Tutorial Surf Cam

3, 4 and 5 Axis Programming with

SURFCAM 2001/2002

3, 4 and 5 Axis CNC Project Tutorial

MET 443/514 Dr. Russ Biekert

Arizona State University East

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TABLE OF CONTENTS 1 INTRODUCTION......................................................................................4 1.1 The purpose and goal of this material…….…………...............................................................4 1.2 Composition of this material…………… .................................................................................4 1.3 The Practice Files.......................................................................................................................5 1.4 A short presentation of solid modeling…………………..........................................................5 2 THE CREATION AND EXPORT OF A USABLE FILE...............6 2.1 Hints for creating a Solid Model………………………………………………………….…. 5 2.1.1 Planning your work ...............................................................................................................6 2.1.2 Steps to have less data in your model….…............................................................................6 2.1.3 Least surface modeling ..........................................................................................................6 2.1.4 3D world association .............................................................................................................7 2.1.5 Third Angle Projection...........................................................................................................7 2.2 EXPORT OPTIONS………………........................................................................................8 2.2.1 File Types……………………………………………...........................................................8 2.2.2 File Type Features..................................................................................................................9 2.2.3 Solid Edge exporter dialog with options ...............................................................................9 2.2.4 Different types of compression……………………………………………………………...9 2.2.4 Solid Model exercise......................................................................................................…...10 3 WORKING WITH SURFCAM 2001/2002………..........................15 3.1 STARTING THE PROGRAM....................................................................................15 3.2.1 Hardware Lock Version............................................................................................15 3.2.2 Network Lock Version... ..........................................................................................16 3.2 THE BASIC FUNCTIONS OF THE PROGRAM......................................................17 3.2.1 New/Open file...........................................................................................................17 3.2.2 Import intermediate file ...........................................................................................17 3.2.3 Save your work ........................................................................................................21 3.2.4 Orientate part for 3 axis CNC work..........................................................................21 3.2.5 Summary ..................................................................................................................21 3.3 THE USER INTERFACE............. .............................................................................22 3.3.1 Acquainting yourself with the different windows....................................................22 3.3.2 Visual functions........................................................................................................23 3.3.3 The options menu listings to set part visibility……….............................................23 3.3.4 COORD World vs. View..........................................................................................23 3.3.5 C View Properties window……...............................................................................24 3.3.6 View Properties window...........................................................................................24 3.4 EXERCISES ...........................................................................................................25 3.4.1 Import sample file……...................................................................................................25 3.4.2 Wire frame and Surface separation ..............................................................................25 3.4.3 Color and Layer separation……...................................................................................26 3.4.4 Surface positive orientation .........................................................................................26 3.4.5 Surface Flow orientation...............................................................................................27 3.4.6 Create cview .................................................................................................................27

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3.4.7 NC 3- Axis, Z Rough, Z Finish, Planer …………… ................................................28 3.5 SurfCAM Functions.................................................................................................34 4 PRESENTING THE FINAL RESULT.....................................................................35 4.1 POST PROCESSOR SELECTION…………………................................................35 5 PRACTICE PROJECTS…........................................................................................36 5.1 Parts Provided…………………………………………............................................36 5.1.1 The 4 Axis Cube (Positional...................................................................................36 5.1.2 The Valve Body (Positional)...................................................................................48 5.1.3 The 5 Axis Pyramid (Positional)............................................................................54 5.1.4 The 4 Axis Tapered Helix (Simultaneous)..............................................................55 Project Drawings……...................................................................................................62

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1 INTRODUCTION This tutorial is focused on 4 and 5 axis positional and simultaneous CNC Programming with SURFCAM 2001. It is intended for people who want to achieve competency in multi-axis CNC programming of imported solids data. 1.1 The purpose and goal of this material The purpose of the material is to give you basic understanding of how to prepare and export work from a solid modeling tool such as Solid Edge, Pro Engineer or Solid Works. Rather the user imports from an intermediate file or uses a source code compatible direct read, Solid Model data will be interpreted by SurfCAM 2001. The goal is to give you knowledge that you can apply in a meaningful way. 1.2 Composition of this material This material is designed so that you may learn data importing and data translation from the ground and up. The material has four main chapters that will take you from start to goal (production of 4 or 5 axis CNC code) in your project. Chapter 1: Introduction This chapter presents the goals and composition as well as the pedagogic idea. Chapter 1 also gives a brief presentation of the program and its components. Chapter 2: The creation and export of a usable file Prepares you for the work within SurfCAM 2001/2002; gives you techniques and hints on how to maximize the quality of the exportable file from a solid design tool. In this chapter you will learn how to optimize a solid design. You will also be acquainted with the options if intermediate files, exporter dialog and how to work efficiently with export options. Chapter 3: Working with SurfCAM 2001/2002 Chapter covers basic steps to use layers, colors, part orientation, view and cview. This chapter is the core for learning and understanding 4 and 5 axis CNC programming using SurfCAM. Chapter 4: Presenting the final result This chapter explains how to simulate tool path and generate output of multi-axis CNC code. You also get some useful examples post processor selection and compiling CL data.

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1.3 The practice files Included in this material is a floppy disk with practice files. The formats of the practice files are SurfCAM 2001 (*.dem). Intermediate files (*.dxf and *.igs). Drawing files from Solid Edge, (*.par) and AutoCAD (*.dwg). The practice files are included to make it easier for you to work. The Exercises in this material are based on the files on the floppy disk or geometry created from scratch. When you load the practice files they will be installed in; load point \SURFCAM\file specific directory. The sub maps DSM, Igs, Dxf, Par 5, and Dwg. You should save all the SurfCAM files (.dem) into the DSN directory 1.4 A short presentation of Solid Modeling Solid Modeling is a multi-platform mechanical design tool with a purpose to build feature associative objects for pre manufacturing evaluation. Solid modeling has been a huge technological breakthrough. With advances in computer technology no longer is a extremely expensive computer necessary to take advantage of productivity gains from in fully associative solid design tools. Continuous development of this technology will not only support data integration within a single manufacturer such as Pro/Engineer with multiple modules i.e.; design, manufacturing or analysis. We will see partnerships of data collaboration with the ability to read “source code compatible” files like, .PAR (native Solid Edge file read by SurfCAM), were no intermediate file such as DXF or IGS are necessary. Feature associativity will be bi-lateral, across computer platforms, operating systems and competing software manufactures. With advances in world communications via the internet, data collaboration around the globe is very much a part of doing business in manufacturing today. Solid design models are composed of many different entities, primarily 2D and 3D or Planer and Composite. Further broken down, Wire Frame and Surface data. Chapter 2 will describe how to build a functional solid model for translation or direct read in to SurfCAM.

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2 THE CREATION AND EXPORT OF A USABLE FILE The process to create programmable data for SurfCAM can be divided into 4 steps: Modeling Use your 3D-modeling package (Solid Edge) and create one from scratch or take an existing model in native source code (*.PAR, Solid Edge or .DWG, AutoCAD). Remember that even though SurfCAM can handle very complex objects, the end-user experience is going to be much better with a model that is well balanced between not too many details and small size. Exporting Once you are happy with the way the model looks in your 3D modeling application, it is time to export it as a IGES file *.igs. This is the file format used to translate date to SurfCAM. Importing Open the *.igs file into SurfCAM, you can now edit the object in the SurfCAM to separate wire frame, surfaces, layers, etc. Wire Frame and Surface Separation When creating an export file be sure to create surface and wire frame data for export. Wire frame drives tool offset edge, Surface drives tool offset vector. 2.1 Hints for creating an exportable file in a solid modeling program 2.1.1 Planning your work Before you begin to make an object in a solid modeling program you must plan to get the best results. It’s important to think about how the model will be oriented as a machine-able file. It is crucial that you plan your work according to the functions executed in the machining process. (i.e. work holding, machine capability, tooling, etc.), standard Right Hand Rule orientation. 2.1.2 Steps to have less data in your model All spline curves or surfaces are divided into small straight lines that approximate the true curve. The number of divisions between each vertex on the spline is called steps. The number of steps indicates how many segments you will have when it becomes a translated model. The more steps you use the smoother the curve will appear.

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It is recommended that you use a surface optimize option if your solid design software has this capability. With this option checked the program would remove unneeded steps from straight segments in the spline or surface. Don’t use more steps than necessary. By using a low segment number on a standard primitive you can reduce the amount of polygons on your object. Each segment is the sum of divisions along each axis of the model. The number of segments can be set before or after creation. Don’t use more segments then you need. 2.1.3 Least surface modeling There are many ways to make a low polygon surface model. Here are a few suggestions: • Create an object with as few faces or surface intersections from the beginning. Extrude features intended for the part model. Exclude fillets generated by tool path from the solid model. • If you can, change the U - V surface count to a high mesh density 2.1.4 3D world association Most solid modeling tools have a world association and a user defined association, or user defined coordinate system (UCS). The world is a fixed origin where a UCS is a planer surface user defined for geometry creation and uses a local coordinate system. In SurfCAM this setting is toggled with “Coord: WORLD” and “Coord: VIEW” 2.1.5 Third Angle Projection Solid Design tools in the United States have a default view orientation set to Third Angle Projection. This standard defines which plane is displayed when viewing a part model. SurfCAM uses this standard and is controlled in the view menu:

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2.2 EXPORT OPTIONS 2.2.1 File Types Most Solid Design or Programming tools such as SurfCAM allow translation of multiple file types. The following is a list of compatible translated file s for SurfCAM.

AutoCAD

Solid Edge

DXF 2D Data

IGS 3D and Surface Data

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2.2.2 File Type Features Translation Software such as IGS or DXF has data filters. This is for the purpose of being able to translate only the information needed for the next operation. When Translating data for machining SurfCAM does not need point information to drill a hole, center point data is imbedded in any arc or diameter. Filter all points during translation. Some translators allow for coordinate system selection for output orientation. Use this feature to orientate part before translation.

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2.2.3 Solid Model Exercise Create a solid model using the following techniques. In this Exercise you will create a solid model for export into SurfCAM. 1. Start your solid modeler and create a new file. 2. First feature is a rectangular extrusion of defined thickness.

3. Second feature is first depth cut

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4. Third feature is second depth cut.

5. Fourth feature is the pyramid cut (you might need to use extrude also).

Pyramid Feature

Second Depth Cut

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6. Fifth feature is a portion of a sphere (select the correct work plane and rotate the wire frame feature).

8. The sixth is the revolved cone.

Sphere Feature

Cone Feature

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9. The final feature will be surface radii. When ever possible, design a part radius larger than the tool radius used to machine the part, this will ensure a smooth transition from surface to surface Ex:

Be sure to save the model file before the next step. Make sure your solid model has a coordinate system defined for part orientation during extraction. Ex:

Extraction Coordinate System

Model Coordinate System

All edges selected are .126R for an expected finish tool of .25 dia. ball end mill.

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9. With the part model saved it is time to create an intermediate file for translation into SurfCAM. We will use an IGES file export, the time of translation request “Wire Frame” data, and “Surface” data.

10. Save the IGES file in a location accessible to SurfCAM Select, file name and storage location

Wire frame and Surfaces selected

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3 Working with SurfCAM 2001/2002 3.1 Starting the program Start the program with GL on. This will allow dynamic viewing of a solid model.

3.1.1 Hardware Lock Version Use the above procedure for the key lock version or when running in demo mode.

GL ON

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3.1.2 Network Lock Version When the network version has been launched, key in the server name and select an available user license.

Once a user license is served-up check the following settings for the right mode:

Licensed Version Not Demo Mode

GL ON

License Server Name

Select availableLicense here

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3.2 The Basic Functions of the Program 3.2.1 Open/Start a file (Ref. 3.2 in SurfCAM Text book) Start a file in SurfCAM using, File – New. With this process SurfCAM starts a new file as an untitled document. It’s not a bad idea to save your file with a name, now all you have to do is click save or use ‘CTRL – S” 3.2.2 Import Intermediate file If you choose to import an intermediate file, select the “File Type” to access translation types.

Inside SurfCAM Select “File-Open” then “File Type”.

File Type

Select IGS as file type

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1. Save the imported file under new name with SurfCAM “.DSN” file type.

Close any windows opened during the translation process. Sample of part model translated in to SurfCAM.

2. Now we will separate wire frame data from surface data.

Mask all entities leaving only surfaces checked.

Default part Orientation CVIEW 1

Only Surface Checked

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3. Next, create a new layer called, “Surface”. At the same time select the new layer to activate and select “move geometry”

4. Next screen will ask for geometry to select.

• Check Mask set to ON • Toggle “MultSelOn” • Select visible (everything should be highlighted) • Select done

5. Go back to the layer tool and make “surface” layer invisible. You should see only wire frame geometry.

Move Geometry

Select here to activate

Surface LayerInvisible

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Sample Import

View of “Wire Frame Only” Geometry.

You should now be able to toggle between wire frame and surface layers.

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3.2.3 Save your work Save your file with, “Save As”, (do not use spaces in the name selected) from this point on in your session all you have to do is click save or use ‘CTRL – S” for frequent saves to your work progresses. 3.2.4 Orientate part for 3 Axis CNC Axis work

3.2.5 Summary

• Start a new file • Save your file with, “Save As” • Check for License Version • Check for OL running • Select CVIEW1(x-y plane) • Set VIEW7(isometric)

CVIEW1

VIEW7

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3.3 The User Interface The axis direction uses industry standard conventions for specifying the direction. The direction can be specified as being: +X; -X; +Y; -Y; +Z or -Z. The following diagram shows the relationship between the rotary axis directions and the X, Y & Z-axes.

It is important to note that the arrows depicting rotations (+A, +B & +C) show the positive direction of the tool, not the direction of rotation of the table. These may or may not agree with the actual programmed axis and direction. In the case of a machine with a removable rotary table for instance, the Programmed Axis may be A, but its physical location on the machine may cause it to rotate about the Y axis (normally considered to be a B axis). We would select +Y from the Direction list box. In this case, an A90 programmed move will be modeled as a B+ move. 3.3.1 Acquainting yourself with different windows (SurfCAM textbook Chapter 3) Be sure you know how to change “VIEW” and “CVIEW” and understand the difference in the two. VIEW is strictly visual manipulation (Can also access with RMB. Right Mouse Button) CVIEW is necessary to change the construction plane to a local coordinate system for creation of geometry on other than the G17 (XY) plane.

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3.3.2 Visual Functions SurfCAM is imbedded with popup and pull down menus. Don’t forget the new commands in RMB:

3.3.3 The options menu to set part visibility Select: DISPLAY – SHADE – OPTIONS

3.3.4 Coord; World vs. View WORLD COORDINATES World coordinates are the X, Y, and Z axes as defined in 3D space. World coordinates are similar to absolute coordinates on an NC machine. They are always measured from the origin (X0 Y0 Z0) point.

Default and Saved view selection

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VIEW COORDINATES View coordinates use the construction view. Using View coordinates gives you the option to measure from the origin as it is seen from a particular view. 3.3.5 CVIEW Properties Window

3.3.6 View Properties Window

Current View

Current Construction view

Current Construction View

Current View

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3.4 Exercises (3 axis machining solid mold part) 3.4.1 Import Sample File Import the sample file from source files; XXXMOLD.IGS

xxxmold.igs

3.4.2 Wire frame and Surface separation Use Mask settings to filter wire frame geometry and move to new layer.

3.4.3 Color and Layer separation Use the Layer tool to create a new layer for the surface geometry.

1. Set only the wire frame layer active 2. Select; EDIT – COLOR, pick a color, VISIBLE – DONE.

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The color should be updated to the new color. Remember, Colors and Layers are independent (not linked). Update the color in the settings tool bar to match color to the geometry being created.

3.4.4 Surface positive orientation Next we will remove all surfaces not necessary for the machining operation (move to another, change color or delete them entirely) your part model might look like the following:

No sides and no bottom. Next we must orientate all surface normals to a positive Z orientation. This is important for surface machining only; not necessary for “Z Rough” and “Z Finish”. Toggle surface normal vectors on/off. (be sure multselon is set to on) Select EDIT – SURFACE – ARROW – VISIBLE – DONE Your part should look like the following:

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Some surface normals will be orientated below the surface; those normal vectors need to be re-orientated to a positive direction (in this case inside the pocket to be machined) Select EDIT – SURFACE – SIDE – SINGLE – pick individual surfaces until each normal vector is in the right orientation.

TOGGLE MULTSELON/OFF TO OFF FOR THIS OPERATION 3.4.5 Surface Flow orientation Set the surface flow indicator to be in the same direction (not all surface vector indicators will be able to toggle in the same direction, set as many as possible), this depends greatly on how the surface was created. Select EDIT – SURFACE – DIRECTION – pick individual surfaces until each normal vector is in the right orientation. 3.4.6 Create CVIEW Check to see if part has the correct cview, if not create one with this method:

There are four choices in SurfCAM for creating a construction View:

Select New

Name the construction View

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Select an option and create a construction view, remember to activate the new construction view after it was created. Use this only if needed.

3.4.7 NC 3 AXIS-Z Rough, Z Finish, Planer For this project we will use,”Z Rough”, “Z Finish”, and “Planer” tool path. Select –NC – 3 Axis – Z Rough. (MULTSELOFF) VISABLE NO MATERIAL (pop up box) Next you will see the tool control box:

Minimum information

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Click next tab for tool control

Sample tool path for Z Rough:

Next let’s use Z Finish (hide previous tool path).

Sample Settings

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Select –NC – 3 Axis – Z FINISH. (MULTSELOFF) VISABLE Select ¼ in. Ball End Mill for Z Finish. Set all tooling information. Next, Select Tool control tab;

Z Finish Tool Path: no bottom cut

Sample Settings

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The final process will be to finish the floor of the cavity. To do this we will select 3 Axis Planer cut. First create a boundary curve for tool containment. (Hide Surface geometry, create a new layer and new color, work with Wire Frame Geometry only) Select EDIT – TRANSFORM – OFFSET – CHANGE OFFSET (fin tool radius) - CHAIN – “offset side”, pick inside chained geometry.

Select –NC – 3 Axis – Planer. (MULTSELOFF) VISABLE Use the same ball end mill from Z Finish for Planer operation

Boundary curve offset, “Finish tool, radius amount.”

Select outer edge to chain

“Offset Side”, inside chained geometry

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Surfaces to select for avoidance:

You will be prompted for boundary curve; start point/end point to define cut direction (select any vector), offset side (select inside boundary curve), beginning element (select any entity on the boundary curve and close) – DONE. Finished Planer tool path:

Avoid

Boundary Curve, “YES”

Check Surface, “YES”

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Open Operations manager and simulate tool path, if all is well post code.

Operations Manager

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3.5 SurfCAM Functions Start the program with GL on. This will allow for solid visualization. SURFCAM HOT KEY DEFAULTS Function Default Hot Key Save As CTRL+S Delete CTRL+D Fit CTRL+F Rotate UpDownLeftRightDynamically Alt+Up arrowAlt+Down arrowAlt+Left arrowAlt+Right arrowMiddle Button Zoom In CTRL+ZMouse Wheel ForwardCTRL+IPlus key Zoom Out CTRL+U (10% decrease)Mouse Wheel AwayMinus key Pan CTRL+PCTRL+Middle ButtonCTRL+Left arrowCTRL+Right arrowCTRL+Up arrowCTRL+Down arrow Repaint CTRL+Q CView dialog box CTRL+C Views dialog box CTRL+VSpacebar ©Copyright 2002 Surfware, Inc. All Rights Reserved. Select the correct orientation of work piece and rotary table fixture. This will depend on the placement of the rotary table on your CNC Machine. Right side placement should look like the following illustration.

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4 PRESENTING THE FINAL RESULT 4.1 Verification and Code Generation

Select to Post CNC Code

Select CNC Process And Machine Control

Select Set-up One to post code for all operations

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5 PRACTICE PROJECTS 5.1 Parts provided The following projects demonstrate a variety of multi axis operations, including 3, 4 Axis simultaneous and 4, 5 Axis positional. Part geometry will be provided from IGS translations or created in SurfCAM. We will be working with Wire Frame and NO Surface Geometry. 5.1.1 4 Axis Cube (positional)

For this Project we will create the geometry in SurfCAM.

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For proper rotation of 4th Axis be sure to place “CVIEW 1” at center and face of rotary table. Create a block or cylinder that represents your part stock (machining area only) drill end with a # 3 or #4 C-drill. This end will be supported by the rotary table “live center”. Ex:

X

Y

Z

Rotary Table Tail Stock

Right Side Placement Rotary Table (“A” Axis)

4th Axis bar Stock

CVIEW 1 Orientation

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1) Switch COORD to View. Start with CVIEW 5 and VIEW 7. Create a rectangle with center as (0, 0). Transform Copy, 3,0 inches, draw lines to connect all for corners.

2) Create a local construction plane for each of the four sides. (Label Top, Front, Bottom, Back. Keep all geometry in quadrant 1)

CVIEW 5

VIEW 7

Connect end to end, all 4 corners

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Select 3 point –

End Point (system prompts for this input) - First X - Pos X - Pos Y - Origin

Continue this process for each of the remaining sides, Front, Bottom, and Back.

Front Bottom Back

First X

Pos X

Pos Y Origin

Y

X Z Y X

Z

Y

X Z

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After all planes are completed you can toggle construction planes in CVIEW menu box. 3) Mill flats on 2 .0 dia. bar stock. Our material blank will be 2in dia. bar stock. We will need to machine the four flats in the round stock on each plane we created. Do this with a 2D pocket routine (boundary curve created .3 above finished plane).

Change to CVIEW 5 and TRANSFORM - COPY – ROTATE Pocket Boundary Geometry to the remaining three sides. EX:

Set CVIEW 1

Created Pocket Boundary

Set CVIEW 5

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2 Axis Pocket cut control settings

2 Axis pocket on Top CVIEW

Total Material Removal

Depth Cut

Rapid Plane

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Switch to CVIEW 2 Front and repeat NC 2 Axis pocketing routine in new CVIEW. Repeat this operation for CVIEW 4 BOTTOM. Repeat this operation for CVIEW 3 BACK. Be sure to follow this sequence. This will keep the rotary table indexing in one direction for a productive tool path. Finished tool path, four sides;

Hide all tool paths and the Pocket Boundary Layer. Let’s move on to the next step.

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4) Change to your created CVIEW (should be CVIEW.9, TOP ) Create a 1in x 1in Pocket at the Z zero level. 5) Change to your created CVIEW (should be CVIEW.10, FONT ) Create a 1in diameter Pocket at the Z zero level. 6) Change to your created CVIEW (should be CVIEW.11, BOTTOM ) Create a 1in. Triangle Pocket at the Z zero level. 7) Change to your created CVIEW (should be CVIEW.12, BACK ) Create any geometry you wish (different from the first three sides), including text for machining. EX: (CENTER GEOMETRY ON EACH PLANE)

After all geometry has been created, switch to each construction plane and create 2 axis tool paths.

Text on Back Side

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2Axis tool path created on any plane rotating about the X Axis creates a 4 Axis positional program. Rotation axis is “A”, direction will be positive or negative units will be degrees.

A Four Axis part sometime requires manual set up of simulation settings. Select; OPERATIONS MANAGER – RUN SURFCAM VERIFY (not auto verify) MODEL STOCK CYLINDER

Menu box prompts for dimensions. Use dimensions to encompass part with a

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stock diameter of 2.0 in. (values for CVIEW1)

Picture of cylinder for material simulation;

Use these settings for cylinder size

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Solid simulation of operations; EX;.

Final operation is to post code. To do this we will select operations manager; EX;

Select 4 Axis

Select HAAS

Text was cut as 3 axis contour, to cut outline only

Select Setup One to post all operations.

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Simulation of text tool path;

Have code verified by the Lab Technician before running on HAAS CNC.

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5.1.2 Valve Body (Drilling, Positional)

1) In SurfCAM Select; OPEN – FILE TYPES. Set to IGS. Open “Valve_Body.IGS” from source files.

2) EDIT – TRANSFORM – MOVE and ROTATE to place part on location for four axis rotary table work. (Remember: translations and Rotations best occur around the Z Axis point)

EX;

CVIEW1

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3) Select; FILE – SAVE AS – FILE TYPES - .STL EX;

4) Separate Layer and Wire Frame Geometry. Show only wire frame geometry. Select; NC – 2AXIS – Drill – SELECT GEOMETRY

Save in SurfCAM load point, Stl Folder

Type

Select Top Surface circle ONLY

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5) Select tools and set values in drill operations manager. EX;

6) Check for tool clearance on rotary move.

EX;

Add next tool

Select each tool to set values

Drill depth or Spot Diameter (Tool Dependant)

Z Clear

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7) An imported part requires manual set up of simulation settings to select the STL model from a previous save.

Select; OPERATIONS MANAGER – RUN SURFCAM VERIFY (not auto verify) MODEL STOCK STL SOLID EX;

Your part should look like the following;

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7) After running the solid verify you will see a simulated verification of tool path;

8) Before we post code we will go back into Operations Manager and change the hole depth for the hole on the top of the part.

Select hole ops. Right mouse click and select Regen. with original geometry

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The following menu pops up.

9) Post code and check for “A” Axis rotation moves

Change this Value to 1.25 for tool 2 and 3, OK when done.

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5.1.2 5 Axis Pyramid (Positional) SurfCAM Book 15-16

5 Axis Project Create a new CVIEW for

each side

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5.1.4 4 Axis Tapered Helix (Simultaneous) For a true simultaneous 4-axis CNC part the geometry must be a tapered rotational shape. Part geometry will be provided from IGES translations or created in SurfCAM. The following geometry was selected to demonstrate simultaneous 4-axis tool path. The geometry twists 30˚ in 2 inches and tapers from 2” diameter to 3/8” diameter in the same length.

1) Our first step would be to create geometry or import a solid from a design tool. With this step completed orientate geometry with the origin at the face of the part.

2” Dia.

½ “Dia.

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Part orientation in SurfCAM (since we have a symmetrical part we will isolate a single surface)

2) Next we will create a single surface from a multi surface object

CVIEW 1

Isolated Surface

Multi Surface Object.

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Select; CREATE – SPLINE – SURFACE SPLINE.

Select; Boundary Curves Tab and the following buttons.

You should have the following Spline Data. Remove all internal Splines leaving only outlining Splines.

Surface Spline Command

Use the following settings

Remove internal Splines

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Select; CREATE – SURFACE – CROSSECTION – GRID – VISIBLE – DONE – LINEAR – OK (Be sure only Boundary Curves are visible before starting)

Next let’s edit U – V Cross Section Count. Select; EDIT – SURFACES – DISPLAY – VISIBLE – DONE. Change U – V count to 20.

New Surface Mesh.

U-V CountSet to 20

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3) Next step will be to “Extent Surface”, “Set Surface Normal” and “Set Flow Direction.

Select; EDIT – EXTEND. Select a horizontal cross section from the surface to extend (use diameter of tool for value).

4) Select; EDIT – SURFACE - ARROW (toggle arrow on/off) - DIRECTION ( for cut flow) - CORNER ( for start Point) - SIDE ( for pos/neg side of surface)

Select Horizontal line for surface extension. (use tool diameter for extension value).

Boundary for projected tool path.

Surface Normal and Flow Direction

Surface Edit Tools

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5) Create Tool path to Project.

6) Select, NC – 4AXIS – PROJECT

Select tool path to project. Select surface to project to.

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New Projected Tool path

7) Select Projected tool path for posting of CNC code .

New Projected tool path

Post Projected tool path ONLY

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Project Drawings

(Provided by Instructor)