Ken,
I've tried using the sketcher, but it does not let me select the tool I've created for roughing or surfacing. I did get it to work in a Trajectory Milling Sequence, but that is not really useful for what I'd try to use it on.
The "relations" I mentioned are required for the use of solid tools. Basically you would model the cutter, add a CS called TIP to the cutter model and then go through the defining sketch and assign relations (such as "cutter_diam", "length") through the "properties" of each dimension on the sketch. My understanding is that the relations are what Creo uses to calculate the path. If the relations are not correctly assigned to the dimensions of the solid model of the cutting tool, the paths created will not be what you expect. In effect, if you model a bullnose cutter and do not assign a relation for the corner radius it will cut like a square corner cutter would and not recognize that there is a radius on the solid model cutting tool.
