PROFILE MILLING (CAM)

EXERCISE 1
In this exercise we will define a profile milling NC Sequence to machine the vertical walls of a block.
The topics covered in this exercise are as follows
�� Defining a new Profile Milling NC Sequence
�� Selecting the surfaces using Loop option
�� Creating smooth entry/exit motions
�� Optimizing the entry/exit conditions
Set the working directory to INSERT and open the manufacturing model insert.mfg.
For better visualization it is good to display the workpiece in wireframe. So select View>View Manager or pick icon to launch the View Manager Dialog box and double click the predefined style state Wireframe.
Select to exit the dialog box.
To define a new profile milling NC Sequence select Machining>NC Sequence >Profile>Done.
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In the SEQ SETUP menu add Name to the list of checked items and select Done.
Enter the sequence name PROFILE and pick icon or middle-click.
In the Tools Setup dialog box pick FEM20 from the list and select .
In the MFG PARAMS menu, select Set and enter the parameters as follows.
CUT_FEED
1200
STEP_DEPTH
5
SPINDLE_SPEED
3000
CLEAR_DIST
1
Pick to apply the changes and exit the Parameter Tree Dialog box.
Select Done in the MFG PARAMS menu to proceed.
Now the SURF PICK menu appears. This menu gives us three options to select the surfaces to be faced. Model option is selected by default as shown below.
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As we want to select the surfaces from the reference part, so select Done.
Model option is used to select surfaces to be milled from reference part.
In the SURF/LOOP menu select Loop.
Loop option is used to select a closed loop of surfaces by choosing a face they surround.
Now select the top face of the reference model as shown below.
After picking the top surface (face), system will select the closed loop of surfaces that surround the top surface as shown below.
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Select Done>Done>Done to complete the selection of surfaces
To display the toolpath on screen, select Play Path>Screen Play. Play Path Dialog box will appear.
Click the Play Forward button and toolpath will appear as shown below.
Zoom to the toolpath and look at it carefully, you will notice that the tool plunges directly to the next slice.
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Direct Plunge is not a good practice. So to introduce smooth entry/exit into the cut, pick and set the following parameters.
LEAD_RADIUS
30
LEAD_IN
YES
LEAD_OUT
YES
Pick to apply the changes and exit the Parameter Tree Dialog box.
Now play the tool path using PLAY PATH dialog box. From TOP view it will appear as shown below.
Although now tool enters and exits into the cut very smoothly but it is wasting a lot of time in non-cutting motion. To reduce this non-cutting time, again pick and set the following parameters.
ENTRY_ANGLE
50
EXIT_ANGLE
50
Pick to apply the changes and exit the Parameter Tree Dialog box.
Now play the tool path using PLAY PATH dialog box. From TOP view it will appear as shown below.
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Notice that the non-cutting motion has been reduced significantly. The Entry and Exit angles must be sufficient large so that tool makes the plunge motion when it is out of the workpiece.
The entry/exit parameters can be readily understood from the figure below.
It is always advantageous to use a large LEAD_RADIUS because the larger the radius smoother the entry/exit into cut. But it also increases the idle time while the tool completes its non-cutting movement. To reduce this non-cutting time we have set the ENTRY_ANGLE and EXIT_ANGLE to a smaller value than default. By doing this we have achieved both i.e. smoother motion by setting a large LEAD_RADIUS value and reduction in non-cutting time by smaller entry/exit angles.
As the toolpath looks satisfactory so change the following parameters for final toolpath computation.
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STEP_DEPTH
2
Select Done Seq to complete the definition of the NC Sequence.
Select File>Save to save the manufacturing model.
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EXERCISE 2
In this exercise first we will define a Mill Surface to find the area which previous Ball End Mill cutter could not machine. Then we will machine this surface with a Profile Milling NC Sequence. We will also learn how to setup a new retract plane, at the desired Z level, during the definition of NC Sequence.
The topics covered in this exercise are as follows
�� Defining a Mill Surface as “Machinable Area”
�� Creating smooth entry/exit motions
�� Setting up Retract plane at NC Sequence level
The Machinable Area Mill Surface is an advanced technique that calculates whether the selected surfaces can be entirely machined with the selected cutting tool, and creates explicit surface representations of the millable area (the portion of the selected surfaces that can be milled), as well as of the remainder area (the portion that can not be milled with the selected tool).
This technique allows to automate surface selection for subsequent machining with a smaller tool or with a different machining strategy.
You have to specify surfaces to be milled, additional surfaces for gouge checking (if any), the cutting radius of a ball end mill tool and the tool axis orientation. The system then calculates the machinable area based on tool contact and gouge avoidance.
The manufacturing model, referred in this exercise, has been finish machined in the previous chapter “Volume and Local Milling” with a ball end mill of diameter 10mm. So for this exercise we assume that the reference model was previously finished with the ball end mill.
Set the working directory to TOP_COVER and open the manufacturing model top_cover.mfg
To create mill surface, select Mfg Setup>Mfg Geometry>Mill Surface>Create.
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Enter MS_A as the name of mill surface and pick icon or middle-click.
In the SURF DEFINE menu select Add>Advanced>Done>Machinable Area>Done.
System will ask to select the surfaces for finding the machinable area. So pick the highlighted surface of reference model shown in the figure below.
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Select or middle-click to proceed.
In the SRF PRT SEL menu, check the Add Ref Prts option then select Done.
When Add Ref Prts (Add Reference Parts) option is checked, system uses all the surfaces of the reference model to check gouging against.
Now the system will ask to enter radius of ball end mill for calculating Machinable Area.
So enter 5.2 and pick icon or middle-click.
Although we should enter 5 as we used Ball end mill of diameter 10 to machine the cavity in a previous NC Sequence but we have entered a larger value just to make sure that we get smooth surface quality.
Now select the top surface of the reference model as the direction reference.
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You may also pick the retract plane or any other surface or plane that is parallel to the retract plane.
Make sure that arrow points upward then select Okay.
This direction of the arrow specifies the tool axis orientation.
Double click the Srf Option in the dialog box.
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In the MILLABLE OR REMAINING menu select Find Remaining Area>Done.
Find Remaining Area option finds the portion of the surface that can not be milled with the specified tool.
Select to exit the dialog box. The surface will appear as shown below.
Now we will trim the unwanted part of the surface.
In the SRF DEFINE menu select Trim>Done>Both Sides>Done.
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Pick ASM_RIGHT as the sketch plane then select Okay in the DIRECTION menu.
Select Right in the SKET VIEW menu and pick the ASM_TOP datum as reference.
Now sketch the following cross section.
Pick to complete the section
In the MATERIAL SIDE menu pick Side 1>Done to keep the inner side of the sketch.
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Side 1 is represented by single arrow on screen as shown below.
Select Done
Select to exit the dialog box.
Make sure that Thru All is highlighted in the DETPH menu then pick Done.
The mill surface will appear as shown below.
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Select Done>Done>Done to return to the main menu.
To define a new profile milling NC Sequence select Machining>NC Sequence >Profile>Done.
In the SEQ SETUP menu add Name to the list of checked items and select Done.
Enter the sequence name CORNER and pick icon or middle-click.
In the Tools Setup dialog box pick FEM10 from the list then select .
In the MFG PARAMS menu select Set and enter the parameters as follows.
CUT_FEED
1200
STEP_DEPTH
.5
SPINDLE_SPEED
4000
COOLANT_OPTION
ON
CLEAR_DIST
1
LEAD_IN
YES
LEAD_OUT
YES
LEAD_RADIUS
20
ENTRY_ANGLE
15
EXIT_ANGLE
15
Pick to apply the changes and exit the Parameter Tree Dialog box.
Select Done in the MFG PARAMS menu to proceed.
In SURF PICK menu select Mill Surface>Done.
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Now pick Select Srf and select the above defined mill surface MS_A.
In the DIRECTION menu select Okay after making sure that arrow points away from the surface. This direction indicates side of surface to be machined.
In the SEL/SEL ALL menu pick Select All to select all the surfaces included in the mill surface.
This menu gives the option to select only desired surface patches included in the Mill Surface quilt or complete mill surface.
Select Done to complete the selection of surfaces
Play the toolpath using PLAY PATH dialog box. It should appear as shown below.
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You will notice that after every pass, tool retracts to the retract plane and then traverses above the start point of the next pass. We can reduce the non-cutting time of tool by setting up a new retract plane at a lower level.
So select Seq Setup and check the Retract option then pick Done.
In the Retract Selection dialog box pick .
Enter -5 in Enter Z Depth input field and select .
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Play the toolpath using PLAY PATH dialog box. It should appear as shown below.
As the toolpath looks satisfactory so change the following parameters for good surface finish.
STEP_DEPTH
.2
Remember never to use WALL_SCALLOP_HGT parameter for controlling the surface finish, while machining with a flat end mill.
Select Done Seq to complete the definition of the NC Sequence
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Select File>Save to save the manufacturing model.
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EXERCISE 3
In this exercise we will define a profile milling NC Sequence to machine a sharp corner with a single pass of cutter.
Set the working directory to COVER_INSERT and open the manufacturing model cover_insert.mfg.
To define a new profile milling NC Sequence select Machining>NC Sequence >Profile>Done.
In the SEQ SETUP menu add Name to the list of checked items and select Done.
Enter the sequence name CORNER and pick icon or middle-click.
In the Tools Setup dialog box pick FEM25 from the list then select .
In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED
1200
STEP_DEPTH
50
SPINDLE_SPEED
3000
COOLANT_OPTION
ON
CLEAR_DIST
1
LEAD_IN
YES
LEAD_OUT
YES
LEAD_RADIUS
20
The large value of STEP_DEPTH will force the tool to machine only the last slice.
Pick to apply the changes and exit the Parameter Tree Dialog box.
Select Done in the MFG PARAMS menu to proceed.
In SURF PICK menu select Done and select the model surfaces (while holding down the Ctrl key) as shown in the figure below.
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Select Done>Done to complete the selection of surfaces
Play the toolpath using PLAY PATH dialog box and notice that the tool is machining the complete surface with a single pass only as shown below.
Select Done Seq to complete the definition of the NC Sequence.
Select File>Save to save the manufacturing model.
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EXERCISE 4
In this exercise we will use the profile milling NC Sequence to finish a hole. We will also learn the following
�� How to control the plunge location of the tool
�� How to perform multi-pass machining
�� How to create CL data for a given NC Sequence.
�� How to mirror the CL Data.
We assume that the hole has been previously drilled with the drill of diameter 12mm.
Set the working directory to LID_CAVITY and open the manufacturing model lid_cavity.mfg.
To define a new profile milling NC Sequence select Machining>NC Sequence >Profile>Done.
In the SEQ SETUP menu add Name to the list of checked items and select Done.
Enter the sequence name FINISH and pick icon or middle-click.
In the Tools Setup dialog box select FEM10 from the list and select .
In the MFG PARAMS menu select Set and enter the parameters as follows.
CUT_FEED
1200
STEP_DEPTH
2
SPINDLE_SPEED
5000
COOLANT_OPTION
ON
CLEAR_DIST
1
LEAD_RADIUS
8
LEAD_IN
YES
LEAD_OUT
YES
Pick to apply the changes and exit the Parameter Tree Dialog box.
Select Done in the MFG PARAMS menu to proceed.
In SURF PICK menu select Done and select the right hole surfaces while holding down the Ctrl key. The selected surfaces are shown below.
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Select Done>Done to complete the selection of surfaces.
Play the toolpath using PLAY PATH dialog box. It should appear as shown below.
Notice that there is no lead in or lead out motion. It is so because lead radius value we have specified is larger than the radius value toolpath consists of. This fact can be elaborated by the following figure.
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In this case tool will gouge the part while making lead in or lead out motion therefore system has ignored them.
So we should set the lead radius less than 5 to make sure that tool makes lead in and lead out motions.
So set the following parameter in parameter tree dialog box.
LEAD_RADIUS
4
Play the toolpath using Screen Play. It should appear as shown below.
As we assumed at the start of the exercise that the hole was pre-drilled with the drill of diameter 12mm. So the tool will be cutting material during plunge motion because there is enough material at the walls of the hole. The tool must plunge to the next slice at the center of the hole to avoid cutting of material during plunge motion.
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Select Seq Setup and check the Build Cut option then pick Done.
Select Approach and make sure that Each Slice option is highlighted then pick Done
Select the axis AA_1 as start point.
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Select Exit and make sure that Each Slice option is highlighted then pick Done.
Select the axis AA_1 as exit point.
Pick Done in the NC BUILD CUT menu.
Pick and set the following parameters
PLUNGE_FEED
100
PLUNGE_FEED parameter controls the feed rate along the plunge motion. By default it is set to dash (-) in which case the CUT_FEED is used as PLUNGE_FEED.
Pick to apply the changes and exit the Parameter Tree Dialog box.
Select Done in the MFG PARAMS menu to proceed.
Play the toolpath on screen using PLAY PATH dialog box and notice that the tool is plunging right on the axis AA_1 as shown below.
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We can machine the hole in multiple passes so that we don’t have to define separate sequences for semifinishing and finishing toolpaths.
Pick and set the following parameters to machine the hole in two steps.
NUM_PROF_PASSES
2
PROF_INCREMENT
.3
NUM_PROF_PASSES together with PROF_INCREMENT allows to create multiple profiling passes horizontally offset from each other.
NUM_PROF_PASSES specifies the number of passes that will be generated.
PROF_INCREMENT specifies the horizontal distance between the passes generated according to NUM_PROF_PASSES.
Play the toolpath on screen using PLAY PATH dialog box. It will appear as shown below.
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Notice that tool first machines the walls from top to bottom of hole at the offset of PROF_INCREMENT then retracts and again machines the walls from top to bottom without PROF_INCREMENT. This type of machining is called PASS_BY_PASS scanning. We can machine the hole by fist making the profile passes specified by the NUM_PROF_PASSES at the given z level and then plunging down to the next slice. This type of machining is called SLICE_BY_SLICE scanning. The scanning strategy is specified by the SLICE_PATH_SCAN parameter.
As the toolpath looks satisfactory so change the following parameters for good surface finish.
STEP_DEPTH
.5
Select Done Seq to complete the definition of the NC Sequence
Now we will create the CL Data file for this sequence and also for the mirrored toolpath.
To create the CL data file for FINISH NC Sequence, select CL Data>NC Sequence
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Now select the FINISH sequence in the NC Sequence SEQ LIST menu.
In the PATH menu pick File and then Done
Pick in the Save a Copy dialog box. The file finish.ncl.1 will be created.
To mirror the toolpath to machine the second hole, select Mirror in the PATH menu.
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Pick the datum ASM_RIGHT as mirroring plane.
Now select File>Done to create the CL Data file for mirrored toolpath.
Enter the mirrored CL data file name as FINISH_M in the Save a Copy dialog box.
Pick to create the file.
Select Display>Done to view the simulation of CL Data file on screen.
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It should appear as shown below.
Select File>Save to save the manufacturing model.
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EXERCISE 5
In this exercise we will define a profile milling NC Sequence to machine an undercut, with a special round insert milling cutter.
The topics covered in this exercise are as follows
�� Defining a side milling cutter
�� Selection of surfaces by loop option
�� Checking gouges visually, by placing the tool at desired location on the tool path
The cutter to be used in this exercise is shown below.
Set the working directory to BACK_PLATE and open the manufacturing model back_plate.mfg.
Zoom to the reference part and see that lower surfaces of the plate form an undercut.
Conventionally, to machine this undercut we will need to machine first from top side and then invert the plate and machine the bottom side i.e. two separate operations in Pro/NC. By using the special round insert cutter we will machine the complete plate with only one operation.
To define a new profile milling NC Sequence select Machining>NC Sequence>Profile>Done.
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In the SEQ SETUP menu add Name to the list of checked items and select Done.
Enter the sequence name UNDERCUT and pick icon or middle-click.
In the Tools Setup dialog box, define a new Side Milling cutter of diameter 25. Other parameter of the tool should be as shown below.
To see the tool in separate window click and the detailed sketch of the tool will appear as shown below.
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Pick to close this window.
Select to complete the definition of the tool.
In the MFG PARAMS menu select Set and enter the parameters as follows.
CUT_FEED
1200
STEP_DEPTH
3
SPINDLE_SPEED
2000
COOLANT_OPTION
ON
CLEAR_DIST
1
LEAD_IN
YES
LEAD_OUT
YES
LEAD_RADIUS
20
ENTRY_ANGLE
20
EXIT_ANGLE
20
We have set the large value of STEP_DEPTH to make the computation of the toolpath faster. Later when the toolpath has been defined satisfactorily we will change it to suit the surface finish required.
Pick to apply the changes and exit the Parameter Tree Dialog box.
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Select Done in the MFG PARAMS menu to proceed.
Now the SURF PICK menu appears. As we want to select the surfaces from the reference part, so select Done.
In the SURF/LOOP menu select Loop.
Loop option is used to select a closed loop of surfaces, by choosing a face, they surround.
Now select the bottom surface of the reference model as shown below.
Now the system is asking to select the edge of the selected surface to specify whether we want to select the inner loop or outer loop of surfaces. As we want to select the inner loop of surfaces so select any edge forming the inner loop of selected surface as shown below.
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The selected loop of surfaces will be highlighted as shown below.
Select Done>Done>Done to complete the selection of surfaces
Play the toolpath using PLAY PATH dialog box and it will appear as shown below.
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Change the view to Front and zoom to see that toolpath has followed the surface forming undercut as shown below.
To check visually if the tool is gouging anywhere on the part, pick icon on the PLAY PATH dialog box.
Now pick on the toolpath as shown below.
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The tool will move to the picked point as shown below.
Notice that tool shank is clear of the reference part surfaces and does not gouges the part anywhere.
To be sure, that the tool does not violate the reference part, we should perform the gouge checking.
So select Gouge Check in the PLAY PATH menu.
Now the system will ask to select the surfaces for checking gouges. As we want to check the gouges for the surfaces of complete part so check the Add Ref Prts option.
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When Add Ref Prts option is checked, system adds all surfaces of the reference part for gouge checking.
Select Done>Run.
System will report that no gouges are detected.
It is always good practice while machining undercut to use larger values for ENTRY_ANGLE and EXIT_ANGLE parameter. So that on the retract path tool does not gouges the part.
As the toolpath looks satisfactory so change the following parameters for good surface finish.
STEP_DEPTH
.2
Select Done Seq to complete the definition of the NC Sequence.
Select File>Save to save the manufacturing model.
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EXERCISE 6
In this exercise we will define a profile milling NC Sequence to machine an undercut with a T-slot cutter.
The topics covered in this exercise are as follows
�� Defining a new profile milling NC Sequence to machine and undercut
�� Defining a new side milling cutter
�� Introduction to NORMAL_LEAD_STEP parameter
�� Inserting a CL Command at the end of CL Data
�� Patterning a NC Sequence
�� Generating CL Data for a patterned NC Sequence
�� Gouge checking patterned NC Sequence
Set the working directory to FLOAT_PLATE and open the manufacturing model float_plate.mfg.
Zoom to the reference part and see that each bore has an undercut.
To define a new profile milling NC Sequence select Machining>NC Sequence>Profile>Done.
In the SEQ SETUP menu add Name to the list of checked items and select Done.
Enter the sequence name UNDERCUT and pick icon or middle-click.
In the Tools Setup dialog box, define a new side milling cutter of diameter 16. Other parameter of the tool should be as shown below.
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To see the tool in separate window click and the detailed sketch of the tool will appear as shown below.

Pick to close this window.
Select to complete the definition of the tool.
In the MFG PARAMS menu select Set and enter the parameters as follows.
CUT_FEED
800
STEP_DEPTH
2
SPINDLE_SPEED
2000
COOLANT_OPTION
ON
CLEAR_DIST
1
LEAD_IN
YES
LEAD_OUT
YES
LEAD_RADIUS
15
ENTRY_ANGLE
25
EXIT_ANGLE
25
It is always good practice while machining undercut to use larger values for ENTRY_ANGLE and EXIT_ANGLE parameter. So that on the retract path, tool does not gouges the part.
Pick to apply the changes and exit the Parameter Tree Dialog box.
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Select Done in the MFG PARAMS menu to proceed.
In SURF PICK menu select Done and pick the surfaces forming undercut of first hole as shown in the figure below.
Select Done>Done to complete the selection of surfaces.
Play the toolpath using PLAY PATH dialog box. It should appear as shown below.
To perform gouge checking, select Gouge Check in the PLAY PATH menu.
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As we want to check the gouges for the surfaces of complete part so check the Add Ref Prts option and select Done>Run.
System will report gouges by the following message at message area.
Tool is gouging the part during plunge and retract motion. So we should modify the toolpath so that tool clears the reference part during motions along z-axis.
So set the following parameter.
NORMAL_LEAD_STEP
5
NORMAL_LEAD_STEP is the length of the linear movement that is normal to the lead-in or lead-out motion.
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Play the toolpath using PLAY PATH dialog box. It should appear as shown below.
To perform gouge checking select Gouge Check and check the Add Ref Prts option.
Select Done>Run. System will report that no gouges are detected.
To insert an Optional Stop at the end of the CL Data select Customize
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Now make sure that in the Customize dialog box <end of tool path> is highlighted and select CL Command in the Insert drop down field as shown below.
In the CL Command dialog box pick icon.
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In the “cmd edit” menu select LOADTL-OPTSTOP>OPTSTOP.
OPTSTOP command will appear in the dialog box as shown below.
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Select to exit the CL Command dialog box.
Select to exit the Customize dialog box.
Select Done Seq to complete the definition of the NC Sequence.
Now we will pattern the sequence to machine all the undercuts. Although we can perform a Reference Pattern but we will pattern the sequence by Csys Pattern technique just to be familiarize with it.
To pattern this sequence select Machining>Utilities>Pattern>NC Sequence and select the UNDERCUT NC Sequence.
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Now make sure that Csys Pattern is selected in the next menu.
Pick Done>Translate>Done.
For further steps constantly monitor the message area otherwise you may easily go wrong.
Now the system is asking to enter displacement in X direction so select Enter
Now enter -80 and pick icon or middle-click.
Select 0 for the displacement in Y and Z direction.
Now the system will ask you to enter total number of instances in this direction. So in the ENTER VAL menu select Enter and enter 3 as the number of instances in X direction then pick icon.
Now the PAT TYPE menu will again appear asking to select pattern type for the second direction.
Select Translate
Then pick 0 for X direction.
Enter 70 for displacement in Y direction and pick icon or middle-click.
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Select 0 for the displacement in Z direction.
Now the system will ask you to enter total number of instances in this direction. So in the ENTER VAL menu select Enter and enter 2 as the number of instances in Y direction then pick icon.
Now we will create the CL Data file for this sequence and also for the mirrored toolpath.
To create the CL data file for UNDERCUT sequence, select CL Data>NC Sequence
Now select the UNERCUT sequence in the NC Sequence SEQ LIST menu.
In the PATH menu pick File and then Done
Pick in the Save a Copy dialog box. The file undercut.ncl.1 will be created.
To display the toolpath on screen select Display>Done on the PATH menu.
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The toolpath will appear as shown below.
To perform gouge checking select CL Data>Gouge Check
Select the newly created file undercut.ncl and pick
Check the box Add Ref Prts and select Done>Run.
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System will report that no gouges are detected.
Although we could insert an optional stop in Parameter Tree dialog box, but it will only appear at the end of patterned MCD data i.e. once in the tape file. By inserting CL Command at the end of CL Data, the Optional Stop will appear at the end of each patterned instance i.e. 6 times in tape file for above case as shown in the figure below.
So the machine operator may have the option to stop the machine at the end of machining each bore and check the cutter condition or may perform some other task.
Select File>Save to save the manufacturing model.
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EXERCISE 7
In this exercise first we will define a “Sloped” mill surface and then use the profile milling NC Sequence to machine it.
The topics covered in this exercise are as follows.
�� Defining a Sloped Mill Surface
�� Introduction to Check Surfaces functionality
�� Setting the “Configuration file” option related to check surfaces.
While finish machining a part it is preferable to machine the steep walls with a constant Z type toolpath (as Profile and Volume Milling NC Sequence offer) and shallow surfaces with a little step over (as Surface Milling NC Sequence offers). Sloped Mill Surface is used to classify surfaces into Steep (near vertical) and Shallow (near horizontal) areas.
The criterion to classify surfaces into Steep and Shallow areas is the Slope Angle. At any given point, Slope angle is defined as the angle between Surface Normal and the Direction Vector as elaborated in the following figure.
Direction vector is always parallel to the Z-axis and Surface Normal depends upon the topology of the surface.
So a Flat surface has Slope angle of 00 and a Vertical surface has Slope Angle of 900.
During the definition of Sloped Surface, we specify a Draft Angle. If a surface patch has Slope angle greater than this Draft Angle it is considered a Steep area and if its value is lesser then it is considered as Shallow area.
During the definition of Sloped Surface, we have the option either to keep the steep or shallow side of the selected surfaces. When we select Keep Steep Side, the system keeps only those portions of the selected surfaces where the Slope Angle is greater than the specified Draft Angle value. And when we select to Keep Shallow Side, the system keeps only those portions of the selected surfaces where the Slope Angle is less than the specified Draft Angle value.
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Set the working directory to BASE_PUNCH and open the manufacturing model base_punch.mfg.
Select Mfg Setup>Mfg Geometry>Mill Surface>Create.
Enter MS_A as the name of mill surface and pick icon or middle-click.
In the SURF DEFINE menu select Add>Advanced>Done>Sloped>Done.
We will use the Seed and Boundary surface selection method to speed up the surface selection process.
Select the model surface as shown in the figure below as the seed surface.
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Now hold down the Shift key and select the following two highlighted surfaces as Boundary surfaces.
After relieving the Shift key the system will highlight the selected surfaces as shown below.
Select or middle-click.
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Now select the top surface of the reference model as the direction reference. Make sure that arrow points upward. This direction is used for measuring the slope angle.
Then select Okay.
In the message area system will ask to enter the Draft angle value. This value is used to classify surfaces as steep or shallow.
Enter 60 and hit Enter key or middle-click.
Now select Keep Steep Side>Done
Select to complete the definition of mill surface.
Select Done>Done>Done.
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To define a new profile milling NC Sequence select Machining>NC Sequence> Profile>Done.
In the SEQ SETUP menu add Name to the list of checked items and select Done.
Enter the sequence name STEEP and pick icon or middle-click.
In the Tools Setup dialog box pick BEM10 from the list and select .
In the MFG PARAMS menu select Set and enter the parameters as follows.
CUT_FEED
1000
STEP_DEPTH
3
SPINDLE_SPEED
2000
COOLANT_OPTION
ON
CLEAR_DIST
1
LEAD_IN
YES
LEAD_OUT
YES
LEAD_RADIUS
20
ENTRY_ANGLE
15
EXIT_ANGLE
15
Pick to apply the changes and exit the Parameter Tree Dialog box.
Select Done in the MFG PARAMS menu to proceed.
In SURF PICK menu select Mill Surface>Done>Select Srf and pick the currently defined mill surface MS_A.
Now the system is asking to decide the side of surface to be machined. Make sure that arrow points outward and select Okay.
As we want to machine all the surfaces included in the mill surface so select Select All>Done.
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Play the toolpath using PLAY PATH dialog box and notice that tool is gouging the part as shown below.
To avoid the gouging Pro/NC provides the function of Check Surfaces. Although system checks gouging against the surfaces selected as cut geometry (Mill Surface in this case) automatically but it does not perform gouge checking against the reference part surfaces while computing the toolpath. So by declaring a surface to be Check Surface we are explicitly telling the system to avoid gouging them while computing the toolpath.
Select Seq Setup and check the Check Surfs box then pick Done.
Check the Add Ref Prts box so that system checks gouging against all the surfaces of the reference part.
When Add Ref Prts (Add Reference Parts) option is checked, system uses all the surfaces of the reference model to check gouging against.

Select Done.
Play the toolpath using PLAY PATH dialog box. It should appear as shown below.
So select Gouge Check in the PLAY PATH menu.
Now the system will ask to select the surfaces for checking gouges. As Add Ref Prts is already checked so select Done>Run.
System will report that no gouges are detected.
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As the toolpath looks satisfactory so change the following parameters for good surface finish.
STEP_DEPTH
.2
Select Done Seq to complete the definition of the NC Sequence.
We can set the Configuration file option chk_part_surfs_profpock to Yes to force the system to add all the surfaces of the reference part as Check surfaces.
Select File>Save to save the manufacturing model.