Creo Manufacturing 9.0 Black Book

By Gaurav Verma and Matt Weber

The Creo Manufacturing 9.0 Black Book, new and updated 2nd edition, is written to help professionals as well as learners in creating NC programs for very complex jobs that are machined in the Machine shop. The book covers almost all the information required by a learner to master the Expert Machinist, NC Assembly, and CMM modules of Creo. It covers basic as well as advanced topics like NC machines, milling tools with their uses, tool setting, machine setting, cutting strategies, NC Features, creation of output for a specific machine, CMM, and so on. Some of the salient features of this book are:

 

In-Depth explanation of concepts

Every new topic of this book starts with the explanation of the basic concepts. In this way, the user becomes capable of relating the things with real world.

 

Topics Covered

Every chapter starts with a list of topics being covered in that chapter. In this way, the user can easily find the topic of his/her interest easily.

 

Instruction through illustration

The instructions to perform any action are provided by maximum number of illustrations so that the user can perform the actions discussed in the book easily and effectively. There are about 750 small and large illustrations that make the learning process effective.

 

Tutorial point of view

At the end of concept's explanation, the tutorial makes the understanding of user firm and long lasting. Almost each chapter of the book has tutorials that are real world projects. Moreover, most of the tools in this book are discussed in the form of tutorials.

 

For Faculty

If you are a faculty member, then you can ask for video tutorials on any of the topic, exercise, tutorial, or concept. As faculty, you can register on our website to get electronic desk copies of our latest books, self-assessment, and solution of practical. Faculty resources are available in the Faculty Member page of our website once you login. Note that faculty registration approval is manual and it may take two days for approval before you can access the faculty website.

• Language: English
• Publisher: CADCAMCAE Works
• Release date: Jul 23, 2022
• ISBN: 9798201906917

Gaurav Verma

Gaurav Verma is currently a Full Professor at the Panjab University, Chandigarh, India (Dr. SS Bhatnagar University Institute of Chemical Engineering and Technology, and Adjunct Faculty at the Department of Nanoscience and Nanotechnology). He is a former CV Raman Post-Doctoral fellow from the Department of Chemical Engineering, Massachusetts Institute of Technology (MIT), USA. His research focuses on the areas of applied nanoscience and nanostructured materials.

Book preview

Creo_Manuf_9_BW_cvr.jpg

Creo Manufacturing 9.0 Black Book

By

Gaurav Verma

Matt Weber

(CADCAMCAE Works)

Edited by

Kristen

Published by CADCAMCAE WORKS, USA. Copyright © 2022. All rights reserved. No part of this publication may be reproduced or distributed in any form or by any means, or stored in the database or retrieval system without the prior permission of CADCAMCAE WORKS. To get the permissions, contact at [e-mail]

NOTICE TO THE READER

Publisher does not warrant or guarantee any of the products described in the text or perform any independent analysis in connection with any of the product information contained in the text. Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer.

The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions.

The Publisher makes no representation or warranties of any kind, including but not limited to, the warranties of fitness for a particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material. The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the reader’s use of, or reliance upon, this material.

DEDICATION

To teachers, who make it possible to disseminate knowledge

to enlighten the young and curious minds

of our future generations

To students, who are the future of the world

THANKS

To my friends and colleagues

To my family for their love and support

Training and Consultant Services

At CADCAMCAE Works, we provide effective and affordable one to one online training on various software packages in Computer Aided Design(CAD), Computer Aided Manufacturing(CAM), Computer Aided Engineering (CAE), Computer programming languages(C/C++, Java, .NET, Android, JavaScript, HTML and so on). The training is delivered through remote access to your system and voice chat via Internet at any time, any place, and at any pace to individuals, groups, students of colleges/universities, and CAD/CAM/CAE training centers. The main features of this program are:

Training as per your need

Highly experienced Engineers and Technician conduct the classes on the software applications used in the industries. The methodology adopted to teach the software is totally practical based, so that the learner can adapt to the design and development industries in almost no time. The efforts are to make the training process cost effective and time saving while you have the comfort of your time and place, thereby relieving you from the hassles of traveling to training centers or rearranging your time table.

Software Packages on which we provide basic and advanced training are:

CAD/CAM/CAE: CATIA, Creo Parametric, Creo Direct, SolidWorks, Autodesk Inventor, Solid Edge, UG NX, AutoCAD, AutoCAD LT, EdgeCAM, MasterCAM, SolidCAM, DelCAM, BOBCAM, UG NX Manufacturing, UG Mold Wizard, UG Progressive Die, UG Die Design, SolidWorks Mold, Creo Manufacturing, Creo Expert Machinist, NX Nastran, Hypermesh, SolidWorks Simulation, Autodesk Simulation Mechanical, Creo Simulate, Gambit, ANSYS and many others.

Computer Programming Languages: C++, VB.NET, HTML, Android, Javascript and so on.

Game Designing: Unity.

Civil Engineering: AutoCAD MEP, Revit Structure, Revit Architecture, AutoCAD Map 3D and so on.

We also provide consultant services for Design and development on the above mentioned software packages

For more information you can mail us at:

[e-mail]

Table of Contents

Creo Manufacturing 9.0 Black Book

Training and Consultant Services iv

Preface xii

About Authors xiv

Chapter 1 : Starting with Manufacturing

Introduction to manufacturing 1-2

Roughing Process 1-2

Finishing Process 1-3

Types of Machines 1-3

Turning Machines 1-3

Milling Machines 1-4

Drilling Machines 1-4

Shaper 1-4

Planer 1-4

Electric Discharge Machine 1-4

Electro Chemical Machine 1-5

Laser Beam Machine 1-5

NC Machines 1-5

Applications of Computer Aided Manufacturing 1-6

Manufacturing apps in Creo Parametric 1-7

Starting Expert Machinist 1-8

Creo Parametric Interface 1-10

Navigator panel 1-11

In-Graphics Toolbar 1-13

Ribbon 1-15

File Menu 1-15

Search Bar 1-16

Minimize the Ribbon 1-17

Command Search Button 1-17

PTC Learning Connector 1-17

Creo Parametric Help 1-18

Navigator 1-18

Chapter 2 : Starting with Expert Machinist

Manufacturing Sequence in Expert Machinist 2-2

Importing NC model 2-3

Creating Stock 2-4

Creating NC model 2-8

Modify Model 2-9

Delete Model 2-10

Retrieving Stock 2-10

Setting Units for the NC Model 2-12

Tutorial 1 2-15

Tutorial 2 2-20

Practice 1 2-24

Practice 2 2-25

Chapter 3 : Tool Setting

Tooling Of a Machine 3-2

Tools Available for Machining in Expert Machinist 3-2

End Mill 3-2

Ball Mill 3-2

Bull Mill 3-3

Taper Mill 3-3

Taper Ball Mill 3-3

Drill 3-4

Basic Drill 3-4

Countersink 3-4

Spot Drill 3-4

Tap 3-4

Reamer 3-4

Boring Bar 3-5

Center Drill 3-5

Back Spotting 3-5

Side Milling 3-5

Key Cutter 3-6

Lollipop 3-6

Grooving 3-6

Corner Rounding 3-6

Chamfering 3-6

Thread Mill 3-6

Plunge Mill 3-7

Multi Tip 3-7

Creating a Tool Setup 3-7

General Tab 3-9

Settings Tab 3-9

Cut Data Tab 3-10

BOM Tab 3-12

Offset Table Tab 3-12

Save tool parameters to a file 3-13

New drop-down 3-13

Retrieve tool from disk 3-13

Showing Tool Info 3-14

Delete a tool table entry 3-14

Display tool in a separate window based on current data settings 3-14

Customize Tool Parameters Columns 3-15

Checking for minimum radius 3-15

Checking for shortest edge 3-17

Checking for maximum depth of cut in the workpiece 3-18

Tutorial 1 3-18

Analyzing for tool setup 3-22

Problem 1 3-29

Problem 2 3-29

Chapter 4 : Machine Setting

Milling Machine 4-2

3-Axis Machine 4-2

4-Axis Machine 4-2

5-Axis Machine 4-3

Use of 3-Axes, 4-Axes, and 5-Axes Machines 4-4

Machines in Creo Manufacturing 4-5

Name 4-6

Type 4-6

CNC Control 4-6

Post Processor 4-6

ID 4-7

Number of Axes 4-7

Enable Probing 4-7

Output tab 4-7

Tools tab 4-9

Parameters Tab 4-12

Assembly Tab 4-17

Practical 1 4-22

Problem 1 4-25

Chapter 5 : Operations and Cutting Strategies

Operations 5-2

Operations in Creo Manufacturing 5-2

Work Center 5-2

Program Zero 5-2

Parameters Tab 5-2

Options Tab 5-3

Fixture Setup 5-4

Process 5-5

Properties 5-6

NC Features & Machining 5-6

Face 5-7

Profile 5-11

Step 5-16

Slot 5-18

Through Slot 5-19

Channel 5-20

Pocket 5-21

Through Pocket 5-23

Flange 5-24

Slab 5-25

Top Chamfer 5-26

Top Round 5-28

Ribtop 5-28

Bosstop 5-29

Free Form 5-31

O-Ring 5-34

Undercut 5-35

Entry Hole 5-37

Hole Group 5-38

Tutorial 1 5-43

Tutorial 2 5-53

Creating Machine Setup 5-54

Creating an Operation 5-56

Problem 1 5-60

Problem 2 5-61

Chapter 6 : Creating Toolpaths and Output

Toolpaths 6-2

Tool path for a Milling 6-2

Tool Path Properties dialog box 6-8

CL Commands 6-9

Feed Rates 6-11

Clearance 6-11

Entry/Exit 6-12

Cut Control 6-13

Tool Path Player 6-15

File Menu 6-15

View Menu 6-16

NCL File Menu 6-17

CL Data 6-17

Tool Clearance 6-18

Gouge Check 6-18

Position Cutting Tool 6-19

Generating output files 6-19

Generating Cutter Location Data 6-19

Generating post processed output file 6-21

Tutorial 6-24

Problem 1 6-29

Problem 2 6-30

Chapter 7 : CMM Introduction

Introduction to CMM and its Purpose 7-2

Adding Reference Model 7-2

Setting Up a Fixture 7-4

CMM Setting 7-4

Creating Measuring Operations 7-8

Creating Measuring Steps 7-8

Probe Path Output 7-11

Constructing Geometry for Measurement 7-12

Creating Plane for Measurement 7-12

Constructing Line/Axis 7-13

Problem 1 7-14

Problem 2 7-14

Creating and Managing Option File for NC 7-15

Creating a New Option File 7-15

Chapter 8 : Project

Starting an Expert Machinist File 8-2

Importing the reference model and creating the workpiece 8-3

Creating Machine Setup 8-5

Creating Operation Setup 8-7

Creating Tool Setup 8-8

Creating NC Features 8-13

Creating Toolpaths 8-20

Creating Output Files 8-24

Chapter 9 : Starting with NC Assembly

Introduction to NC Assembly 9-2

Starting NC Assembly 9-2

Using New button 9-2

Using NC button 9-4

Setting Model and Workpiece 9-5

Setting up a reference model 9-5

Inherit Reference Model 9-10

Merge Reference Model 9-11

Creating Workpiece 9-12

Automatic Workpiece 9-13

Assemble Workpiece 9-16

Inherit Workpiece 9-17

Merge Workpiece 9-18

Create Workpiece 9-20

Classify 9-23

Component Operations 9-24

Manufacturing Assembly 9-31

Workpiece Wizard 9-32

Reference Model Wizard 9-33

Practical 1 9-35

Starting the NC Assembly 9-35

Adding Reference Model 9-37

Creating Workpiece 9-38

Practical 2 9-40

Adding Reference Model 9-40

Adding Workpiece 9-41

Practice 1 9-44

Practice 2 9-44

Chapter 10 : Machine Setup

Creating Machine tool 10-2

Work Center 10-2

Mill 10-2

Mill-Turn 10-3

Lathe 10-8

Wire EDM 10-9

User-Defined Work Center 10-11

Creating an Operation 10-12

Operation tab 10-12

Process Manager 10-14

Preparing Geometry for Manufacturing 10-15

Mill Window 10-15

Mill Volume 10-15

Mill Surface 10-19

Machinable Area Reference 10-23

Drill Group 10-27

Turn Profile 10-28

Stock Boundary 10-31

Practical 1 10-32

Starting the NC Assembly 10-32

Adding Reference Model 10-34

Crating Workpiece 10-35

Creating Operation 10-39

Creating Mill Window 10-42

Practical 2 10-42

Adding Reference Model 10-43

Crating Workpiece 10-44

Creating Lathe Operation 10-45

Creating Operation 10-47

Creating Turn Profile 10-47

Practice 1 10-49

Practice 2 10-50

Chapter 11 : Milling Operations

Introduction 11-2

Setup a Milling operations 11-2

Milling Operation 11-2

Roughing Toolpath 11-2

Volume Rough 11-4

Face 11-5

Re-Rough tool 11-6

Profile Milling 11-7

Surface Milling 11-8

Finishing 11-12

Corner Finishing 11-13

2-Axis Trajectory 11-14

Trajectory 11-15

Engraving 11-16

Conventional Milling 11-17

Cut Line Milling 11-18

Thread Milling 11-19

Manual Cycle Toolpath 11-21

Standard 11-22

Deep 11-23

Breakchip 11-24

Practical 1 11-25

Starting the NC Assembly 11-25

Adding Reference Model 11-27

Creating Workpiece 11-28

Creating Operation 11-31

Creating Turn Profile 11-31

Creating Turning Operation 11-32

Creating Drilling Operation 11-34

Creating Boring Operation 11-36

Simulating Material Removal 11-36

Practical 2 11-38

Adding Reference Model 11-39

Creating Workpiece 11-40

Creating Mill Window 11-40

Creating Mill Machine 11-41

Creating Operation 11-43

Practice 1 11-47

Practice 2 11-47

Preface

Creo Manufacturing is the group of apps in Creo Elements/Pro package that are used to assist in various streams of Computer Aided Manufacturing like NC Assembly, Expert Machinist, CMM, Sheetmetal, Cast Cavity, Mold Cavity, Harness, and Process Plan. This book covers the applications of Expert Machinist, NC Assembly, and CMM apps. Using the Expert Machinist app, you can create NC programs for machining some of the most difficult machining jobs. This app gives you the capability to generate NC programs suitable for 3-axes, 4-axes, or 5-axes milling machines.

The Creo Manufacturing 9.0 Black Book, is written to help professionals as well as learners in creating NC programs for very complex jobs that are machined in the Machine shop. The book covers almost all the information required by a learner to master the Expert Machinist, NC Assembly, and CMM modules of Creo. It covers basic as well as advanced topics like NC machines, milling tools with their uses, tool setting, machine setting, cutting strategies, NC Features, creation of output for a specific machine, CMM, and so on. Some of the salient features of this book are :

In-Depth explanation of concepts

Every new topic of this book starts with the explanation of the basic concepts. In this way, the user becomes capable of relating the things with real world.

Topics Covered

Every chapter starts with a list of topics being covered in that chapter. In this way, the user can easily find the topic of his/her interest easily.

Instruction through illustration

The instructions to perform any action are provided by maximum number of illustrations so that the user can perform the actions discussed in the book easily and effectively. There are about 750 small and large illustrations that make the learning process effective.

Tutorial point of view

At the end of concept’s explanation, the tutorial make the understanding of users firm and long lasting. Almost each chapter of the book has tutorials that are real world projects. Moreover, most of the tools in this book are discussed in the form of tutorials.

For Faculty

If you are a faculty member, then you can ask for video tutorials on any of the topic, exercise, tutorial, or concept. As faculty, you can register on our website to get electronic desk copies of our latest books, self-assessment, and solution of practical. Faculty resources are available in the Faculty Member page of our website (www.cadcamcaeworks.com) once you login. Note that faculty registration approval is manual and it may take two days for approval before you can access the faculty website.

Formatting Conventions Used in the Text

All the key terms like name of button, tool, drop-down etc. are kept bold.

Free Resources

Link to the resources used in this book are provided to the users via email. To get the resources, mail us at [e-mail] with your contact information. With your contact record with us, you will be provided latest updates and informations regarding various technologies. The format to write us mail for resources is as follows:

Subject of E-mail as Application for resources of ................. book.

Also, given your information like

Name:

Course pursuing/Profession:

Contact Address:

E-mail ID:

Note: We respect your privacy and value it. If you do not want to give your personal informations then you can ask for resources without giving your information.

About Authors

The author of this book, Matt Weber, has authored many books on CAD/CAM/CAE available already in market. Mastercam Black Books are one of the most selling books in Mastercam field. The author has hands on experience on almost all the CAD/CAM/CAE packages. If you have any query/doubt in any CAD/CAM/CAE package, then you can contact the author by writing at [e-mail]

The author of this book, Gaurav Verma, has written and assisted in more than 16 titles in CAD/CAM/CAE which are already available in market. He has authored AutoCAD Electrical Black Books which are available in both English and Russian language. He has also authored books on vocational courses like Automotive Service Technician and Machinist. He has provided consultant services to many industries in US, Greece, Canada, and UK.

For Any query or suggestion

If you have any query or suggestion, please let us know by mailing us on [e-mail]. Your valuable constructive suggestions will be incorporated in our books and your name will be addressed in special thanks area of our books on your confirmation.

Chapter 1

Starting with Manufacturing

The major topics covered in this chapter are:

•Introduction to Manufacturing

•Types of Machines

•NC Machines

•Applications of CAM

•Starting Creo Parametric Manufacturing

•Creo Parametric Manufacturing User Interface

•Common Operations like Save, Close, Send, and so on

•Advantages and Disadvantages of CAM

Introduction to manufacturing

Manufacturing is the process of creating a useful product by using a machine, a process, or both. For manufacturing a product, there are some steps to be followed:

•Generating model of final product.

•Deciding Workpiece; selection of raw material and shape/size of workpiece depends on the application of the product.

•Forging, Casting, or any other pre machining method for creating layout for final shape.

•Roughing processes.

•Finishing Processes.

•Quality Control.

These processes are the main area of concern in this book. An introduction of these processes is given next.

As the Generating Layout of final product is above all the steps, it is the most important step. One should be very clear about the final product because all the other steps are totally dependent on the first step. The layout of final product can be a drawing or a model created by using any modeling software like SolidWorks, Inventor, Solid Edge, and so on. You can also use the Design environment of Mastercam software to create the model.

The next step is Selection of Raw material/Workpiece. This step is solely dependent on the first step. Our final product defines what should be the raw material and the workpiece shape. Here, workpiece is the piece of raw material of desired shape to be used for the next step or process.

The next step is Forging, Casting, or any other process for creating outline of the final shape. The outline created for the final shape is also called Blank in industries. In this step, various machines like Press, Cutter, or Moulding machines are used for creating the blank. In some cases of Casting, there is no requirement of machining processes. For example, in case of Investment casting, most of the time there is no requirement of machining process. Machining processes can be divided further into two processes:

•Roughing Processes

•Finishing Processes

These processes are the main discussion area of this book. An introduction to these processes is given next.

Roughing Process

Roughing process is the first step of machining process. Generally, roughing process is the removal of large amount of stock material in comparison to finishing process. In a roughing process, the quantity of material removed from the workpiece is more important than the quality of the machining. There are no close tolerances for roughing process, so the main areas of concern are maximum limit of material that can be removed without harming the cutting tool life. So, these processes are relatively cheaper than the finishing process.

In manufacturing industries, there are three principle machining processes called Turning, Milling, and Drilling. In case of roughing process, there can be turning, milling, drilling, combination of any two, or all the processes. Along with these machining processes, there are various other processes like shaping, planing, broaching, reaming, and so on. But these processes are used in special cases.

Finishing Process

Finishing process can include all the machining processes discussed in case of roughing processes but in close tolerances. Also, the quality of machining at required accuracy level is very important for finishing. Along with the above discussed machining processes, there are a few more machining processes like Electric Discharge Machining(EDM), Laser Beam Machining, Electrochemical Machining, and so on. These processes are called unconventional machining processes because of their cutting method. In unconventional machining processes, the cutting is not performed by mechanical pull/push of tool in the workpiece. In these machining processes, electrical discharge, chemical reaction, laser beams, and other sources are used for cutting. Some of the common machines used for machining processes are discussed next.

Types of Machines

There are various types of machines for different type of machining process. For example- for turning process, there are machines like conventional lathe and CNC Turner. Similarly for milling process, there are machines called Milling machine, VMC or HMC. Some of the machines are discussed next with details of their functioning.

Turning Machines

Turning machine is a category of machines used for turning process. In this machine, the workpiece is held in a chuck (collet in case of small workpieces). This chuck revolves at a defined rotational speed. Note that the workpiece can revolve in either CW(Clockwise) or CCW(Counter-Clockwise) direction but cannot translate in any direction. The cutting tool used for removing material can translate in X and Y directions. The most basic type of turning machine is a lathe. But now a days, lathes are being replaced by CNC Turning machines, which are faster and more accurate than the traditional lathes. The CNC Turning machines are controlled by numeric codes. These codes are interpreted by machine controller attached in the machine and then the controller commands various sections of the machine to do a specific job like asking the motor of cutting tool to rotate in clockwise direction by 10 degree. The basic operations that can be done on turning machines are:

•Taper turning

•Spherical generation

•Facing

•Grooving

•Parting (in few cases)

•Drilling

•Boring

•Reaming

•Threading

Milling Machines

Milling machine is a category of machines used for removing material by using a perpendicular tool relative to the workpiece. In this type of machine, workpiece is held on a bed with the help of fixtures. The tool rotates at a defined speed. This tool can move in X, Y, and Z directions. In some machines, the bed can also translate and rotate like in Turret milling machines, 5-axis machines, and so on. Milling machines are of two types; horizontal milling machine and vertical milling machine. In Horizontal milling machine, the tool is aligned with the horizontal axis (X-axis). In Vertical milling machine, the tool is aligned with the vertical axis (Y-axis). The Vertical milling machine is generally used for complex cutting processes like contouring, engraving, embossing, and so on. The Horizontal milling machines are used for cutting slots, grooves, gear teeth, and so on. In some Horizontal milling machines, table can move up-down by motor mechanism or power system. By using the synchronization of table movement with the rotation of rotary fixture, we can also create spiral features. The tools used in both type milling machine have cutting edge on the sides as well as at the tip.

Drilling Machines

Drilling machine is a category of machines used for creating holes in the workpiece. In Drilling machine, the tool (drill bit) is fixed in a tool holder and the tool can move up-down. The workpiece is fixed on the bed. The tool goes down, by motor or by hand, penetrating through the workpiece. There are various types of Drilling machine available like drill presses, cordless drills, pistol grip drills, and so on.

Shaper

Shaper is a category of machines, which is used to cut material in a linear motion. Shaper has a single point