1. I bought Pro/NC… Now What?!?
Todd Liebenow
Coldfire Enterprises

2. Agenda 3 steps Supplemental information Q & A (time permitting)
Foundation
Workflow
Documentation
Supplemental information
Q & A (time permitting)

3. First, CONGRATULATIONS!
The reasons you bought Pro/Engineer, and Pro/NC probably include:
Fully integrated and associative Machining applications
NC Programming Functionality
Mill
Turn
Wire EDM
Post-processing
Verification
Process planning and documentation
Robust automated toolpath creation
The most versatile NC programming solution available
Machines anything
Enables truly concurrent design through manufacturing

4. Mold Inserts & Electrodes
Single Product Model
Features
Single product model ensures consistency among all manufacturing deliverables
No translation means accurate toolpaths
Intuitive, manufacturing- based user interface
Handles non-Pro/ENGINEER data
Benefits
Requires no geometric remodeling
Minimizes penalties due to design changes
Reduces cycle time
More throughput with the same staff
Moldbase Assembly
Mold Inserts & Electrodes
NC Toolpaths
Molded Part
Inspection
NC Drawings
Machine Control Data
Hand finishing and rework minimized
Product Model
Like Pro/ENGINEER, Pro/NC’s single product model ensures consistency among all manufacturing deliverables. No translation means that the toolpaths will always be accurate, and that the user is never making assumptions and interpretations.
Pro/NC boasts of an intuitive, manufacturing-based user interface, which guides the user through the programming task. Additionally, while Pro/NC works directly with Pro/ENGINEER’s native data, it can also easily handle non-Pro/ENGINEER data, whether they are in solids, surfaces or wireframe.
The benefit of these functionalities is that Pro/NC requires no geometric remodeling in order to start programming parts, working directly on the design geometry. Additionally, its unique associative nature allows users minimizes penalties due to design changes, by recovering most of their prior work. This feature allows them to start their task before the designs are finalized, and therefore, reducing cycle time. This ability to concurrently starting the programming as the designs are being finalized minimizes idle time, helps better manage programming capacity, and results in more throughput with the same staff.

5. Verification & Optimization
Process Model
Modeling
Mold Creation
Filling Analysis
Mold Base Libraries
NC Machining
Detailing
Inspection
Verification & Optimization
Features
Fully integrated and specialized applications
Complete process definition
Robust models
Robust associativity
Benefits
Totally eliminates downstream data translation
Permits changes late in the development cycle
Enables truly concurrent mold design through manufacturing
What are the advantages of using the Pro/NC?
Because Pro/NC has :
- Specialized applications for all types of NC programming
- Seamless integration with all pro/ENGINEER applications
- Robust models and a associativity
You can:
- Quickly and accurately design, detail and create toolpaths for all the tooling required
- Eliminate downstream data translation between applications
- Have a truly concurrent development process which enables painless changes even late in the development cycle.
This presentation will outline a total process definition and a complete mold through manufacturing cycle. Everything from the time you bid on a job, all the way until you get the mold (tool or die) out of the door.

6. NC Programming Solutions
Automatic toolpath creation coupled with graphical customization and editing
Optimized for both prototype and production work
Dynamic material removal simulation
Generate toolpaths directly on the solid model
Toolpath optimized based on in-process workpiece state
Deliverables include toolpaths, G code, setup and tool sheets, BOMs
Solid tool and fixture library
Pro/NC features automatic toolpath creation that can be customized using a graphical customization and editing tool to allow users to fine tune the results generated automatically. The toolpath creation capabilities are optimized for both prototype and production work, taking into consideration requirement for both types of work.
Pro/NC includes dynamic material removal simulation. It also allows users to generate toolpaths directly on the solid model, or on surfaces if solids do not exist.
Toolpath are computed, not only based on the finished part model, but they are also optimized based on the in-process workpiece state. The result is a fundamentally accurate toolpath, that can be post-processed using the post-processors that are included to generate edit-free G code.
Furthermore, Pro/NC can automatically output setup and tool sheets, BOMs of the manufacturing assembly, and can work with exact solid representation of the tool and fixture.

7. Next, Don’t PANIC!

8. The Plan
3 phase approach to complete implementation

9. Training – It’s not optional!
Some choices include:
PTC University
Certified Training Partners

10. Establish the Environment
Step 1: Set up the foundation

11. Don’t forget to SAVE them!
Workcells
Config.pro option: pro_mf_workcell_dir <drive?:\path\to\workcell\directory>
Mills
Lathes
Wire EDM
Sheet Metal
Don’t forget to SAVE them!

12. Tools Parameter based Sketched Solid
Config.pro option: pro_mf_tprm_dir <drive?:\path\to\tooling\directory>
Parameter based
Sketched
Solid

13. Speed / Feed info Pre Wildfire 3.0:
Config.pro option: pro_mf_tprm_dir <drive?:\path\to\tooling\directory>
Pre Wildfire 3.0:
Use a directory structure / flat ASCII files (*.tpm)
*.tpm for tool geom
*.tpm for speed / feed
One folder / material

14. Speed / Feed info (con’t)
Select material in Operation drop down menu, then…
Read DB option in tooling dialog
One method for entering S / F data

15. Speed / Feed info (con’t)
Wildfire 3.0 and beyond:
Store the machining tool parameter file in XML format, simplifying the interface to the external tool database management system. This single file, combining tool geometry and cutting technology, can also be easily managed by PDMLink.

16. Parameter files Loading Parameters from a File
Store and retrieve parameters from your disk:
Store specific manufacturing strategy
Search path defines by Pro_mf_param_dir config.pro option (default is working directory)
Parameter(s) loaded from a file will overwrite current setting
Parameter file can contain from one to all the parameters for a specific toolpath
Good for automation :
Create a Parameter with 1 single line:
Create a mapkey to load the parameter file
Create as many as you need

17. Site Files
Site File allows you to setup defaults for all the manufacturing parameters
Created in Pro/NC or with a text editor
Loaded or stored with the Workcell
Parameter and Site files have certain ‘-1’ options which need to filled in every time
Minimum and Maximum values can be controlled
Visibility can be controlled (NC Sequence and Info)
Inheritance can be controlled (site changes - NC sequence changes)

18. Site Files (con’t) Values can be ‘hard-coded’ Driven via relations
-or-
Spindle speed=500/cutter_diam*3.82
Relations can be used in parameters, too!

19. Fixtures
Are optional, but can be useful for visualization and collision avoidance
May consist of assemblies or a single part

20. Post Processors Mills Lathes Wire EDM Sheet Metal Do it yourself, or
NC G-Post
Best-in-Class Post Processor Development tool
FREE! Bundled with Pro/NC
Do it yourself, or
Have one built

21. Customization Templates available in Expert Machinist: Step Pocket
Profile
Face
Hole making
Through Pocket
Channel
Slab
Flange
Slot
Boss top
O-Ring Groove
Through Slot
Undercut
Rib top
Round
Chamfer

22. Customization (Con’t)
Stuff you can build:
Start Models
Fixtures
Operations
Workcells
etc.
Mapkeys
Menus / Toolbars
Icons
Templates (XML)
M/UDF's
Holes
Threads
Pockets
Other Apps
Toolkit
Weblink
External Applications

23. Define the workflow (or using the tools)
Step 2: Create the toolpaths

24. Workcell (Machine Tool)
Type
Mill
Lathe
Wire EDM
Sheet Metal
Number of Axes
Output
Spindle
Feed info
Cutting Tools
Travel
Custom Cycles
Comments
PPRINTS
Cutter Comp. configuration

25. Workcell (Machine Tool) - Sheetmetal
Parameters
Zones
Clamps
Turret
Pads

26. Type
Mill
Lathe
Wire EDM
Sheet Metal
Punch
Contour
Hybrid

27. Comments Comments can be added at the operation level…
…or at the sequence level

28. PPRINTS
Add information to be passed to the post processor, or the operator
Save PPRINT file for later retrieval

29. Cutter Compensation configuration
Defined in Workcell
Output defined for either:
Tool Center
Tool Edge

30. Sheetmetal
Zones
Pads
Clamps
Turret

31. Operation Machine tool * Coordinate system * Retract * Stock Material
Fixture Setup
Mfg Geometry
* required!

32. Meet the Process Manager…
The Process Manager can be called from a Pro/NC session
Manufacture / Process Manager
This is the central control point for the process creation

33. Overview of the GUI Create step from template Create holemaking step
Create Jig/Fixture
Create milling step
Create Operation
Time Graph
Create Workcell
Create Template
View builder
Highlight step references
View selection
View types
Create NC Features
Selected Step
Edit Selected Step
Play Path
Time computation
Steps view area

34. Sequences Mfg Geometry (optional) Types Parameters Tools Geometry
Customize

35. Mfg Geometry (optional)
Can be used to define surfaces to cut
May be different from the reference model
Use as a ‘collection feature’ to save time when selecting geometry to cut
Types
Window
Surface
Volume
Hole Group

36. Sequence Types: Milling
Volume
Local Mill
Surface
Facing
Profiling
Pocketing
Trajectory
Aux
Engraving
Plunge
Roughing
Re-Roughing
Finishing
Holemaking
Thread

37. Sequence Types: Turning
Area
Profiling
Groove
Thread
Holemaking
Aux

38. Sequence Types: Wire EDM
2 Axis
Contouring
4 Axis
Taper Angle
XY-UV Type
Aux

39. Sequence Types: Sheetmetal
Contouring
Aux
Slitting
Approach Punch
Punching
- Edge Nibble
- Area Nibbling
- Slot
- UDF Punch
- Point Punch
- Tool Shaping
- Forming
- Shearing
- Aux

40. Sheetmetal (2) Modifiers to Sequences include: Lead in / out
Shakeaway tabs
Check Edges
Overhang
Multiple Tool (think long obround slots, use both round and rect.)
Remove Hits
Change Order
CL Command

41. Sheetmetal (3) Single part Automation (Nesting) Populate (Subroutines)
Optimize
Control tool path after all parts are placed on the sheet.
Options for minimizing tool travel, tool change, etc.

42. Parameters Parameters are what defines how the geometry gets cut
Step depth
Step over
Scan type
Etc.
Can have a dramatic effect on sequence
Are context sensitive, based on sequence

43. Tools Can be created on the fly or retrieved from library
Can load parameters, based on material
Remember to specify material in the Operation
3 different types
Parameter based
Sketched
Solid part

44. Geometry Optionally selected from
Model
Sketched (think trajectory)
Manufacturing geometry
Selected
Created ‘on the fly’
Don’t forget about imported and 2D legacy data!

45. Customize
Provides low level control of components of sequences

46. NCL Data
Create
Visualize
NC Check
Vericut
Post Process
GPost

47. Documentation Standards Best Practices Process Tips & Tricks
New Functionality / enhancements
‘Loop back’ to capture new automation as you develop it

48. config.pro for manufacturing
Accuracy : it is strongly recommended to work with absolute accuracy enable.
enable_absolute_accuracy yes
accuracy_lower_bound number (small enough, metric)
It is also important to be sure that all the components and the assembly have the same accuracy
CL File output :
for 3 axis it is recommended to have at least one digit more than the number of digits required in the NC tape.
mfg_xyz_num_digits for metric (5 for inches)
For 5 axis it is recommended to have at least 8 digits for I,J,K
Mfg_ijk_num_digits 8
XML Import / Export : enable export and import on NC process in XML format
output_mfg_xml yes
Remove arrow in the toolpath display
cl_arrow_scale 0

49. config.pro for manufacturing (con’t)
VERICUT : to improve export performance for mold machining (simple stock)
vericut_stock_tolerance (mm)
vericut_fixture_tolerance (mm)
vericut_export_all_tools YES
Workpiece transparency default value
mfg_workpiece_transparency (75% transparent)
Mill Window : automatic creation of the mill window based in workpiece silhouette
allow_workpiece_silhouette auto
Other options are
No : no workpiece taken in account (default)
Yes : user select workpiece or ref model
Auto : workpiece silhouette only

50. config.pro for manufacturing (con’t)
Make job manager available (optional)
nc_jobman_visible yes
Support for multi-tips tool
Allow_multiple_tips_tool yes
Post-processor directory definition
gpostpp_dir path (path can be .\ for current directory)
Important paths to define
Mfg_start_model_dir path to manufacturing start parts
pro_mf_param_dir NC sequence parameters library path
Pro_mf_tprm_dir Tool library path
Mfg_template_dir path to manufacturing template directory

51. This presentation will be available at www.coldfire-e.com
The end
This presentation will be available at