MS Exercise

8/11/2019 MS Exercise

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global solutions

innovation

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2001 PTC

TrainingExercisesVERICUT for Pro/ENGINEER

Mach ine Simu lat ion


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2001 PTC 2

Introduction

Terms

MS stands for Machine Simulation in this exercise


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2001 PTC 3

Exercise 1 - Outline

Outl ine

3 ax is m i l l ing m achine

Work in Pro/ECreate machine components and assembly in Pro/EExport STL file of each machine component against Machine

Zero CSYSCreate tool path file(NCL and TAP) using Pro/NC and G-PostWork in VERICUT Machine Simulation

Build machine kinematics in VERICUT Machine SimulationLoad machine components (STL file) to VERICUT MS

Load Control fileSave MCH, CTL and JOB file in your working directoryTest machine with MDIJob, Machine settingCreate or load tool library file, tool gauge length settingLoad tool path file and simulate tool path


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Exercise 1 - 3 axis milling machine

Bu i ld 3 ax is m i l l ing m achine and s im ula te too l p a th

Work in Pro/E

PreparationCopy all the machine simulation exercise folder and files to yourcomputer, set Pro/E working directory to: \exercise 1

Machine components and assemblyIn Pro/E, Open file 3axis-mill.asm

base-x-slide

x-axisy-axis

z-axis

stockfixture

z-axis-cylinder

base

base-z-slide


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2001 PTC 5

Export component: base.prt in STL format In Pro/E, choose: File/Export/Model/STLSelect 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



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Export all of other components in STL formatTips

Choose the right Coordinate System - machine zero (ACSO) for all components, becausethere 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 themwhen 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



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Work in VERICUT Machin e Simu lat ion

Access VERICUT Machine SimulationIn 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 kinematicsIn MS, choose: Machine / Components


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

ComponentsTree


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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


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Components: X-Linear, Fixture and Stock

After finish last component -Stock, click OK in Add Component window

X Linear Fixture Stock


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Load STL files to VERICUT MSLoad 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.


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Load STL files to other componentsLoad 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 PrimitivesIn 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


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Change Tool connect positionIn Pro/E, find distance from gauge point to work table plane(machine zero), It is 15.2 inch. We will move tool connectposition from machine zero to gauge pointIn VERICUT MS, choose: Machine / ComponentsIn Components window, choose: Tool, then click Modify

In Modify window, set Connect position=(0 0 15.2), then clickOKClose Components window

15.2

Gauge Point

Machine Zero


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Save machine file in your working directoryIn VERICUT MS, choose: Machine / Save as, give file name3ax-mill.mch, make sure you save it in \exercise 1 folder

Load control fileIn VERICUT MS, choose: Control / Open, open file generic.ctl,find this control file in category CGTECH_RP2LIB

Save control file in your working directoryIn VERICUT MS, choose: Control / Save as, give file namegeneric.ctl, make sure save it in \exercise 1 folder


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Set machine tableIn Pro/E, use Analysis/Measure, check distance between gaugepoint to stock surface, It is 7.7 inch. We will set top surfacecenter of stock as programming zeroIn VERICUT MS, choose: Machine / TableIn 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 JobTable, if a Job Table is defined, it will over write Machine Table)

7.7


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Set Travel LimitsIn VERICUT MS, choose: Machine / Travel LimitsIn Travel Limits window, type in Min and Max travel limits ofeach axis, then click ModifySee following figure for limits value of 3 axisToggle Overtravel Detection On

Click OK


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Collision setupIn VERICUT MS, choose: Job / CollisionSet: Component 1=Fixture, Component 2=Tool, Tolerance=0.1Toggle Collision Detection OnClick OK


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Tool libraryMethod 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 workingdirectory -VERICUT MS exercise 1 folder

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

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


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In Tool Modify window, click Properties

In Tool Properties window, set Gage Length=4, click OKIn Tool Modify window, click OK

In Tool Manager window, click Save, then Close


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Method 2, create tool library in VERICUT MS by yourself

In Tool Manager window, click AddIn 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 windowClick Yes in the small question window


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Load tool pathIn VERICUT MS, choose Job / SettingIn Job Settings window, open Toolpath file tool -com.tap, findthis file in exercise 1 folderOther 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 OKReset Machine Simulation

Run machine simulation


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Outl ine

4 ax is m i l l ing m achine

Build machine kinematicsLoad STL filesMachine Table, Travel Limits, Collision setting

Load tool library, set tool gauge length offsetLoad tool path file, control fileTool path simulation


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Bu i ld 4 ax is mi l l ing m achine

Bu i ld machine k inem atics

See following figures for machine kinematicsMake sure component Type, Connect to, Motion axis andConnect Position is right

Notice connect position of rotary axis A is: (0 0 4), Designis: (0.5 0 0)(Notes: For Multi-Axis machineuses CSYS on rotary centerlinefor rotary axis)


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Lo ad STL f i les

Base - base.stl Z - head.stl and spindle.stl Tool - NothingY - 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)


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Set Machin e Table

See following Machine Table figure for detailsSet Travel l im its

See following Travel Limits figure for details

Save m achine f i le

Give file name: prolight.mch, save it in \exercise 2 folder


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Job se t t ing

Load tool path file: op010.tap, find this file in \exercise 2folderOther settings, see following figure

Col l is ion se tup

See following Collision Setup figure for details


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Load too l l ib rary and s et too l g auge length off se t

Load tool library file ncmach_gage.tls, find it in\exercise 2 folderSet gauge point at top of each tool

Contro l f i le

Load control file tmc2000.ctl, find this file in\exercise 2 folderSave Jo b f i le

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

Tool pa th s im ula tion

Gauge Point


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2001 PTC 32

Exercise 2a- Outline

Outl ine

5 axis laser m achine

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

Build machine kinematics, rotary axis and tool connectposition calculationLoad STL files to machineMachine Table, initial machine location, RTCP pivot offsetcalculation

Load tool library and set gauge length offsetLoad tool path file, control fileTool path simulation


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2001 PTC 33

Exercise 2a - 5 axis laser machine

Bu ild 5 axis laser m achine

Preparation

Set Pro/E working directory to \exercise 2aOpen file laserdyne.asm

Expor t com pon ents in STL form at

Export base and all linear axis using CSYSat machine zero

Base

XAXIS

YAXIS

ZAXIS

Table

CAXIS

DAXIS


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2001 PTC 34


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

centerline of rotary axisUsing ACS0 for CAXIS, and ACS1 for DAXIS

(Notes: Use same name as Pro/E part for STL files)

CAXISDAXIS


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Bu i ld m achine k inem atics & load STL f i les

BaseType: 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)

XAXISType: 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)

ZAXISType: 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)


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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)

DAXISType: B Rotary, Name: D, Motion Axis: Y, Connect To: C, Connect Position: (0 8 -6) Color: Ta, Mixed Mode:Shade, Angles: (0 0 0)

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

ToolType: Tool, Name: Tool, Motion Axis: Z, Connect To: D, Connect Position: (0, 8.5, -15) Color:Red , Mixed Mode: Shade, Angles: (0 0 0)

TableType: Other, Name: Table, Connect To: Base, Connect Position: (0 0 0) Color: Blue , MixedMode: Shade, Angles: (0 0 0)

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


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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


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Rotary axis & tool connect position calculation

C-axis connect position is measured from Machine Zero to C-axis CSYSD-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 MachineZero)

Machine Zero-16.5

21

8

-6

C-axis CSYS

D-axis CSYS


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Load too l l ib rary and se t gauge length o ff set

Load file tool.tls, find it in exercise 2a folder Set gauge offset=8

Load con t ro l

Load control file laserdyne.ctl, find it in exercise 2a folder Lo ad Too lpath f i le

Load file op010.tap, find it in exercise 2a folder Save JOB fi le

Run s imula t ion


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Exercise 3 - Build your own machine

4 Ax is Ver t ical Mil l

Table A

4 Axis Hor izontal Mil l

Table B


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5 Axis Ver t ical Mil l

Head A on B

5 Ax is Ver t ical Mil l

Head B / Table A


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5 Axis Ver t ical Mil l

tab les A o n C


Heads A on B


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tab les B on A


Head A / Table B


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5 A xis Gantry Mil l - Heads B o n C


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5 A xis Gantry Mil l - Heads A o n B


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Exercise 4, 4a, 4b

Exercis e 4

Menu View AttributesView Select/Store

Exercis e 4a

Menu Jo bJob SettingJob TableCollision

Exercise 4bMenu Mach ine

Machine TablesTravel Limits


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Exercise 4 - Menu/View

Menu View

Open file prolight.job in \exercis e 4 fold er

At t r ibu tes

In VERICUT MS, choose: View / AttributesShow CSYS

Toggle Component Origin, Primitive Origin and Machine ZeroOn, then click ApplyCSYS appears


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Draw Mode

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

you can switch to line mode, find where tool is

Line Hidden


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View Select/Store

Choose: View / Orient. In Orientation window, click ISO iconChoose: View / Select/Store. In Select/Store View window,click AddIn View Add window, give view name: iso1, then click OK Using same method, add XY and YZ viewYou can switch view by clicking view name


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Exercise 4a - Menu/Job

Menu Jo b

Job Set t ingChoose: Job / SettingIn Job Setting, click Select (beside output file) to specifyoutput APT file name(ex4a.apt) and directory( \exercise 4)

In Job Setting, click Select (beside Log File) to specifyoutput Log file name(ex4a.apt) and directory( \exercise 4)In Job Setting window, Click OKToggle Conversion: OnReset VERICUT MS

Run simulationFind file ex4a.apt and ex4a.login your \exercise 4 folder


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Job Table

(Notes: Job Table performs same function as MachineTable. If the same tables are defined in both job andmachine configurations, the job table values override thosein the machine)Choose: Job / Tables, in Job Table window, select Initial

Machine Location, give Values= (0 0 12), click Add thenCloseReset VERICUT MS, see change of initial machine locationDelete Job Table contents


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Col l i s ion

Choose: Job / CollisionIn Collision Setup window, select first line (component A andTool), change Tolerance to 5 (this is for exercise purposeonly). Click Modify, then click Ok Reset VERICUT MS, run simulationDuring simulation, both A axis and tool are in error color-redChange tolerance back to 0.1


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Exercise 4b - Menu/Machine

Travel Lim its

Choose: Machine / Travel LimitsChange Z limits to: (Min=-1, Max=7), click ModifyToggle Overtravel Detection On, click OKReset VERICUT MS, run simulation

Z axis becomes red (error color) during simulation. An errormessage also appears in message line. Open Log file toview error informationChange Z limits back to (-1, 8)


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Outl ine

Run VERICUT and Mach ine Simu lation s im ultaneous lyMachine simulation setting

Change Fixture and Stock connection positionJob Table settingJob SettingLoad tool library, set gauge length offset

VERICUT SettingTool retract setting


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Exercise 5 - Run VERICUT & Machine


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Exercise 5 Run VERICUT & MachineSimulation simultaneously

Move fixture and stock to center of machine table

In VERICUT MS, choose: Machine / ComponentsIn 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



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Job table setting

Set Input Program ZeroIn VERICUT MS, choose: Job / Tables

In Job Tables, choose Input Program Zero, give value (-12.5, -12.5, -14.2), this is to moveinput 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



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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 settingChoose: 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. ConversionMethod, 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)



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Test your machine with MDI

Give (X0Y0Z0), machine should be at position as following figure showsRest machine simulation

XZ plane YZ plane



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Load tools and Set gauge length offset

In VERICUT MS, choose: Tools / Tool File, open file tools.tls,find it in exercise 5 folderTool gauge length setting

Choose: Tools / Tool Manager

In Tool Manager window, choose a tool then click Modify

In Tool Modify window, choose Tool PropertiesIn Tool Properties window, give tool gauge length value

Change gauge point of all five tools to the most top point of each toolGauge point



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e c se 5 u V CU & ac eSimulation simultaneously

Save machine file, save job file

Set Layout to 3 viewsRun simulation


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Simulation simultaneouslyG-Code setting

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

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

Save User fileResize VERICUT, and Machine Simulation window

Run simulation (Hint: you can control simulation in both window)


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E ercise 6 6a O tline


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Exercise 6, 6a - Outline

Exercis e 6

Menu Cont ro lUse Control/Subroutine

Create main program and subroutineLoad subroutine to controlLoad new toolpath file (main program)

Exercis e 6a

Menu Mo dals

Control simulationSlow down machine simulationStop simulation when error occurs

Exercise 6 Menu/Control


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Exercise 6 - Menu/Control

Use Contro l / Subro ut in e

Create new m ain p rogram and sub rout ine f i leCreate 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(theend of main program), paste it in file main -program.tap.Copy remaining of sub.tap (subroutines) and paste it in filesubroutine.sub



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

and subroutines)Load subro ut ine to Cont ro l

In VERICUT MS, choose: Control / SubroutinesIn Subroutine window, open file subroutine.sub, find it inexercise 6 folderChoose file subroutine.sub, click Insert, then click OK



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Change toolp ath f i le

Choose: Job / Job Setting, change toolpath file to main -program.tap Run s imula t ion

(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 subroutinefiles for the specified subroutine

Exercise 6a Menu/Modals


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Contro l machine s imula t ion

Open file 3ax - mill.job, find it in exercise 6 folder S low dow n m ach ine movemen ts

In VERICUT MS, choose: Modals / Motion / Max DistanceGive Max Distance=0.1, run machine simulation

Notice speed differenceChange Max Distance back to 0



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Stop s imu lat ion w hen an er ror occurs

In VERICUT, choose: Modals / General / Max ErrorsGive Max Errors=1Toggle Collision Detection(find it in menu: Job / Collision)and Over Travel Detection(find it in menu: Machine / TravelLimits) OnRun simulationIt stops when an error occurs

Exercise 7 Outline


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Turning machine

Bui ld tu rn ing m ach ineIn Pro/E, export STL file of each component (optional)Build machine kinematicsLoad STL files

Load controlSet Input program zeroTest machine with MDITransfer tools from Pro/NC to VERICUTLoad tool library to Machine SimulationSet tool gauge offsetLoad tool path file, build tool index tableRun simulationUse X-Caliper to check dimension of model after cut

Exercise 7 Turning machine


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Exercise 7 - Turning machine

Bui ld tu rn ing m ach ine

In Pro/E, expor t STL f i le of each co m po nent (opt ion al)Export all components except Turret against machine ZeroCSYSMachine Zero is located at right plane center of spindle

Z

X

Machine Zero



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Export Turret

Use CSYS-ACS4It is at located at left plane center of turret



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Read next two pages for detailsFind STL files in exercise 7 folder

Base

SpindleFixture

Stock

Z-axis

X-axis

Turret



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Machine components

BaseType: 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)

FixtureType: 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)

StockType: 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)



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ZType: 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

XType: 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)

TurretType: 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 1Type: Tool, Name: Too l 1, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) ColorRed, Mixed Mode: Shade, Angles: (0 0 0)



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Tool 2Type: Tool, Name: Too l 2, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) ColorMagenta, Mixed Mode: Shade, Angles: (0 0 -90)

Save machine file in exercise 7 folder, give file name2xturn.mch

Ad d con t ro l f i le to m achine

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



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About control file

A super group Toolchangemust be in control file toenable turret rotation whentool change.See right box for detailsOpen control file2xturn-inch.ctl to find thissuper 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"

}}



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Set Inp ut Pro gram Zero

Choose: Job / TablesIn Job Tables window, choose: Input Program Zero, seefollowing figure for other parameters settingGive Index=1(Note 1: Values (-12.9103, 0, -8) is measured from left planecenter of turret to right plane center of stock)(Note 2: We are going to use right plane center of stock asprogramming center)

X

Z



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Test yo ur m achine with MDI

X0Z0 position is shown in the following figureStock and turret center lines are coincidentRight plane of stock and left plane of turret are adjacent



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Trans fer tools f rom Pro/NC to VERICUT

Open MFG file in Pro/NCChange Pro/E working directory to \exercise 7Open MFG file turn.mfg,In Pro/NC, choose: CL Data / NC Check / CL File (openturn.ncl) /Done

Run simulation, exit VERICUT(Notes, by running VERICUT simulation, tools data can betransferred from Pro/NC to VERICUT automatically, which willbe called in VERICUT MS)

Lo ad too l l ibrary to VERICUT MS

In VERICUT MS, choose: Tools / Tool FileOpen file cgtpro.tls, find this file in exercise 7 folder



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2001 PTC 86


Set Tool g auge offset

In VERICUT MS, choose: Tools / Tool ManagerIn Tool Manager window, choose Tool 1, then click ModifyIn Tool Modify window, choose PropertiesIn Tool Properties window, change Gage Offsets to: (7, 0,0.25)Change Tool 2 gauge offset to (7 0 0.25)Save tool libraryClose Tool Manager window



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2001 PTC 87

e c se u g ac e

Lo ad tool path f i le

In VERICUT MS, choose: Job / SettingIn Job Setting window, load tool path file to turn.tap, find inexercise 7 folderChange Log file to 2xturn.log, save it in exercise 7 folder See following figure for other settings



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2001 PTC 88

g

Bu ild Tool Index Table

In VERICUT MS, choose: Tools / TablesIn Tool Tables window, choose Table Name as Tool IndexTable, then click Build Tool List, 2 lines of tool index infoappears. Two tools appears on turret too.Close Tool Tables window.

Save JOB fi le

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



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2001 PTC 89

g

Run s imula t ion

Check d im ens ion af ter s im ula tionUse Analysis / X-Caliper to check diameters, D1 and D2,see if it is same as design model in Pro/NC

D1 D2



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2001 PTC 90

Outl ine

Mil l /Turn m achinin g centerCreate components and assembly in Pro/EExport components in STL format

Linear componentsRotary components

Build machine kinematics and load STL filesSet input program zeroLoad control file, mill-turn control introductionCreate MFG file in Pro/NC, generate TAP file using PP

Run NC Check to transfer tools and Stock data from Pro/NCto VERICUT, which will be used laterLoad tool library file to Machine Simulation. Set turning toolgage offsetLoad Tool path file



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2001 PTC 91

Build tool list

Set Turret rotation angle for milling toolsPlay Machine SimulationRun VERICUT and Machine Simulation simultaneously

Open USR fileLoad stock fileSet toolpath orientationLoad Tool library fileLoad Tool path fileG-Code setting, connect USR file with a JOB fileOpen Machine Simulation form VERICUT

Run VERICUT and Machine Simulation together

Exercise 8 - Mill/Turn


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2001 PTC 92

Bu i ld Mi l l/Turn m achin ing cen ter

Load m achine com pon ents and assembly in Pro /ESet Pro/E working directory to: \exercise 8\machine-proe\Open file: mill -turn.asm Find all components andassembly file in folder:\exercise 8\machine-proe\


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2001 PTC 94

Export rotary components

It includes turret and four tool -holder Use CSYS (ACS4) at rotating center of turretExport four holder components separately, give them nameholder -1, holder-3,holder-5, holder-7.See following figurefor holder numberand location

Holder-1

Holder-5

Holder-3Holder-7



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2001 PTC 95


See following figure and next 3 pages for detailsTipsMake sure Tool Index Number is set right

Make sure Angle is right


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2001 PTC 97

ZType: 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

XType: 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)

Primitives: x-slide.stl, Color, white, Position (0 0 0), Angle (0 0 0)

YType: 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)



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2001 PTC 98

TurretType: B Turret, Name: Turret, Motion Axis, Z, Connect To: Y, Connect Position:(12.9103, 0,13) Color: 2Green, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0)

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

Tool 3Type: 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)Tool 5

Type: Tool, Name: Too l 5, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) ColorMagenta, 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)


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2001 PTC 100

Set Input program zero

It is measured from left side turret plane center to right sidestock plane centerLoad Control file

Open control file mill -turn.ctl Save JOB file, mill -turn.job

Test your machine with MDI X

Z

X0Y0Z0



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2001 PTC 101

Ab out Mi ll -Turn Con t ro l

A super group Toolchangemust be in control file toenable turret rotation whentool change.

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"

}}



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2001 PTC 102

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"}



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2001 PTC 103

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



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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 toVERICUT

In Pro/NC, choose: CL Data / NC Check / CL File / (choose filemill-turn.ncl) /Done

Create TAP fileUsing Post- Processor fan16t to post the NCL file, give TAP filename mill -turn.tap PP fan16t is merged with PP fan16m, it is a mill/turn mergedpost-processor



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2001 PTC 105

Lo ad Tool and Tool Path f i le

Copy file cgtpro.tls and mill -turn.tap to folder \exercise8\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 offsetSet both turning tool (T2 and T4) gage offset to (7, 0, 0.25).Refer Exercise 7 for details



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2001 PTC 106

Lo ad Too l path f i le

In VERICUT MS, choose: Job / Job SettingLoad tool path file mill -turn.tap Bu i ld too l l is t

Choose: Tools / Tables / Tool Index Table /Build Tool List

Reset Machine Simulation, tools appear on turret



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2001 PTC 107

Set tu r ret ro ta t ion angle for tw o m i l l ing too ls

Turret rotation angle only need to be set for milling toolsChoose: Tools / Tables / Turret Rotation, see followingfigure for details, index # here reflects Tool ID #Turret rotates this angle when the tool is called in tool pathfile

The angle is measured from the tool original orientation todash line (position when tool in use)Save JOB file

X

Y

Tool 1

Tool 3

Rotate To


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2001 PTC 109

Set Toolpath orientationIn 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



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2001 PTC 110

Load Tool library fileIn VERICUT, choose: Tools / Tool Control / Tool Library (opentool library file mill-turn.tls) / OK



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2001 PTC 111

Load Tool path fileIn VERICUT, choose: Toolpath / Toolpath ControlIn Toolpath Control window, open Tool path file mill -turn.tap,set toolpath type=G-Code Data, Multiple Toolpath Files=No


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Resize VERICUT and Machine Simulation window

Click Play button (in either window)

Documents

MS Exercise