SIMULATION OF CNC MACHINING IN PTC CREO

BySuresh Arulanantham

(11026898)

Introduction In this modern industries, CAM has constantly developed in advance technology.

CAM simulation, is the powerful analysis tool for the manufacturing systems. Simulation for the manufacturing system is one-time use of analytical model. In the model simulation CAM plays an important role, which reduces the

complication of the model by encapsulating the complicated-logic. This paper describes how CAM generating automatic simulation model and

codes in CREO. This paper includes various CREO techniques and type of milling simulations.

AimThe main aim of this project is to undergo learning process for simulation of CNC machining using PTC CREO easier for students by preparing learning materials with detailed explanations. Secondly the aim is to improve PTC CREO ability in simulation of CNC Machining and simulate the case study of product application.

Objectives Learn CREO Manufacturing for the simulation of CNC Machining. Learn Milling Simulation Process. Learn New Techniques and Ideas in the milling simulation process. Simulation of Case study for LP12 product. Manufacture the product simulation in CNC machine. Details of learning materials.

Milling Simulation in CREO

In CREO Simulation of milling have following steps : Reference Models Workpiece Models Work cells Operation information. Fixtures NC

Types of Milling Simulation in CREO

Profile Milling Face Milling Volume milling Pocket Milling Basic drilling Trajectory Milling

Post-processing MethodsPost-processing is the final stage in the manufacturing process. When toolpaths has been completed, it can create ASCII format Cutter Location (CL) data files for operations or selected NC steps. Then post-process CL data files into specific Machine Control Data (MCD) files using a post-processor. It is important to understand that changing NC steps requires to recreate the CL data file for the operation and post-process this file is used again to produce an updated MCD file.

Product Application and Case studyThe Arm board and Chassis is the product application of LP12 has been chosen for the simulation. The LP12 is highly regarded transcription turntable. The Design of LP12 is completely modular and upgradeable. The LP12 consists of Arm board, Sub chassis, base, motor control, tonearm and cartridge. The 3D design of the product, designed in CREO and Simulation has to be done in CREO.

Face Milling ( Flatten the surface) : 6mm Flat End mill Pocket Milling (roughing the pocket) : 6mm Flat End mill Volume milling (Flat end finishing) : 6mm Flat End mill Pocket Milling (Corner Finishing) : 6mm Round Ball mill Profile Milling (Roughing) : 6mm Flat End mill Profile Milling (Finishing) : 6mm Flat End mill Volume Milling (Hole) : 6mm Flat End mill Drilling (Tap holes) : 5mm Drill Bit

Armboard and Chassis Machining

Problems and Solutions in Simulation The cavity or pocket in the 3Ddesign has been simulate with the pocket milling with 6mm flat standard mill tool.

The problems found in machining the round corner finish and there is left out material in the curved corner.

This problem solved after a trial and error method with all Milling simulation NC sequences method and found the sequences of milling method to achieve the proper machining simulation.

The following NC sequences are the proper simulation for the Armboard manufacturing: Pocket Milling (roughing the pocket), Volume milling (Flat end finishing), Pocket Milling (Corner Finishing).

Machining the Armboard from the stock material by using the profile milling sequence. In this profile milling NC sequence simulation machining the profile of Armboard is good enough with software simulation, but in real time CNC machining is not possible. This problem has been solved by change of design in the Armboard, so that in real time machining, the new design helps to hold the bit piece of Armboard profile with stock material.

Cont…

CNC Machining The Armboard and chassis design has been simulated by PTC CREO

software. The post-processing method is used to generating G-Code from the .ncl file,

the G-code program saved in .tap file. The Kryle VMC 700 Is the vertical CNC machining centre, which is used to

machine the Armboard and chassis. The Armboard and Chassis are test manufactured in foam

After machining on the foam, certain problems has been found are as follows : Rib thickness is very thin, which is not suitable for machining in aluminium. The Armboard and chassis having very small pocket or cavity, which is

difficult to manufacture with 6mm end mill tool.

Problems in Machining

Conclusion and Further work Milling Simulation Process and its different types in CREO was learnt in

detail using CREO parametric 2.0. Learning tutorials for simulation of CNC machining in CREO was prepared

in easier way for students. Case study simulation has been done successfully using PTC CREO 2.0. Generated successfully CNC codes for machining with the help of CREO

parametric 2.0. Manufactured testing in foam has been done successfully for the case study

product with the help of Kryle VMC 700. Increase the Rib length from 1.8mm to 3mm, so that it gives rib rigidity and

manufacturing time will reduce. Remove the unwanted small pocket, which is hard to machining. Unwanted pocket has to be removed to speed up the manufacturing

process.

Thank you

Questions