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2001 PTC
Training
Exercises

VERICUT for Pro/ENGINEER
Machine Simulation
2001 PTC 2
Introduction
Terms
MS stands for Machine Simulation in this exercise
2001 PTC 3
Exercise 1 - Outline
Outline
3 axis milling machine
Work in Pro/E
Create machine components and assembly in Pro/E
Export STL file of each machine component against Machine
Zero CSYS
Create tool path file(NCL and TAP) using Pro/NC and G-Post
Work in VERICUT Machine Simulation
Build machine kinematics in VERICUT Machine Simulation
Load machine components (STL file) to VERICUT MS
Load Control file
Save MCH, CTL and JOB file in your working directory
Test machine with MDI
Job, Machine setting
Create or load tool library file, tool gauge length setting
Load tool path file and simulate tool path
2001 PTC 4
Exercise 1 - 3 axis milling machine
Build 3 axis milling machine and simulate tool path
Work in Pro/E
Preparation
Copy all the machine simulation exercise folder and files to your
computer, set Pro/E working directory to: \exercise 1
Machine components and assembly
In Pro/E, Open file 3axis-mill.asm
base-x-slide
x-axis
y-axis
z-axis
stock
fixture
z-axis-cylinder
base
base-z-slide
2001 PTC 5
Export component: base.prt in STL format
In Pro/E, choose: File/Export/Model/STL
Select 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
Exercise 1 - 3 axis milling machine
2001 PTC 6
Export all of other components in STL format
Tips
Choose the right Coordinate System - machine zero (ACSO) for all components, because
there 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 them
when exporting base-y-slide, same comments for base-z-slide
x-axis
y-axis
z-axis
stock
fixture
z-axis-cylinder
base
base-y-slide
base-z-slide
Exercise 1 - 3 axis milling machine
2001 PTC 7
Exercise 1 - 3 axis milling machine
Work in VERICUT Machine Simulation
Access VERICUT Machine Simulation
In 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 kinematics
In MS, choose: Machine / Components
2001 PTC 8
Exercise 1 - 3 axis milling machine
Build components tree as following figure shows
In components window, click Add
Add base component: In Add components window, give type as base, color as cyan, then click
Apply
Components
Tree
2001 PTC 9
Exercise 1 - 3 axis milling machine
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
2001 PTC 10
Exercise 1 - 3 axis milling machine
Components: X-Linear, Fixture and Stock
After finish last component - Stock, click OK in Add Component window
X Linear Fixture Stock
2001 PTC 11
Exercise 1 - 3 axis milling machine
Load STL files to VERICUT MS
Load 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.
2001 PTC 12
Exercise 1 - 3 axis milling machine
Load STL files to other components
Load 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 Primitives
In 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
2001 PTC 13
Exercise 1 - 3 axis milling machine
Change Tool connect position
In Pro/E, find distance from gauge point to work table plane
(machine zero), It is 15.2 inch. We will move tool connect
position from machine zero to gauge point
In VERICUT MS, choose: Machine / Components
In Components window, choose: Tool, then click Modify
In Modify window, set Connect position=(0 0 15.2), then click
OK
Close Components window
15.2
Gauge Point
Machine Zero
2001 PTC 14
Exercise 1 - 3 axis milling machine
Save machine file in your working directory
In VERICUT MS, choose: Machine / Save as, give file name
3ax-mill.mch, make sure you save it in \exercise 1 folder
Load control file
In VERICUT MS, choose: Control / Open, open file generic.ctl,
find this control file in category CGTECH_RP2LIB
Save control file in your working directory
In VERICUT MS, choose: Control / Save as, give file name
generic.ctl, make sure save it in \exercise 1 folder
2001 PTC 15
Exercise 1 - 3 axis milling machine
Test your machine with MDI
In VERICUT MS, choose: Job / MDI
Test X axis, type in x10 in MDI, click Apply. Notice movement
of X axis
Test negative direction of X axis (x-10)
Test Y and Z axis
(Notes: if axis doesnt move, check if
you load control file correctly)
2001 PTC 16
Exercise 1 - 3 axis milling machine
Set machine table
In Pro/E, use Analysis/Measure, check distance between gauge
point to stock surface, It is 7.7 inch. We will set top surface
center of stock as programming zero
In VERICUT MS, choose: Machine / Table
In 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 Job
Table, if a Job Table is defined, it will over write Machine Table)
7.7
2001 PTC 17
Exercise 1 - 3 axis milling machine
Set Travel Limits
In VERICUT MS, choose: Machine / Travel Limits
In Travel Limits window, type in Min and Max travel limits of
each axis, then click Modify
See following figure for limits value of 3 axis
Toggle Overtravel Detection On
Click OK
2001 PTC 18
Exercise 1 - 3 axis milling machine
Collision setup
In VERICUT MS, choose: Job / Collision
Set: Component 1=Fixture, Component 2=Tool, Tolerance=0.1
Toggle Collision Detection On
Click OK
2001 PTC 19
Exercise 1 - 3 axis milling machine
Tool library
Method 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 working
directory - VERICUT MS exercise 1 folder
In VERICUT MS, choose: Tools / Tool File, open file cgtpro.tls, find it in your current working
directory
Change tool gauge length. In VERICUT MS, choose: Tools / Tool Manager
In Tool Manager window, click Modify
2001 PTC 20
Exercise 1 - 3 axis milling machine
In Tool Modify window, click Properties
In Tool Properties window, set Gage Length=4, click OK
In Tool Modify window, click OK
In Tool Manager window, click Save, then Close
2001 PTC 21
Exercise 1 - 3 axis milling machine
Method 2, create tool library in VERICUT MS by yourself
In Tool Manager window, click Add
In 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 window
Click Yes in the small question window
2001 PTC 22
Exercise 1 - 3 axis milling machine
Load tool path
In VERICUT MS, choose Job / Setting
In Job Settings window, open Toolpath file tool-com.tap, find
this file in exercise 1 folder
Other 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 OK
Reset Machine Simulation


Run machine simulation
2001 PTC 23
Exercise 2 - Outline
Outline
4 axis milling machine
Build machine kinematics
Load STL files
Machine Table, Travel Limits, Collision setting
Load tool library, set tool gauge length offset
Load tool path file, control file
Tool path simulation
2001 PTC 24
Exercise 2 - 4 axis milling machine
Build 4 axis milling machine
Build machine kinematics
See following figures for machine kinematics
Make sure component Type, Connect to, Motion axis and
Connect Position is right
Notice connect position of rotary axis A is: (0 0 4), Design
is: (0.5 0 0)
(Notes: For Multi-Axis machine
uses CSYS on rotary centerline
for rotary axis)
2001 PTC 25
Exercise 2 - 4 axis milling machine
Build machine kinematics
2001 PTC 26
Exercise 2 - 4 axis milling machine
Build machine kinematics
2001 PTC 27
Exercise 2 - 4 axis milling machine
Build machine kinematics
2001 PTC 28
Exercise 2 - 4 axis milling machine
Load STL files
Base - base.stl
Z - head.stl and spindle.stl
Tool - Nothing
Y - 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)
2001 PTC 29
Exercise 2 - 4 axis milling machine
Set Machine Table
See following Machine Table figure for details
Set Travel limits
See following Travel Limits figure for details
Save machine file
Give file name: prolight.mch, save it in \exercise 2 folder
2001 PTC 30
Exercise 2 - 4 axis milling machine
J ob setting
Load tool path file: op010.tap, find this file in \exercise 2
folder
Other settings, see following figure
Collision setup
See following Collision Setup figure for details
2001 PTC 31
Exercise 2 - 4 axis milling machine
Load tool library and set tool gauge length offset
Load tool library file ncmach_gage.tls, find it in
\exercise 2 folder
Set gauge point at top of each tool
Control file
Load control file tmc2000.ctl, find this file in
\exercise 2 folder
Save J ob file
Give JOB file name: prolight.job, save it in
\exercise 2 folder
Tool path simulation
Gauge Point
2001 PTC 32
Exercise 2a- Outline
Outline
5 axis laser machine
In Pro/E, export components in STL format
Base and linear axis - Against Machine Zero CSYS
Rotary axis - Against CSYS at rotary center
Build machine kinematics, rotary axis and tool connect
position calculation
Load STL files to machine
Machine Table, initial machine location, RTCP pivot offset
calculation
Load tool library and set gauge length offset
Load tool path file, control file
Tool path simulation


2001 PTC 33
Exercise 2a - 5 axis laser machine
Build 5 axis laser machine
Preparation
Set Pro/E working directory to \exercise 2a
Open file laserdyne.asm
Export components in STL format
Export base and all linear axis using CSYS
at machine zero
Base
XAXIS
YAXIS
ZAXIS
Table
CAXIS
DAXIS
2001 PTC 34
Exercise 2a - 5 axis laser machine
Export rotary components (C and D axis) using CSYS at
centerline of rotary axis
Using ACS0 for CAXIS, and ACS1 for DAXIS
(Notes: Use same name as Pro/E part for STL files)
CAXIS
DAXIS
2001 PTC 35
Exercise 2a - 5 axis laser machine
Build machine kinematics & load STL files
Base
Type: 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)
XAXIS
Type: 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)
ZAXIS
Type: 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)
2001 PTC 36
Exercise 2a - 5 axis laser machine
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)
DAXIS
Type: B Rotary, Name: D, Motion Axis: Y, Connect To: C, Connect Position: (0 8 -6) Color: Tan
, Mixed Mode:Shade, Angles: (0 0 0)
Primitives: daxis.stl, Color, Inherit, Position (0 0 0), Angle (0 0 0)
Tool
Type: Tool, Name: Tool, Motion Axis: Z, Connect To: D, Connect Position: (0, 8.5, -15) Color:
Red , Mixed Mode: Shade, Angles: (0 0 0)
Table
Type: Other, Name: Table, Connect To: Base, Connect Position: (0 0 0) Color: Blue , Mixed
Mode: Shade, Angles: (0 0 0)
Primitives: table.stl, Color, Inherit, Position (0 0 0), Angle (0 0 0)
2001 PTC 37
Exercise 2a - 5 axis laser machine
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
2001 PTC 38
Exercise 2a - 5 axis laser machine
Rotary axis & tool connect position calculation
C-axis connect position is measured from Machine Zero to C-axis CSYS
D-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 Machine
Zero)
Machine Zero
-16.5
21
8
-6
C-axis CSYS
D-axis CSYS
2001 PTC 39
Exercise 2a - 5 axis laser machine
Set machine table
Set Initial Machine Location=(0 0 20)
Set RTCP pivot offset=(0 -16.5 15)
RTCP Offset Xval-Zval are calculated by subtracting the location of the Tool component origin
from the rotary pivot point location (with all axes at their Initial Machine Location )
Save machine file
-16.5
15
2001 PTC 40
Exercise 2a - 5 axis laser machine
Load tool library and set gauge length offset
Load file tool.tls, find it in exercise 2a folder
Set gauge offset=8
Load control
Load control file laserdyne.ctl, find it in exercise 2a folder
Load Toolpath file
Load file op010.tap, find it in exercise 2a folder
Save J OB file
Run simulation
2001 PTC 41
Exercise 3 - Outline
Outline
Build your own machine
Choose one machine from list shown in next 7 slides
Build machine components and assembly in Pro-E
Export components in STL format against right CSYS
Create machine kinematics in VERICUT Machine Simulation
Load machine components (STL file) to VERICUT MS
Load control file (fan16M, find it in category of
CGTECH_RP2LIB) and save it in your current directory
Machine & Job setting
Test your machine with MDI
Create or load tool library file, set tool gauge length
Create Post-Processor (optional), generate TAP file
Load a tool path file (TAP file), run simulation
2001 PTC 42
Exercise 3 - Build your own machine
3 Axis Vertical Mill












3 Axis Horizontal Mill
2001 PTC 43
Exercise 3 - Build your own machine
4 Axis Vertical Mill
Table A
4 Axis Horizontal Mill
Table B
2001 PTC 44
Exercise 3 - Build your own machine
5 Axis Vertical Mill
Head A on B
5 Axis Vertical Mill
Head B / Table A
2001 PTC 45
Exercise 3 - Build your own machine
5 Axis Vertical Mill
tables A on C
5 Axis Horizontal Mill
Heads A on B
2001 PTC 46
Exercise 3 - Build your own machine
5 Axis Horizontal Mill
tables B on A
5 Axis Horizontal Mill
Head A / Table B
2001 PTC 47
Exercise 3 - Build your own machine
5 Axis Gantry Mill - Heads B on C
2001 PTC 48
Exercise 3 - Build your own machine
5 Axis Gantry Mill - Heads A on B
2001 PTC 49
Exercise 4, 4a, 4b
Exercise 4
Menu View
Attributes
View Select/Store
Exercise 4a
Menu J ob
Job Setting
Job Table
Collision
Exercise 4b
Menu Machine
Machine Tables
Travel Limits

2001 PTC 50
Exercise 4 - Menu/View
Menu View
Open file prolight.job in \exercise 4 folder
Attributes
In VERICUT MS, choose: View / Attributes
Show CSYS
Toggle Component Origin, Primitive Origin and Machine Zero
On, then click Apply
CSYS appears
2001 PTC 51
Exercise 4 - Menu/View
Draw Mode
Choose Draw Mode=Lines, click Apply, notice the change
Choose Draw Mode=Hidden, click Apply, notice the change
Change Draw Mode back to Shade
You can also use the icon show below to switch draw mode
Usage of line mode, when simulation, if tool is not shown up,
you can switch to line mode, find where tool is
Line Hidden
2001 PTC 52
Exercise 4 - Menu/View
View Select/Store
Choose: View / Orient. In Orientation window, click ISO icon
Choose: View / Select/Store. In Select/Store View window,
click Add
In View Add window, give view name: iso1, then click OK
Using same method, add XY and YZ view
You can switch view by clicking view name
2001 PTC 53
Exercise 4a - Menu/Job
Menu J ob
J ob Setting
Choose: Job / Setting
In Job Setting, click Select (beside output file) to specify
output APT file name(ex4a.apt) and directory(\exercise 4)
In Job Setting, click Select (beside Log File) to specify
output Log file name(ex4a.apt) and directory(\exercise 4)
In Job Setting window, Click OK
Toggle Conversion: On
Reset VERICUT MS
Run simulation
Find file ex4a.apt and ex4a.log
in your \exercise 4 folder
2001 PTC 54
Exercise 4a - Menu/Job
J ob Table
(Notes: Job Table performs same function as Machine
Table. If the same tables are defined in both job and
machine configurations, the job table values override those
in the machine)
Choose: Job / Tables, in Job Table window, select Initial
Machine Location, give Values= (0 0 12), click Add then
Close
Reset VERICUT MS, see change of initial machine location
Delete Job Table contents
2001 PTC 55
Exercise 4a - Menu/Job
Collision
Choose: Job / Collision
In Collision Setup window, select first line (component A and
Tool), change Tolerance to 5 (this is for exercise purpose
only). Click Modify, then click Ok
Reset VERICUT MS, run simulation
During simulation, both A axis and tool are in error color-red
Change tolerance back to 0.1
2001 PTC 56
Exercise 4b - Menu/Machine
Menu Machine
Tables
Choose: Machine / Tables
In Machine Tables, change Initial Machine Location values
to: (0 0 12), click Modify, then close
Reset VERICUT MS, notice change of machine initial
location
Change it back to (0 0 8)
(Notes: 1. if there is the
same record in Job Table,
Machine Table will be over
written. 2. Changes to Table
are only effective after reset
VERICUT MS)
2001 PTC 57
Exercise 4b - Menu/Machine
Travel Limits
Choose: Machine / Travel Limits
Change Z limits to: (Min=-1, Max=7), click Modify
Toggle Overtravel Detection On, click OK
Reset VERICUT MS, run simulation
Z axis becomes red (error color) during simulation. An error
message also appears in message line. Open Log file to
view error information
Change Z limits back to (-1, 8)
2001 PTC 58
Exercise 5 - Outline
Outline
Run VERICUT and Machine Simulation simultaneously
Machine simulation setting
Change Fixture and Stock connection position
Job Table setting
Job Setting
Load tool library, set gauge length offset
VERICUT Setting
Tool retract setting

2001 PTC 59
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
Run VERICUT and Machine Simulation simultaneously
Machine Simulation setting
Open file 3ax-mill.job, find it in exercise 5 folder
Notes: differences between this job file and the one in exercise
1 are:
Fixture and Stock STL files are replaced by those in VERICUT exercise 6 - sub.usr
Tool library file is replaced by tools.tls in VERICUT exercise 6-sub.usr
We find fixture and stock are not in right position
2001 PTC 60
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
Move fixture and stock to center of machine table
In VERICUT MS, choose: Machine / Components
In 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
2001 PTC 61
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
Job table setting
Set Input Program Zero
In VERICUT MS, choose: Job / Tables
In Job Tables, choose Input Program Zero, give value (-12.5, -12.5, -14.2), this is to move
input 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
Y
Z
2001 PTC 62
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
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 setting
Choose: 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. Conversion
Method, 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)
2001 PTC 63
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
Test your machine with MDI
Give (X0Y0Z0), machine should be at position as following figure shows
Rest machine simulation
XZ plane
YZ plane
2001 PTC 64
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
Load tools and Set gauge length offset
In VERICUT MS, choose: Tools / Tool File, open file tools.tls,
find it in exercise 5 folder
Tool gauge length setting
Choose: Tools / Tool Manager
In Tool Manager window, choose a tool then click Modify
In Tool Modify window, choose Tool Properties
In Tool Properties window, give tool gauge length value
Change gauge point of all five tools to the most top point of each tool
Gauge point
2001 PTC 65
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
Save machine file, save job file
Set Layout to 3 views
Run simulation
2001 PTC 66
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
VERICUT Setting
Open user file sub.usr, find it in exercise 5 folder
Machine simulation window is opened too
(Notes: this user file is same as the one in VERICUT exercise 6)
Change user file setting
In VERICUT, choose: Toolpath / Toolpath Control
In toolpath control window, choose toolpath file sub.tap(its in VERICUT MS exercise 5 folder)
2001 PTC 67
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
G-Code setting
In G-Code Setting window, open Job file 3ax-mill.job, find this file in VERICUT MS exercise 5
folder. Close window
Right after successfully change Job file, machine appears in VERICUT MS window.
Save User file
Resize VERICUT, and Machine Simulation window
Run simulation (Hint: you can control simulation in both window)
2001 PTC 68
Exercise 5 - Run VERICUT & Machine
Simulation simultaneously
Tool retract setting
We find there is a gouge in both fixture and stock, it because
that there is no tool retract when tool changing
Set tool retract
In VERICUT MS, choose: Modals / Tooling
In Tooling window, change Tool Change Retract Method to Retract (Z-Axis only),then click
OK
(Notes: this can also be set in VERICUT / Toolpath / Toolpath Control / G-Code setting)
Save Job file, reset VERICUT
Run simulation, now everything is running well
2001 PTC 69
Exercise 6, 6a - Outline
Exercise 6
Menu Control
Use Control/Subroutine
Create main program and subroutine
Load subroutine to control
Load new toolpath file (main program)
Exercise 6a
Menu Modals
Control simulation
Slow down machine simulation
Stop simulation when error occurs

2001 PTC 70
Exercise 6 - Menu/Control
Use Control / Subroutine
Create new main program and subroutine file
Create 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(the
end of main program), paste it in file main-program.tap.
Copy remaining of sub.tap (subroutines) and paste it in file
subroutine.sub
2001 PTC 71
Exercise 6 - Menu/Control
(Notes, we divided toolpath file to two files, main program
and subroutines)
Load subroutine to Control
In VERICUT MS, choose: Control / Subroutines
In Subroutine window, open file subroutine.sub, find it in
exercise 6 folder
Choose file subroutine.sub, click Insert, then click OK
2001 PTC 72
Exercise 6 - Menu/Control
Change toolpath file
Choose: Job / Job Setting, change toolpath file to main-
program.tap
Run simulation
(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 subroutine
files for the specified subroutine
2001 PTC 73
Exercise 6a Menu/Modals
Control machine simulation
Open file 3ax-mill.job, find it in exercise 6 folder
Slow down machine movements
In VERICUT MS, choose: Modals / Motion / Max Distance
Give Max Distance=0.1, run machine simulation
Notice speed difference
Change Max Distance back to 0
2001 PTC 74
Exercise 6a Menu/Modals
Stop simulation when an error occurs
In VERICUT, choose: Modals / General / Max Errors
Give Max Errors=1
Toggle Collision Detection(find it in menu: Job / Collision)
and Over Travel Detection(find it in menu: Machine / Travel
Limits) On
Run simulation
It stops when an error occurs
2001 PTC 75
Exercise 7 - Outline
Turning machine
Build turning machine
In Pro/E, export STL file of each component (optional)
Build machine kinematics
Load STL files
Load control
Set Input program zero
Test machine with MDI
Transfer tools from Pro/NC to VERICUT
Load tool library to Machine Simulation
Set tool gauge offset
Load tool path file, build tool index table
Run simulation
Use X-Caliper to check dimension of model after cut
2001 PTC 76
Exercise 7 - Turning machine
Build turning machine
In Pro/E, export STL file of each component (optional)
Export all components except Turret against machine Zero
CSYS
Machine Zero is located at right plane center of spindle
Z
X
Machine Zero
2001 PTC 77
Exercise 7 - Turning machine
Export Turret
Use CSYS-ACS4
It is at located at left plane center of turret

2001 PTC 78
Exercise 7 - Turning machine
Build machine kinematics
Read next two pages for details
Find STL files in exercise 7 folder
Base
Spindle
Fixture
Stock
Z-axis
X-axis
Turret
2001 PTC 79
Exercise 7 - Turning machine
Machine components
Base
Type: 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)
Fixture
Type: 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)
Stock
Type: 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)
2001 PTC 80
Exercise 7 - Turning machine
Z
Type: 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
X
Type: 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)
Turret
Type: 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 1
Type: Tool, Name: Too l 1, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color:
Red, Mixed Mode: Shade, Angles: (0 0 0)
2001 PTC 81
Exercise 7 - Turning machine
Tool 2
Type: Tool, Name: Too l 2, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color:
Magenta, Mixed Mode: Shade, Angles: (0 0 -90)
Save machine file in exercise 7 folder, give file name
2xturn.mch
Add control file to machine
use control file 2xturn-inch.ctl, find it in exercise 7 folder
2001 PTC 82
Exercise 7 - Turning machine
About control file
A super group Toolchange
must be in control file to
enable turret rotation when
tool change.
See right box for details
Open control file
2xturn-inch.ctl to find this
super group
SUPERGROUP "Toolchange" {
WORD_VALUE "T" {
COND_AND "G" "65" {
MACRO "MacroVar"
}
}
WORD_VALUE "T 1" {
COND_AND "G" "65" {
MACRO "NullMacro"
}
}
WORD_VALUE "T 2" {
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" {
COND_AND "G" "65" {
MACRO "NullMacro"
}
MACRO "XAxisIncreMotion" {
OVERRIDE_VALUE 0
}
MACRO "ZAxisIncreMotion" {
OVERRIDE_VALUE 0
}
MACRO "ToolOffsetIndex"
MACRO "ToolOffsetUpdate2"
MACRO "ToolOffsetAptAdj2"
MACRO "CutterCompValue"
MACRO "ToolNoseCompValue"
}
}
2001 PTC 83
Exercise 7 - Turning machine
Set Input Program Zero
Choose: Job / Tables
In Job Tables window, choose: Input Program Zero, see
following figure for other parameters setting
Give Index=1
(Note 1: Values (-12.9103, 0, -8) is measured from left plane
center of turret to right plane center of stock)
(Note 2: We are going to use right plane center of stock as
programming center)
X
Z
2001 PTC 84
Exercise 7 - Turning machine
Test your machine with MDI
X0Z0 position is shown in the following figure
Stock and turret center lines are coincident
Right plane of stock and left plane of turret are adjacent
2001 PTC 85
Exercise 7 - Turning machine
Transfer tools from Pro/NC to VERICUT
Open MFG file in Pro/NC
Change Pro/E working directory to \exercise 7
Open MFG file turn.mfg,
In Pro/NC, choose: CL Data / NC Check / CL File (open
turn.ncl) /Done
Run simulation, exit VERICUT
(Notes, by running VERICUT simulation, tools data can be
transferred from Pro/NC to VERICUT automatically, which will
be called in VERICUT MS)
Load tool library to VERICUT MS
In VERICUT MS, choose: Tools / Tool File
Open file cgtpro.tls, find this file in exercise 7 folder
2001 PTC 86
Exercise 7 - Turning machine
Set Tool gauge offset
In VERICUT MS, choose: Tools / Tool Manager
In Tool Manager window, choose Tool 1, then click Modify
In Tool Modify window, choose Properties
In Tool Properties window, change Gage Offsets to: (7, 0,
0.25)
Change Tool 2 gauge offset to (7 0 0.25)
Save tool library
Close Tool Manager window
2001 PTC 87
Exercise 7 - Turning machine
Load tool path file
In VERICUT MS, choose: Job / Setting
In Job Setting window, load tool path file to turn.tap, find in
exercise 7 folder
Change Log file to 2xturn.log, save it in exercise 7 folder
See following figure for other settings
2001 PTC 88
Exercise 7 - Turning machine
Build Tool Index Table
In VERICUT MS, choose: Tools / Tables
In Tool Tables window, choose Table Name as Tool Index
Table, then click Build Tool List, 2 lines of tool index info
appears. Two tools appears on turret too.
Close Tool Tables window.
Save J OB file
Give JOB file name 2xturn.job, save it in exercise 7 folder

2001 PTC 89
Exercise 7 - Turning machine
Run simulation
Check dimension after simulation
Use Analysis / X-Caliper to check diameters, D1 and D2,
see if it is same as design model in Pro/NC
D1 D2
2001 PTC 90
Exercise 8 - Outline
Outline
Mill/Turn machining center
Create components and assembly in Pro/E
Export components in STL format
Linear components
Rotary components
Build machine kinematics and load STL files
Set input program zero
Load control file, mill-turn control introduction
Create MFG file in Pro/NC, generate TAP file using PP
Run NC Check to transfer tools and Stock data from Pro/NC
to VERICUT, which will be used later
Load tool library file to Machine Simulation. Set turning tool
gage offset
Load Tool path file
2001 PTC 91
Exercise 8 - Outline
Build tool list
Set Turret rotation angle for milling tools
Play Machine Simulation
Run VERICUT and Machine Simulation simultaneously
Open USR file
Load stock file
Set toolpath orientation
Load Tool library file
Load Tool path file
G-Code setting, connect USR file with a JOB file
Open Machine Simulation form VERICUT
Run VERICUT and Machine Simulation together

2001 PTC 92
Exercise 8 - Mill/Turn
Build Mill/Turn machining center
Load machine components and assembly in Pro/E
Set Pro/E working directory to: \exercise 8\machine-proe\
Open file: mill-turn.asm
Find all components and
assembly file in folder:
\exercise 8\machine-proe\
2001 PTC 93
Exercise 8 - Mill/Turn
Export components in STL format
Export non rotary components
It includes all components except turret and tool-holder
User CSYS in machine zero, it is located at right side plane
center of spindle
Take both z-slide components when exporting z-side, same
comments for x-slide
Use 0.1 or smaller for chord height
Give STL files same name as proe
part
X
Z
ACS3
2001 PTC 94
Exercise 8 - Mill/Turn
Export rotary components
It includes turret and four tool-holder
Use CSYS (ACS4) at rotating center of turret
Export four holder components separately, give them name
holder-1, holder-3,
holder-5, holder-7.
See following figure
for holder number
and location
Holder-1
Holder-5
Holder-3
Holder-7
2001 PTC 95
Exercise 8 - Mill/Turn
Build machine kinematics
See following figure and next 3 pages for details
Tips
Make sure Tool Index Number is set right
Make sure Angle is right
2001 PTC 96
Exercise 8 - Mill/Turn
Machine components
Base
Type: 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)
Fixture
Type: 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)
Stock
Type: 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)
2001 PTC 97
Exercise 8 - Mill/Turn
Z
Type: 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
X
Type: 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)
Y
Type: 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)
2001 PTC 98
Exercise 8 - Mill/Turn
Turret
Type: 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 1
Type: 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: 1
Primitives: holder-1.stl, Color, Inherit, Position (-4.5,0,5.5), Angle (0 0 0)
Tool 3
Type: 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) Color:
Magenta, 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)
2001 PTC 99
Exercise 8 - Mill/Turn
Tool 7
Type: Tool, Name: Too l 7, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color:
Magenta, Mixed Mode: Shade, Angles: (0 0 0) , Tool Index Number: 7
Primitives: holder-7.stl, Color, Inherit, Position (0 0 0), Angle (0 0 0)
Tool 2
Type: Tool, Name: Too l 2, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color:
Magenta, Mixed Mode: Shade, Angles: (0 0 45) , Tool Index Number: 2
Tool 4
Type: Tool, Name: Too l 4, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color:
Magenta, Mixed Mode: Shade, Angles: (0 0 135) , Tool Index Number: 4
Save machine file, give name: mill-turn.mch
2001 PTC 100
Exercise 8 - Mill/Turn
Set Input program zero
It is measured from left side turret plane center to right side
stock plane center
Load Control file
Open control file mill-turn.ctl
Save JOB file, mill-turn.job
Test your machine with MDI
X
Z
X0Y0Z0
2001 PTC 101
Exercise 8 - Mill/Turn
About Mill-Turn Control
A super group Toolchange
must be in control file to
enable turret rotation when
tool change.

SUPERGROUP "Toolchange" {
WORD_VALUE "T" {
COND_AND "G" "65" {
MACRO "MacroVar"
}
}
WORD_VALUE "T 1" {
COND_AND "G" "65" {
MACRO "NullMacro"
}
}
WORD_VALUE "T 2" {
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" {
COND_AND "G" "65" {
MACRO "NullMacro"
}
MACRO "XAxisIncreMotion" {
OVERRIDE_VALUE 0
}
MACRO "ZAxisIncreMotion" {
OVERRIDE_VALUE 0
}
MACRO "ToolOffsetIndex"
MACRO "ToolOffsetUpdate2"
MACRO "ToolOffsetAptAdj2"
MACRO "CutterCompValue"
MACRO "ToolNoseCompValue"
}
}
2001 PTC 102
Exercise 8 - Mill/Turn
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"
}
2001 PTC 103
Exercise 8 - Mill/Turn
X multiplier
X multiplier for word X must match the setting in Lathe post-processor
2001 PTC 104
Exercise 8 - Mill/Turn
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 to
VERICUT
In Pro/NC, choose: CL Data / NC Check / CL File / (choose file
mill-turn.ncl) /Done
Create TAP file
Using Post-Processor fan16t to post the NCL file, give TAP file
name mill-turn.tap
PP fan16t is merged with PP fan16m, it is a mill/turn merged
post-processor
2001 PTC 105
Exercise 8 - Mill/Turn
Load Tool and Tool Path file
Copy file cgtpro.tls and mill-turn.tap to folder \exercise
8\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 offset
Set both turning tool (T2 and T4) gage offset to (7, 0, 0.25).
Refer Exercise 7 for details
2001 PTC 106
Exercise 8 - Mill/Turn
Load Tool path file
In VERICUT MS, choose: Job / Job Setting
Load tool path file mill-turn.tap
Build tool list
Choose: Tools / Tables / Tool Index Table /Build Tool List
Reset Machine Simulation, tools appear on turret
2001 PTC 107
Exercise 8 - Mill/Turn
Set turret rotation angle for two milling tools
Turret rotation angle only need to be set for milling tools
Choose: Tools / Tables / Turret Rotation, see following
figure for details, index # here reflects Tool ID #
Turret rotates this angle when the tool is called in tool path
file
The angle is measured from the tool original orientation to
dash line (position when tool in use)
Save JOB file
X
Y
Tool 1
Tool 3
Rotate To
2001 PTC 108
Exercise 8 - Mill/Turn
Play simulation
Reset VERICUT MS, play simulation
Run VERICUT and Machine Simulation simultaneously
USR file setting
Copy files cgpro.usr and cgpro1.stk in folder \exercise
8\mfg-pronc\ then paste then in folder exercise 8\vericut\
Change USR file name to: mill-turn.usr
Open USR file mill-turn.usr
Load stock file. In VERICUT choose: Model / Model Definition / Stock / (open polygon file
cgtpro1.stk) / Apply
2001 PTC 109
Exercise 8 - Mill/Turn
Set Toolpath orientation
In 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
2001 PTC 110
Exercise 8 - Mill/Turn
Load Tool library file
In VERICUT, choose: Tools / Tool Control / Tool Library (open
tool library file mill-turn.tls) / OK
2001 PTC 111
Exercise 8 - Mill/Turn
Load Tool path file
In VERICUT, choose: Toolpath / Toolpath Control
In Toolpath Control window, open Tool path file mill-turn.tap,
set toolpath type=G-Code Data, Multiple Toolpath Files=No
2001 PTC 112
Exercise 8 - Mill/Turn
G-code settting
In Toolpath Control window, choose G-code setting
In G-Code Setting window, choose: File / Open (open file mill-
turn.job)
Choose: File / Close
Choose Ok in Tool path control window
Connect to Machine Simulation
In VERICUT, choose: Applications / Machine Simulation
2001 PTC 113
Exercise 8 - Mill/Turn
Resize VERICUT and Machine Simulation window
Click Play button (in either window)