Creo 8.0 subtractive manufacturing what's new

CREO 8
SUBTRACTIVE
MANUFACTURING
Jose Coronado
Director, Product Management

2
AGENDA
• Creo Manufacturing Portfolio and Strategy
– Introducing the 5-axis Mold Machining Extension
• Value proposition: HSM Rough/Rest Rough
Scan Types
– Automatic 3+2 Axis Rough toolpath
– 5-axis Rough toolpath
• Auto Deburring toolpath
• Value proposition: HSM Finish/Rest Finish
Options
– Convert 3-axis to 5-axis Finish toolpath
• Remarks

3
AGENDA
Scan Types
Options
• Remarks

4
Creo Computer-Aided
verification
CREO MANUFACTURING SOLUTIONS PORTFOLIO
Creo Prismatic & Multi-
Surface Milling
Creo Production
Machining Extension
Creo Complete
Machining Extension
Creo 3 Axis Mold
Machining Extension
Additive Manufacturing
plus for Materialise
Creo Additive
Manufacturing
Generative Topology
Optimization
Creo Parametric
Creo NC Sheetmetal Creo Reverse
Engineering Extension
Creo Progressive Die
Extension
Creo Expert Moldbase
Extension
Creo Tool Design
Option
Creo Mold Analysis
Extension
Multi-Surface 3-axis milling with high-
speed machining support
Added support for 4-axis turning and
wire EDM
2.5- to 5-axis milling, multi-axis
turning, multi-task machining and 4-
axis wire EDM
Digital inspection and verification of
machined parts and assemblies
Reverse engineer from point cloud or
faceted model geometry
NC programming for turret punch
presses, contouring laser/flame
machines, nibbling and shearing
Specialized capabilities to speed 3
axis mold machining
Accelerate the design of production
mold and cast tooling
Automate and speed moldbase
design
Automate and speed progress die
design
Mold filling analysis
Parametrically controlled lattice
structures and data-managed tray
assemblies
Creo AM functionality plus Support
structures for metal and build
processors
Find the most efficient distribution of
material within a user-defined design
space
Connectivity with polymer printers
and service bureaus
Forward looking information subject to change without notice © 2021 PTC
Generative Design
Extension
Consider many scenarios in parallel
and quickly with cloud-based GDX

5
Creo Computer-Aided
verification
CREO MANUFACTURING SOLUTIONS PORTFOLIO
Creo Prismatic & Multi-
Surface Milling
Creo Production
Machining Extension
Creo Complete
Machining Extension
Creo 3 Axis Mold
Machining Extension
Additive Manufacturing
plus for Materialise
Creo Additive
Manufacturing
Generative Topology
Optimization
Creo Parametric
Creo NC Sheetmetal Creo Reverse
Engineering Extension
Creo Progressive Die
Extension
Creo Expert Moldbase
Extension
Creo Tool Design
Option
Creo Mold Analysis
Extension
Multi-Surface 3-axis milling with high-
speed machining support
Added support for 4-axis turning and
wire EDM
2.5- to 5-axis milling, multi-axis
turning, multi-task machining and 4-
axis wire EDM
Digital inspection and verification of
machined parts and assemblies
Reverse engineer from point cloud or
faceted model geometry
NC programming for turret punch
presses, contouring laser/flame
machines, nibbling and shearing
axis mold machining
Accelerate the design of production
mold and cast tooling
Automate and speed moldbase
design
Automate and speed progress die
design
Mold filling analysis
and 5 axis mold machining
Parametrically controlled lattice
structures and data-managed tray
assemblies
Creo AM functionality plus Support
structures for metal and build
processors
Find the most efficient distribution of
material within a user-defined design
space
Connectivity with polymer printers
and service bureaus
Creo 3 and 5 Axis Mold
Machining Extension
Generative Design
Extension
Consider many scenarios in parallel
and quickly with cloud-based GDX

6
Faster exploration of innovative design alternatives and selection
of the most efficient manufacturing processes
MFG
Interoperability
Materials
Structural, Thermal,
Modal, Fluid
Simulation
Placement
Tray Assembly
Supports/Simulation
Generative
Legacy
Lattice
WORKFLOW
AM Process
Simulation
Bionic shapes
Mold/Cast shapes
Directly
Machinable shapes
Machinable shapes
Note: Sample workflow, not exhaustive
3D Printers
Machine tools
Hybrid

7
Faster exploration of innovative design alternatives and selection
of the most efficient manufacturing processes
MFG
Interoperability
Materials
Structural, Thermal,
Modal, Fluid
Simulation
Placement
Tray Assembly
Supports/Simulation
Generative
Legacy
Lattice
WORKFLOW
AM Process
Simulation
Bionic shapes
Mold/Cast shapes
Directly
Machinable shapes
Machinable shapes
Note: Sample workflow, not exhaustive
3D Printers
Machine tools
Hybrid

8
• Partnership with Moduleworks • To speed up the delivery of new
functionality our strategy includes
now a partnership with Moduleworks.
– ModuleWorks in numbers:
• 200+ Software Developers. Toolpaths &
Simulation
• 900+ Man-years. Core Development
• 75% Market share. CAM Market
• 500,000 CAD/CAM end users. every day
• This help us to reduce the time
needed to give you new functionality
– E.g. Material removal simulation, 3 and 5
Axis Machining, laser deposition toolpath
prototype
HOW TO SPEED UP THE DELIVERY OF FUNCTIONALITY
IN CREO NC

9
• Creo NC areas of focus:
– Creo 1 to Creo 4:
• Focus on Production Machining
Specifically to serve the Multi-
Tasking Machines programming
requirements
– E.g : support of multiple heads,
synchronization and cl-data
adjustment
– Creo 5:
• Launch 3 Axis Mold Machining
– Performance improvement
• Material removal simulation
– Creo 6:
• Support of customer’s special cases
• Dynamic B-Axis Turning as a
complement to Multi-Task
Machining
STRATEGY FOR CREO NC
– Creo 7
• Performance improvement with
focus on 3 Axis Mold Machining.
• Beta-tests: Hybrid Additive
prototypes
• Customer’s cases on multi-task
machining
– Creo 8
• Launch 5 Axis Mold Machining
• Continue the Laser Additive
prototype
machining
– Creo 9
• Focus on 5 Axis Mold Machining. (
add Swarf and Geodesic)
machining and Turning

10
• Product Description
– A dedicated Creo machining module
which simplifies 5-axis programming
– High-value, easy-to-use simultaneous 5-
axis and 3+2-axis collision free toolpaths
– Can be used for both Mold & Die and
production parts
– Can initially complement existing 5-axis
Creo finish toolpaths
INTRODUCING CREO 5-AXIS MOLD MACHINING
EXTENSION

11
• New commands:
– HSM 5 Axis Rough
– HSM 5 Axis Rest Rough
– Auto Deburring
• Option to create 3+2 Machining
for:
– HSM Rough
– Rest Rough
• 3to5 axis Conversion for:
– Finish
– Rest Finish
CREO 5-AXIS MOLD MACHINING EXTENSION
3 Axis HSM
3 and 5 Axis HSM
7 HSM Toolpaths implemented in
Creo 8

12
Stay in Creo environment
Increased productivity
Less training required
Higher quality results
• Moduleworks HSM Toolpaths behave as native Creo
NC Toolpaths
– Creo user does not need to switch to external CAM
solution for HSM capabilities
• Reduced programming/machining times & setup
• Easy-to-use 5 Axis toolpaths which can be
programmed with 3-axis experience
• Advanced finishing strategies for high-quality surface
finish
BENEFITS TO THE END-USER

13
AGENDA
Scan Types
Options
• Remarks

14
HSM Rough & Rest Rough Scan Types

15
HSM ROUGH SCAN TYPES: CONSTANT LOAD (DEFAULT)
• A powerful, high-value feature that is comparable to high-priced end-user
products (e.g. Volumill)
• Reduces milling times significantly (40%-60%) compared to conventional
roughing
– By ensuring constant cutting conditions:
• Stable tool load
• Higher feedrate
• Reduced tool-wear
• Important note:
– Creo NC user should use this Constant Load scan type:
• With solid carbide tools
• Where full flute length is engaged for machining

16
HSM ROUGH SCAN TYPES: SPIRAL
• Efficient, collision free and reliable roughing toolpaths using advanced
smoothing:
– Reduced machining time for large volumes of stock
– Stable machine kinematics
– Enhanced tool-life
• Important note:
– Creo NC user should use Spiral scan type:
• With indexable insert tools
• On larger die and mold parts
• With less dynamic machines

17
Automatic 3+2 Axis Rough toolpath

18
• Introduction:
– 3+2 Machining is a technique where the removal of
material is done in 3 Axis, using two rotational axis
to position the part in such a way that shorter
(sturdier) tools can reach.
• Objective:
– This project is to enable the creation of 3+2
machining toolpaths for roughing and rest-roughing.
With an algorithm to automatically calculate the
rotations to reach all the material.
• Scope:
– The user is be able to create 3+2 HSM Rough and
HSM Rest Rough toolpaths with the following
controls:
• Search Angle Increment
• Minimum Stock to detect area
• Maximum Tool Tilt Angle
– Maximum rotation of tool can be 90 degrees.
HSM 3+2 MACHINING

20
AUTO 3+2 AXIS ROUGH
How would you rough this
part?

21
AUTO 3+2 AXIS ROUGH
• Automatically detects the machining directions with
the minimum orientations necessary.
• Automatic collision checking with the in-process stock
and the part itself.
• Works with very complex parts including those with
undercut areas.
• All the system requires is:
– Tool definition
– Stock & part as input surfaces

22
AUTO 3+2 AXIS ROUGH: BENEFITS
Reduced programming time
Ease-of-use
Less user errors

23
AUTO 3+2 ROUGH: APPLICATION AREAS
• Mold and Die • Production parts with undercuts

24
AUTO 3+2 AXIS ROUGH: HOW IT WORKS
How the toolpath algorithm works under the hood?:
1. Automatically checks for the max rest machining area and selects
the biggest to be machined along Z axis
2. Automatically selects the tool direction with best access
3. Machines the area (automatic boundary is being created)
4. This repeats until the stop condition set by the user is met
1. 2.
3. 4.

25
AUTO 3+2 AXIS ROUGH: HOW IT WORKS
• Dynamic holder collision checking is a key element to this toolpath.
• This protects the holder from collisions against:
– the in-process stock model (that changes continuously during machining).
– the actual workpiece

26
AUTO 3+2 ROUGH
VIDEO

28
• Introduction:
– Creo NC users are leveraging 5 Axis milling
machines to be able to produce complex
shapes with fewer setups and better surface
finish.
• Objective:
– The goal of this project is to enable the
creation of concurrent 5 Axis rough toolpaths
• Scope:
– The user is able to create 5 Axis Rough
toolpaths with the following Slice Generation
Strategies
• Offset from Floor
• Offset from Ceiling
• Morph
– With the possibility to select individual containment
loops perpendicularly projected on the areas to be
machined
HSM 5 AXIS ROUGH
Diagram of an Okuma MU-10000H horizontal machining
center.

30
• Introduction:
– Rest rough is the operation to remove the material
left form a previous toolpath to reach the final
shape
• Objective:
– This project is to enable the creation of concurrent
5 Axis Rest Rough toolpaths
• Scope:
– The user is be able to create 5 Axis Rest Rough
toolpaths with the following Slice Generation
Strategies
• Offset from Floor
• Offset from Ceiling
• Morph
– All the slice generation strategies should use a rough
stock file which is used to calculate the rest material
– With the possibility to select individual containment loops
perpendicularly projected on the areas to be machined
HSM 5 AXIS REST ROUGH

32
5-AXIS ROUGH
• High-speed roughing for continuous 5-Axis
machining of pockets with curved floor surfaces
• High level of automation with minimal user input and
collision-checking
• Constant load strategy significantly reduces
machining time and tool wear
• Tool types supported:
– Endmill
– Bullnose
– Taper tools
– Ball mills

33
5-AXIS ROUGH: BENEFITS
Shorter roughing cycle time
Reduced tool wear
Less iterations
Easy-to-use

34
5-AXIS ROUGH: APPLICATION AREAS
• Aerospace parts • Tire molds • Production parts

35
5-AXIS ROUGH
• Morph between
ceiling and floor
• Offset from floor • Offset from ceiling
High efficiency due to 3 optimized slice generation strategies:
Ceiling
Floor Floor
Ceiling

36
5-AXIS ROUGH: PATTERN TYPES
Roughing scan types:
• Constant load • Spiral
Best to use with solid carbide tools
and full flute length engaged for
machining

37
5-AXIS ROUGH: CUTTING METHOD
• One way
• Upcut
• Climb
• Zigzag • Spiral
Cutting method:

38
5-AXIS ROUGH: TOOL AXIS CONTROL
Highly automated tool axis
control option:
The tool is oriented
automatically along the normal
to the floor surface

39
5-AXIS ROUGH: COLLISION CHECKING
Full collision checked tool path:
• Check with machining surfaces • Check with in-process stock

40
5-AXIS ROUGH
VIDEO

41
AGENDA
Scan Types
Options
• Remarks

43
• Introduction:
– Deburring is a very common and time
consuming operation on a part being machined
• Objective:
– The goal of this project is to enable the
automatic creation of deburring toolpaths in in
3 and 5 axis
• Scope:
– The user is be able to select the whole part to
which the deburring toolpaths will be
calculated
• There is a possibility to exclude edges
– 3 Axis and 5 Axis machining supported
AUTO DEBURRING

45
AUTO DEBURRING TOOLPATH
• toolpath to deburr sharp edge of a workpiece
with a spherical tool
• Highly automated: Edges are automatically
detected.
• Automatic tilting, linking and collision-checking
• This toolpath significantly reduces the setup
time of deburring operations

46
AUTO DEBURRING: BENEFITS
Automates a manual process
Saves employee time
Easy-to-use

47
AUTO DEBURRING: APPLICATION AREAS
• Production parts

48
AUTO DEBURRING: AUTOMATED EDGE DETECTION
• The reference model is required
• If desired the user can define:
– edges to be deburred explicitly
– edges not to be deburred explicitly
– minimal length of edges that should be detected
– edges by minimum edge angle

49
Constant width
• The geometry of a chamfer can be
approximated by the edge thickness
parameter.
AUTO DEBURRING: CHAMFER GEOMETRY

50
• By creating multiple cuts along the
edges, chamfers can be approximated on
parts that do not contain these features in
the Creo model.
AUTO DEBURRING: MULTIPLE CUTS

51
AUTO DEBURRING: TOOL AXIS CONTROL
• Tool axis control for different
machine types:
– 3 Axis
– 5 Axis simultaneous

52
AUTO DEBURRING: LINKS
Optimal Linking can reduce the machining time significantly.
Rather than retracting to the clearance area after each tool path segment the algorithm
can create collision free blend spline.

53
AUTO DEBURRING: AUTO COLLISION AVOIDANCE
• Deburring makes use of automatic tilting to
avoid collisions between:
– The part
– Additional fixture surfaces
– All parts of the tool

54
AUTO DEBURRING
VIDEO

55
AGENDA
Scan Types
Options
• Remarks

56
HSM Finish/Rest Finish Options

57
• Introduction:
– 3to5 Axis Conversion is a technique where the
removal of material is done in 3 Axis as much as
possible, wherever the algorithm find a gouging of
the holder it will tilt the tool.
• Objective:
– This project is to enable the creation of 3to5 Axis
machining toolpaths for finishing and rest-finishing
that enable the machining using shorter more
stable tools.
• It will detect the areas where gouges are present and
tilt the tool.
• Scope:
– The user is be able to create 3to5 Axis Conversion
for HSM finish and HSM Rest finish toolpaths with
the controls of the Maximum Tool Tilt Angle
HSM 3TO5 AXIS CONVERSION FOR FINISHING AND
REST-FINISHING

59
HSM FINISH & REST FINISH OPTIONS
• HSM Finish & Rest Finish toolpaths can accurately finish complex
parts with high surface quality.
• These are designed for high speed finishing with smooth cutting
and linking passes.
• Finish Options include:
– Constant_Z
• For steep areas
– Parallel_Cuts
– Constant_Cusp
• For shallow areas
– SmartCut
• Combination of Constant_Z for steep areas and Constant_Cusp for shallow ones
– Flatland machining
– Multi-Pencil (for Rest Finish)
• For cornering

60
Convert 3-axis to 5-axis Finish toolpath

61
CONVERT 3-AXIS TO 5-AXIS FINISH TOOLPATH
• This automatically converts a 3-axis HSM Finish
toolpath into a 5-axis Finish toolpath.
• The main aim is to take the 3-axis HSM toolpath and
use it with a much shorter tool.
• The resulting 5-axis toolpath is fully collision-checked
• The automatic tilting compensates the holder with
the geometry and tilts it away.

62
CONVERT 3-AXIS TO 5-AXIS FINISH TOOLPATH
Reduced programming time
Increased productivity
Less user error
Higher quality results

63
WHY CONVERT 3-AXIS TO 5-AXIS?

64
• Avoid Chatter with long tools
• Avoid tool deflections

65
• Avoid costly collisions
• Avoid manual repositioning
and manual setup

66
• Only Ball mill cutters (with the same
diameter) are supported.
• However, the shaft can be conical, the
shaft can be shorter and the holder
can have a different shape
TOOLS AND TILT ANGLE
Tilt Angle

67
AUTOMATIC 3 TO 5 AXIS CONVERSION
VIDEO

68
AGENDA
Scan Types
Options
• Remarks

69
• New commands:
– HSM 5 Axis Rough
– HSM 5 Axis Rest Rough
– Auto Deburring
• Option to create 3+2 Machining
for:
– HSM Rough
– Rest Rough
• 3to5 axis Conversion for:
– Finish
– Rest Finish
CREO 5-AXIS MOLD MACHINING EXTENSION
3 Axis HSM
3 and 5 Axis HSM
7 HSM Toolpaths implemented in
Creo 8

70
• HSM SWARF offers automation for
flank milling of ruled surfaces:
– Just pick the surface and the edges are
created automatically
• The tool automatically orients in
simultaneous 5-axis for full access to
machining areas
• The system still offers flexibility for
advanced users
TOOLPATHS CONSIDERED FOR 5 AXIS HSM
SWARF FOR FLANK MILLING

71
• Geodesic machining: Innovative 3D
offset Finish for parts with
undercuts
• Smooth toolpaths with a constant
cusp height can be achieved for
complex parts with undercuts
• Can be combined with Convert 3-axis
to 5-axis tilting and collision-checking
• User can input single or multiple
guide curves for offset or morph
pattern types
TOOLPATHS CONSIDERED FOR 5 AXIS HSM
GEODESIC FOR FLOW LINE MACHINING

72
• Unparalleled associativity
• Robust multi-task machining
• HSM toolpaths
• Seven new 5 Axis HSM Toolpaths in
Creo 8
• Reduced programming time
• Automation and control over
toolpath creation
• Familiar Creo User Interface
All in ONE CAD
System: Creo
REMARKS
SUBTRACTIVE MANUFACTURING IN
CREO

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