program and subroutine Load subroutine to control Load new toolpath file (main program)

Exercise 6a Menu Modals

Control simulation Slow down machine simulation Stop simulation when error occurs

© 2001 PTC 70

Exercise 6 - Menu/ControlExercise 6 - Menu/Control

Use Control / Subroutine Create new main program and subroutine file

Create two new text file in exercise 6 folder, named ‘main-program.tap’ and ‘subroutine.sub’

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 Create new main program and subroutine file

Create two new text file in exercise 6 folder, named ‘main-program.tap’ and ‘subroutine.sub’

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 PTC 71


(Notes, we divided toolpath file to two files, main program and subroutines)

Load subroutine to Control In VERICUT MS, choose: Control / Subroutines In Subroutine window, open file ‘subroutine.sub’, find it in

exercise 6 folder Choose file ‘subroutine.sub’, click ‘Insert’, then click OK

(Notes, we divided toolpath file to two files, main program and subroutines)

Load subroutine to Control In VERICUT MS, choose: Control / Subroutines In Subroutine window, open file ‘subroutine.sub’, find it in

exercise 6 folder Choose file ‘subroutine.sub’, click ‘Insert’, then click OK

© 2001 PTC 72


Change toolpath file Choose: Job / Job Setting, change toolpath file to ‘main-

program.tap’ Run simulation

(Note 1: Subroutine can also be defined in: Job / Subroutine) (Note 2: When M98 is executed)

1. Search the remainder of the current tool path file for the specified subroutine 2. If not found, access job subroutine files for the specified subroutine 3. If still not found, access control subroutine

files for the specified subroutine

Change toolpath file Choose: Job / Job Setting, change toolpath file to ‘main-

program.tap’ Run simulation

(Note 1: Subroutine can also be defined in: Job / Subroutine) (Note 2: When M98 is executed)

1. Search the remainder of the current tool path file for the specified subroutine 2. If not found, access job subroutine files for the specified subroutine 3. If still not found, access control subroutine

files for the specified subroutine

© 2001 PTC 73

Exercise 6a Menu/ModalsExercise 6a Menu/Modals

Control machine simulation Open file ‘3ax-mill.job’, find it in exercise 6 folder

Slow down machine movements In VERICUT MS, choose: Modals / Motion / Max Distance Give Max Distance=0.1, run machine simulation Notice speed difference Change Max Distance back to 0

Control machine simulation Open file ‘3ax-mill.job’, find it in exercise 6 folder

Slow down machine movements In VERICUT MS, choose: Modals / Motion / Max Distance Give Max Distance=0.1, run machine simulation Notice speed difference Change Max Distance back to 0

© 2001 PTC 74

Exercise 6a Menu/ModalsExercise 6a Menu/Modals

Stop simulation when an error occurs In VERICUT, choose: Modals / General / Max Errors Give Max Errors=1 Toggle ‘Collision Detection’(find it in menu: Job / Collision)

and ‘Over Travel Detection’(find it in menu: Machine / Travel Limits) On

Run simulation It stops when an error occurs

Stop simulation when an error occurs In VERICUT, choose: Modals / General / Max Errors Give Max Errors=1 Toggle ‘Collision Detection’(find it in menu: Job / Collision)

and ‘Over Travel Detection’(find it in menu: Machine / Travel Limits) On

Run simulation It stops when an error occurs

© 2001 PTC 75


Turning machine Build turning machine

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

Turning machine Build turning machine

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

© 2001 PTC 76

Exercise 7 - Turning machineExercise 7 - Turning machine

Build turning machine In Pro/E, export STL file of each component (optional)

Export all components except Turret against machine Zero CSYS

Machine Zero is located at right plane center of spindle

Build turning machine In Pro/E, export STL file of each component (optional)

Export all components except Turret against machine Zero CSYS

Machine Zero is located at right plane center of spindle

Z

X

Machine Zero

© 2001 PTC 77


Export Turret Use CSYS-ACS4 It is at located at left plane center of turret

Export Turret Use CSYS-ACS4 It is at located at left plane center of turret

© 2001 PTC 78


Build machine kinematics Read next two pages for details Find STL files in exercise 7 folder

Build machine kinematics Read next two pages for details Find STL files in exercise 7 folder

Base

SpindleFixture

Stock

Z-axis

X-axis

Turret

© 2001 PTC 79


Machine components Base

Type: Base, Name: Base, Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) Primitives: ‘base-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0)

Spindle 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) Primitives: ‘spindle.stl’, Color, inherit, Position (0 0 0), Angle (0 0 0)

Fixture Type: Fixture, Name: Fixture, Connect To: Spindle, Connect Position: (0 0 0) Color:

5Magenta , Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘fixture.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Stock Type: Stock, Name: Stock, Connect To: Fixture, Connect Position: (0 0 0) Color: 6Yellow ,

Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘stock.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)









© 2001 PTC 80


Z 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) Primitives: ‘z-axis.stl’, Color, Inherit,Rapid Rate, 200, Position (0 0 0), Angle (0 0 0) Primitives: ‘z-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0

X 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) Primitives: ‘x-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Turret 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) (Notes: Offset value is measured from machine zero to left plane center of turret) Primitives: ‘turret.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Tool 1 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)




3Light Steel Blue, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘x-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Turret Type: B Turret, Name: Turret, Motion Axis, Z, Connect To: X, Connect Position: (12.9103, 0,



Red, Mixed Mode: Shade, Angles: (0 0 0)

© 2001 PTC 81



Magenta, Mixed Mode: Shade, Angles: (0 0 -90) Save machine file in exercise 7 folder, give file name

‘2xturn.mch’ Add control file to machine

use control file ‘2xturn-inch.ctl’, find it in exercise 7 folder


Magenta, Mixed Mode: Shade, Angles: (0 0 -90) Save machine file in exercise 7 folder, give file name

‘2xturn.mch’ Add control file to machine

use control file ‘2xturn-inch.ctl’, find it in exercise 7 folder

© 2001 PTC 82


About control file A super group ‘Toolchange’

must be in control file to enable turret rotation when tool change.

See right box for details Open control file

‘2xturn-inch.ctl’ to find this super group

About control file A super group ‘Toolchange’


See right box for details 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"



}MACRO "TurretRetract"MACRO "TurretIndex"MACRO "TurretLoadTool"MACRO "TurretActivateTool"MACRO "DwellTime" {

OVERRIDE_VALUE 29.1655 }MACRO "DwellMacro"

}WORD_VALUE "T 3" {


}MACRO "XAxisIncreMotion" {

OVERRIDE_VALUE 0 }MACRO "ZAxisIncreMotion" {

OVERRIDE_VALUE 0 }MACRO "ToolOffsetIndex"MACRO "ToolOffsetUpdate2"MACRO "ToolOffsetAptAdj2"MACRO "CutterCompValue"MACRO "ToolNoseCompValue"

}}

© 2001 PTC 83


Set Input Program Zero Choose: Job / Tables In Job Tables window, choose: ‘Input Program Zero’, see

following figure for other parameters setting Give Index=1 (Note 1: Values (-12.9103, 0, -8) is measured from left plane

center of turret to right plane center of stock) (Note 2: We are going to use right plane center of stock as

programming center)

Set Input Program Zero Choose: Job / Tables In Job Tables window, choose: ‘Input Program Zero’, see

following figure for other parameters setting Give Index=1 (Note 1: Values (-12.9103, 0, -8) is measured from left plane

center of turret to right plane center of stock) (Note 2: We are going to use right plane center of stock as

programming center)

X

Z

© 2001 PTC 84


Test your machine with MDI X0Z0 position is shown in the following figure Stock and turret center lines are coincident Right plane of stock and left plane of turret are adjacent

Test your machine with MDI X0Z0 position is shown in the following figure Stock and turret center lines are coincident Right plane of stock and left plane of turret are adjacent

© 2001 PTC 85


Transfer tools from Pro/NC to VERICUT Open MFG file in Pro/NC

Change Pro/E working directory to …\exercise 7 Open MFG file ‘turn.mfg’, In Pro/NC, choose: CL Data / NC Check / CL File (open

‘turn.ncl’) /Done Run simulation, exit VERICUT (Notes, by running VERICUT simulation, tools data can be

transferred from Pro/NC to VERICUT automatically, which will be called in VERICUT MS)

Load tool library to VERICUT MS In VERICUT MS, choose: Tools / Tool File Open file ‘cgtpro.tls’, find this file in exercise 7 folder

Transfer tools from Pro/NC to VERICUT Open MFG file in Pro/NC

Change Pro/E working directory to …\exercise 7 Open MFG file ‘turn.mfg’, In Pro/NC, choose: CL Data / NC Check / CL File (open

‘turn.ncl’) /Done Run simulation, exit VERICUT (Notes, by running VERICUT simulation, tools data can be

transferred from Pro/NC to VERICUT automatically, which will be called in VERICUT MS)

Load tool library to VERICUT MS In VERICUT MS, choose: Tools / Tool File Open file ‘cgtpro.tls’, find this file in exercise 7 folder

© 2001 PTC 86


Set Tool gauge offset In VERICUT MS, choose: Tools / Tool Manager In Tool Manager window, choose Tool 1, then click Modify In Tool Modify window, choose Properties In Tool Properties window, change Gage Offsets to: (7, 0,

0.25) Change Tool 2 gauge offset to (7 0 0.25) Save tool library Close Tool Manager window

Set Tool gauge offset In VERICUT MS, choose: Tools / Tool Manager In Tool Manager window, choose Tool 1, then click Modify In Tool Modify window, choose Properties In Tool Properties window, change Gage Offsets to: (7, 0,

0.25) Change Tool 2 gauge offset to (7 0 0.25) Save tool library Close Tool Manager window

© 2001 PTC 87


Load tool path file In VERICUT MS, choose: Job / Setting In Job Setting window, load tool path file to ‘turn.tap’, find in

exercise 7 folder Change Log file to ‘2xturn.log’, save it in exercise 7 folder See following figure for other settings

Load tool path file In VERICUT MS, choose: Job / Setting In Job Setting window, load tool path file to ‘turn.tap’, find in

exercise 7 folder Change Log file to ‘2xturn.log’, save it in exercise 7 folder See following figure for other settings

© 2001 PTC 88


Build Tool Index Table In VERICUT MS, choose: Tools / Tables 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.

Close Tool Tables window. Save JOB file

Give JOB file name ‘2xturn.job’, save it in exercise 7 folder

Build Tool Index Table In VERICUT MS, choose: Tools / Tables 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.

Close Tool Tables window. Save JOB file

Give JOB file name ‘2xturn.job’, save it in exercise 7 folder

© 2001 PTC 89


Run simulation

Check dimension after simulation Use Analysis / X-Caliper to check diameters, D1 and D2,

see if it is same as design model in Pro/NC

Run simulation

Check dimension after simulation Use Analysis / X-Caliper to check diameters, D1 and D2,

see if it is same as design model in Pro/NC

D1 D2

© 2001 PTC 90


Outline Mill/Turn machining center

Create components and assembly in Pro/E Export components in STL format

Linear components Rotary components

Build machine kinematics and load STL files Set input program zero Load control file, mill-turn control introduction Create MFG file in Pro/NC, generate TAP file using PP Run NC Check to transfer tools and Stock data from Pro/NC

to VERICUT, which will be used later Load tool library file to Machine Simulation. Set turning tool

gage offset Load Tool path file

Outline Mill/Turn machining center

Create components and assembly in Pro/E Export components in STL format

Linear components Rotary components

Build machine kinematics and load STL files Set input program zero Load control file, mill-turn control introduction Create MFG file in Pro/NC, generate TAP file using PP Run NC Check to transfer tools and Stock data from Pro/NC

to VERICUT, which will be used later Load tool library file to Machine Simulation. Set turning tool

gage offset Load Tool path file

© 2001 PTC 91


Build tool list Set Turret rotation angle for milling tools Play Machine Simulation Run VERICUT and Machine Simulation simultaneously

Open USR file Load stock file Set toolpath orientation Load Tool library file Load Tool path file G-Code setting, connect USR file with a JOB file Open Machine Simulation form VERICUT

Run VERICUT and Machine Simulation together

Build tool list Set Turret rotation angle for milling tools Play Machine Simulation Run VERICUT and Machine Simulation simultaneously

Open USR file Load stock file Set toolpath orientation Load Tool library file Load Tool path file G-Code setting, connect USR file with a JOB file Open Machine Simulation form VERICUT

Run VERICUT and Machine Simulation together

© 2001 PTC 92

Exercise 8 - Mill/Turn Exercise 8 - Mill/Turn

Build Mill/Turn machining center Load machine components and assembly in Pro/E

Set Pro/E working directory to: …\exercise 8\machine-proe\ Open file: ‘mill-turn.asm’ Find all components and

assembly file in folder: …\exercise 8\machine-proe\

Build Mill/Turn machining center Load machine components and assembly in Pro/E

Set Pro/E working directory to: …\exercise 8\machine-proe\ Open file: ‘mill-turn.asm’ Find all components and

assembly file in folder: …\exercise 8\machine-proe\

© 2001 PTC 93

Exercise 8 - Mill/TurnExercise 8 - Mill/Turn

Export components in STL format Export non rotary components

It includes all components except ‘turret’ and ‘tool-holder’ User CSYS in machine zero, it is located at right side plane

center of spindle Take both ‘z-slide’ components when exporting ‘z-side’, same

comments for ‘x-slide’ Use ‘0.1’ or smaller for chord height Give STL files same name as proe

part

Export components in STL format Export non rotary components

It includes all components except ‘turret’ and ‘tool-holder’ User CSYS in machine zero, it is located at right side plane

center of spindle Take both ‘z-slide’ components when exporting ‘z-side’, same

comments for ‘x-slide’ Use ‘0.1’ or smaller for chord height Give STL files same name as proe

partX

Z

ACS3

© 2001 PTC 94


Export rotary components It includes ‘turret’ and four ‘tool-holder’ Use CSYS (ACS4) at rotating center of turret Export four holder components separately, give them name

‘holder-1, holder-3, holder-5, holder-7. See following figure for holder number and location

Export rotary components It includes ‘turret’ and four ‘tool-holder’ Use CSYS (ACS4) at rotating center of turret 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-3Holder-7

© 2001 PTC 95


Build machine kinematics See following figure and next 3 pages for details Tips

Make sure Tool Index Number is set right Make sure Angle is right

Build machine kinematics See following figure and next 3 pages for details Tips

Make sure Tool Index Number is set right Make sure Angle is right

© 2001 PTC 97





3Light Steel Blue, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘x-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) Primitives: ‘x-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0)

Y 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) Primitives: ‘y-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)




3Light Steel Blue, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) Primitives: ‘x-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) Primitives: ‘x-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0)

Y 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) Primitives: ‘y-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC 98


Turret Type: B Turret, Name: Turret, Motion Axis, Z, Connect To: Y, Connect Position: (12.9103, 0,


Tool 1 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 Primitives: ‘holder-1.stl’, Color, Inherit, Position (-4.5,0,5.5), Angle (0 0 0)

Tool 3 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 Primitives: ‘holder-3.stl’, Color, Inherit, Position (0, -4.5,5.5), Angle (0 0 0)


Magenta, Mixed Mode: Shade, Angles: (0 0 0) , Tool Index Number: 5 Primitives: ‘holder-5.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

Turret Type: B Turret, Name: Turret, Motion Axis, Z, Connect To: Y, Connect Position: (12.9103, 0,


Tool 1 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 Primitives: ‘holder-1.stl’, Color, Inherit, Position (-4.5,0,5.5), Angle (0 0 0)

Tool 3 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 Primitives: ‘holder-3.stl’, Color, Inherit, Position (0, -4.5,5.5), Angle (0 0 0)



© 2001 PTC 99





Magenta, Mixed Mode: Shade, Angles: (0 0 45) , Tool Index Number: 2 Tool 4

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

Save machine file, give name: ‘mill-turn.mch’




Magenta, Mixed Mode: Shade, Angles: (0 0 45) , Tool Index Number: 2 Tool 4

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

Save machine file, give name: ‘mill-turn.mch’

© 2001 PTC 100


Set Input program zero It is measured from left side turret plane center to right side

stock plane center Load Control file

Open control file ‘mill-turn.ctl’ Save JOB file, ‘mill-turn.job’ Test your machine with MDI

Set Input program zero It is measured from left side turret plane center to right side

stock plane center Load Control file

Open control file ‘mill-turn.ctl’ Save JOB file, ‘mill-turn.job’ Test your machine with MDI X

Z

X0Y0Z0

© 2001 PTC 101


About Mill-Turn Control A super group ‘Toolchange’


About Mill-Turn Control A super group ‘Toolchange’


SUPERGROUP "Toolchange" {WORD_VALUE "T" {

COND_AND "G" "65" {MACRO "MacroVar"





}MACRO "TurretRetract"MACRO "TurretIndex"MACRO "TurretLoadTool"MACRO "TurretActivateTool"MACRO "DwellTime" {

OVERRIDE_VALUE 29.1655 }MACRO "DwellMacro"

}WORD_VALUE "T 3" {


}MACRO "XAxisIncreMotion" {

OVERRIDE_VALUE 0 }MACRO "ZAxisIncreMotion" {

OVERRIDE_VALUE 0 }MACRO "ToolOffsetIndex"MACRO "ToolOffsetUpdate2"MACRO "ToolOffsetAptAdj2"MACRO "CutterCompValue"MACRO "ToolNoseCompValue"

}}

© 2001 PTC 102


Mill/Turn mode change macro must be in M_Misc Supergroup Mill/Turn mode change macro must be in M_Misc Supergroup

WORD_VALUE "M" "35" {MACRO "VC_ModeMilling"

}WORD_VALUE "M" "36" {

MACRO "VC_ModeTurning"}

© 2001 PTC 103


X multiplier X multiplier for word X must match the setting in Lathe post-processor

X multiplier X multiplier for word X must match the setting in Lathe post-processor

© 2001 PTC 104


MFG file in Pro/NC Set Pro/E working directory to: …\exercise 8\mfg-pronc\ Open file: ‘mill-turn-2.mfg’ Create NCL file for whole operation, give name: ‘mill-

turn.ncl’ Performing NC Check to transfer Tools from Pro/NC to

VERICUT In Pro/NC, choose: CL Data / NC Check / CL File / (choose file

‘mill-turn.ncl’) /Done Create TAP file

Using Post-Processor ‘fan16t’ to post the NCL file, give TAP file name ‘mill-turn.tap’

PP ‘fan16t’ is merged with PP ‘fan16m’, it is a mill/turn merged post-processor

MFG file in Pro/NC Set Pro/E working directory to: …\exercise 8\mfg-pronc\ Open file: ‘mill-turn-2.mfg’ Create NCL file for whole operation, give name: ‘mill-

turn.ncl’ Performing NC Check to transfer Tools from Pro/NC to

VERICUT In Pro/NC, choose: CL Data / NC Check / CL File / (choose file

‘mill-turn.ncl’) /Done Create TAP file

Using Post-Processor ‘fan16t’ to post the NCL file, give TAP file name ‘mill-turn.tap’

PP ‘fan16t’ is merged with PP ‘fan16m’, it is a mill/turn merged post-processor

© 2001 PTC 105


Load Tool and Tool Path file Copy file ‘cgtpro.tls’ and ‘mill-turn.tap’ to folder …\exercise

8\VERICUT. Change file name of ‘cgtpro.tls’ to ‘mill-turn.tls’ Load tool library

In VERICUT MS, choose: Tools / Tool File, open file ‘mill-turn.tls’

Set turning tool gage offset Set both turning tool (T2 and T4) gage offset to (7, 0, 0.25).

Refer Exercise 7 for details

Load Tool and Tool Path file Copy file ‘cgtpro.tls’ and ‘mill-turn.tap’ to folder …\exercise

8\VERICUT. Change file name of ‘cgtpro.tls’ to ‘mill-turn.tls’ Load tool library

In VERICUT MS, choose: Tools / Tool File, open file ‘mill-turn.tls’

Set turning tool gage offset Set both turning tool (T2 and T4) gage offset to (7, 0, 0.25).

Refer Exercise 7 for details

© 2001 PTC 106


Load Tool path file In VERICUT MS, choose: Job / Job Setting Load tool path file ‘mill-turn.tap’

Build tool list Choose: Tools / Tables / Tool Index Table /Build Tool List Reset Machine Simulation, tools appear on turret

Load Tool path file In VERICUT MS, choose: Job / Job Setting Load tool path file ‘mill-turn.tap’

Build tool list Choose: Tools / Tables / Tool Index Table /Build Tool List Reset Machine Simulation, tools appear on turret

© 2001 PTC 107


Set turret rotation angle for two milling tools Turret rotation angle only need to be set for milling tools Choose: Tools / Tables / Turret Rotation, see following

figure for details, index # here reflects Tool ID # Turret rotates this angle when the tool is called in tool path

file The angle is measured from the tool original orientation to

dash line (position when tool in use) Save JOB file

Set turret rotation angle for two milling tools Turret rotation angle only need to be set for milling tools Choose: Tools / Tables / Turret Rotation, see following

figure for details, index # here reflects Tool ID # Turret rotates this angle when the tool is called in tool path

file The angle is measured from the tool original orientation to

dash line (position when tool in use) Save JOB file

X

Y

Tool 1

Tool 3

Rotate To

© 2001 PTC 108


Play simulation Reset VERICUT MS, play simulation

Run VERICUT and Machine Simulation simultaneously USR file setting

Copy files ‘cgpro.usr’ and ‘cgpro1.stk’ in folder …\exercise 8\mfg-pronc\ then paste then in folder …exercise 8\vericut\

Change USR file name to: ‘mill-turn.usr’ Open USR file ‘mill-turn.usr’

Load stock file. In VERICUT choose: Model / Model Definition / Stock / (open polygon file ‘cgtpro1.stk’) / Apply

Play simulation Reset VERICUT MS, play simulation

Run VERICUT and Machine Simulation simultaneously USR file setting

Copy files ‘cgpro.usr’ and ‘cgpro1.stk’ in folder …\exercise 8\mfg-pronc\ then paste then in folder …exercise 8\vericut\

Change USR file name to: ‘mill-turn.usr’ Open USR file ‘mill-turn.usr’

Load stock file. In VERICUT choose: Model / Model Definition / Stock / (open polygon file ‘cgtpro1.stk’) / Apply

© 2001 PTC 109


Set Toolpath orientation In VERICUT, choose: Toolpath / Toolpath Orientation Give (0 0 7) for Ref(XYZ) Notice that from right side of stock (input programming zero) to it primitive origin is 7

Set Toolpath orientation In VERICUT, choose: Toolpath / Toolpath Orientation Give (0 0 7) for Ref(XYZ) Notice that from right side of stock (input programming zero) to it primitive origin is 7

7

© 2001 PTC 110


Load Tool library file In VERICUT, choose: Tools / Tool Control / Tool Library (open

tool library file ‘mill-turn.tls’) / OK

Load Tool library file In VERICUT, choose: Tools / Tool Control / Tool Library (open

tool library file ‘mill-turn.tls’) / OK

© 2001 PTC 111


Load Tool path file In VERICUT, choose: Toolpath / Toolpath Control In Toolpath Control window, open Tool path file ‘mill-turn.tap’,

set toolpath type=G-Code Data, Multiple Toolpath Files=No

Load Tool path file In VERICUT, choose: Toolpath / Toolpath Control In Toolpath Control window, open Tool path file ‘mill-turn.tap’,

set toolpath type=G-Code Data, Multiple Toolpath Files=No

© 2001 PTC 112


G-code settting In Toolpath Control window, choose G-code setting In G-Code Setting window, choose: File / Open (open file ‘mill-

turn.job’) Choose: File / Close Choose Ok in Tool path control window

Connect to Machine Simulation In VERICUT, choose: Applications / Machine Simulation

G-code settting In Toolpath Control window, choose G-code setting In G-Code Setting window, choose: File / Open (open file ‘mill-

turn.job’) Choose: File / Close Choose Ok in Tool path control window

Connect to Machine Simulation In VERICUT, choose: Applications / Machine Simulation

© 2001 PTC 113


Resize VERICUT and Machine Simulation window Click Play button (in either window)

Resize VERICUT and Machine Simulation window Click Play button (in either window)

global solutions innovation collaboration © 2001 ptc training exercises vericut for pro/engineer...

Documents

machine slide

test machine

vericut machine simulation

build machine kinematics

load tool path file

slide slide

job file

slide components