PDF- -Tech 140 Lab Manual - San Jose State University - Camworks Tutorial Mill and Turn

Description

CA MWo r k s'2013

Mi l'l an d'Tu r n Tu t o r i al

Disclaimer Geometric Americas,

either express or implied with respect to this manual

Geometric Americas,

reserves the right to revise and improve products as it sees fit,

and to revise the specifications and information contained herein without prior notice

Due to continuing product development,

specifications and capabilities described in this manual are subject to change without notice

Trademarks The following and other product names and corporate references herein are registered or proprietary trademarks of their respective owners

CAMWorks® is a registered trademark of Geometric Americas,

SolidWorks® is a registered trademark of Dassault Systèmes SolidWorks Corp

FeatureManager™ is a trademark owned jointly by DS SolidWorks and Bentley Systems,

All other brands and names are the property of their respective owners

Copyright ©1998-2013 Geometric Americas,

All Rights Reserved

CW30s 20130208

Table of Contents CHAPTER 1 LEARNING 2 AXIS MILL BASICS 1-1 2 Axis Mill 1

Toolpaths and NC code

CHAPTER 2 LEARNING MORE 2 AXIS MILL 2-1 2 Axis Mill 5

Table of Contents

Combining Operations

For More Practice

2-40 Part1

2-40 Part2

CHAPTER 3 LEARNING 3 AXIS MILL 3-1 3 Axis Mill 1

Stock and Machining Direction

Table of Contents

Generating Toolpaths and Post Processing

defining the machine and defining the stock

Table of Contents

CHAPTER 4 LEARNING MORE 3 AXIS MILL 4-1 3 Axis Mill 7

Machining Direction and Multi Surface Feature

CHAPTER 5 LEARNING 2 AXIS TURN 5-1 Turn 1

Table of Contents

Step 4: Step 5: Step 6: Step 7: Step 8: Step 8:

Edit the Stock Definition

Edit the Stock Definition and Extract machinable features

Defining the Machine and Stock

Generating Operations and Modifying Operation Parameters

Table of Contents

Step 8: Defining the Chuck

CHAPTER 6 LEARNING 4 AXIS TURN 6-1 4 Axis Turn 1

adjusting Parameters and Generating Toolpaths

6-14 vi

Table of Contents

Step 9: Simulating the Toolpaths for Turn Setup machined from the Main and Sub Spindles

CHAPTER 7 LEARNING ASSEMBLY MODE 7-1 Generating NC Code in Assembly Mode

Assembly 2

Assembly 3

Assembly 4

CHAPTER 8 LEARNING THE TECHDB 8-1 TechDB 1

TechDB 2

TechDB 3

Tech DB 4

TechDB 5

Table of Contents

TechDB 6

TechDB 7

TechDB 8

TechDB 9

Chapter 1 Learning 2 Axis Mill Basics This chapter provides an opportunity to learn CAMWorks 2 Axis Mill through a step by step hands-on tour of the features and functions

The exercises in this chapter are intended to show you how to use CAMWorks and may not correspond to actual machining practices

The exercise parts are installed when you install CAMWorks and are in the \Examples\Mill folder in the CAMWorks data folder (e

 \CAMWorksData\CAMWorks201x\Examples\Mill)

IMPORTANT

! CAMWorks uses a set of knowledge-based rules to assign machining operations to features

The Technology Database contains the data for the machining process plans and can be customized for your facility's machining methodology

When you do these exercises,

your results may not be the same as described in the steps and illustrated in the figures

This is because the machining sequences and operations data in your Technology Database may be different from the database used to produce the documentation

The following series of exercises show you how to generate finish toolpaths on a SolidWorks/ CAMWorks Solids part model

In order to give you a general understanding of how to use CAMWorks,

you will work with a part that was previously modeled in SolidWorks

When you define the operations and toolpaths,

you will follow steps and instructions

These steps and instructions are brief in nature in order to show you the basics of generating toolpaths from start to finish without getting into the details at this time

In case you wish to have deeper understanding of the functionalities within CAMWorks,

we recommend that you refer to CAMWorks Online Help

Sample parts are provided for the exercises in this manual

When you install CAMWorks,

these files are installed automatically

These sample parts are installed in the Examples folder located within the CAMWorks installation folder

Learning 2 Axis Mill Basics 1-1

Model the part or open the part file in SolidWorks/CAMWorks Solids

Change to the CAMWorks Feature tree

Define the Machine and modify the controller parameters

Define the stock

Define machinable features

Generate the operation plan and adjust operation parameters

Generate toolpaths

Simulate material removal

Post process the toolpaths

Model part in SolidWorks or import part

Change to CAMWorks Feature tree

Define machine/change controller parameters

Simulate toolpaths

Generate toolpaths

Adjust operation parameters as needed

Generate operation plan

Are toolpaths correct

Post process Define machinable features (AFR & IFR) Define Stock Transmit file into CNC

Step 1: Model Part in SolidWorks/CAMWorks Solids or Import Part A part is a solid that is created with SolidWorks/CAMWorks Solids or imported into SolidWorks/CAMWorks Solids from another CAD system via an IGES,

Parasolid,

SAT file,

This exercise uses an existing SolidWorks part

Open the part file MILL2AX_1

SLDPRT in the \Examples\Mill folder

Opening the solid part file

Learning 2 Axis Mill Basics 1-3

The FeatureManager design tree lists the features,

Tabs are provided for moving between the SolidWorks/CAMWorks Solids trees and the CAMWorks trees

If the CAMWorks tabs [ ,

you can expand the size of the tree

Position the cursor on the line that divides the tree area from the graphics area

When the cursor changes to a bar,

drag the bar to the right until the tabs display

Tabs for SolidWorks/ CAMWorks Solids Trees

CAMWorks Feature Tree tab

Line that divides the tree from the graphics area

Graphics area

Items under the Feature Manager Design tree

Step 2: Change to CAMWorks Feature Tree 1

Click the CAMWorks Feature Tree tab

The CAMWorks Feature tree displays

Initially,

the tree lists the NC Manager,

Stock Manager,

Machine and Recycle Bin items

CAMWorks menu

CAMWorks Operation tree CAMWorks Feature tree Items under CAMWorks Feature tree Graphics area

Part Model

CAMWorks Machining Trees The CAMWorks machining trees provide an outline view of the machining information for the model

Initially,

the CAMWorks Feature tree shows only the NC Manager,

Configurations,

Stock Manager,

Machine and Recycle Bin items

As you follow the steps to generate an NC program,

this tree expands to include Mill Part Setups and machinable features

The tabs are for moving between the SolidWorks/CAMWorks Solids trees and the CAMWorks trees

• Configurations Multiple CAMWorks datasets are supported

Each dataset is called a configuration

You can use configurations to support multiple machines and SolidWorks configurations

Stock Manager The stock is the material from which the part will be machined

If the Machine type chosen is Mill,

you can define the stock as a rectangular shape (bounding box) or an extruded sketch or an STL file

You can also specify the type of material

Machine The Machine item defines the machine tool that the part will be machined on

The machine definition includes the type of machine (e

Mill-Turn),

tool definitions and the post processor

The machines are set up in the Technology Database

Recycle Bin The Recycle Bin in the CAMWorks Feature tree is used to store machinable features that you do not intend to machine

Learning 2 Axis Mill Basics 1-5

CAMWorks Menu 1

Click CAMWorks on the SolidWorks/CAMWorks Solids menu bar

The menu lists the CAMWorks commands

The commands are explained in the CAMWorks online Help

Right click on the NC Manager in the tree

This is a shortcut menu

The right-click shortcut menus provide access to a variety of commands

CAMWorks Command Manager The CommandManager is a context-sensitive toolbar that dynamically updates based on the toolbar you want to access

It provides access to the main CAMWorks commands found on the CAMWorks menu

By default,

it has toolbars embedded in it

The CAMWorks Command Manager can be customized

Right-click anywhere on the CAMWorks Command Manager and select Customize menu in the RMB shortcut menu

The Customize dialog will be displayed

Use the Toolbars and Commands tab of this dialog to customize the Command Manager

CAMWorks Command Manager

Customize dialog

Customizing CAMWorks Command Manager

CAMWorks Options Use the CAMWorks Options dialog to changes the various settings you want to change in CAMWorks

To open the CAMWorks Options dialog: 1

Click on the CAMWorks Options icon in the CAMWorks Command Manager OR

Select Options in the CAMWorks menu

Once the Options dialog is open,

Under Extract Machinable Features,

ensure that the Method is set to MfgView (default setting)

CAMWorks Online Help In addition to tutorial documents,

CAMWorks is provided with a context based online help

Every dialog and interface within CAMWorks has an associated Help button

Click on the Help button to open the online Help

Every parameter and tab of each dialog in explained in the Online Help

Step 3: Define the Machine The machine includes information that identifies what to machine,

and the format of the NC output

Important parameters of the machine definition include: • Machine type – mill,

mill-turn or Wire EDM: The machine type defines the machinable feature set that can be recognized automatically and defined interactively

The icons that display in the tree identify the current machine: Mill Machine Turn Machine Mill-Turn Machine Wire EDM An alternative machine can be selected at any time to output different G-code programs for alternative machine tools

If the machine type changes,

then all features and operations will be deleted

• Tool crib: A subset of tools from the tool library that are commonly loaded into or used with the current machine

• Post Processor: The post processor identifies the format of the NC G-code output

Define the machine: 1

Right click Mill-mm in the CAMWorks Feature tree and select Edit Definition or double click the item in the tree

Did You Know

In the Feature and Operation trees,

instead of right clicking items and selecting Edit Definition,

you can double-click the item to open the dialog box for editing the Stock Manager,

Machine,

Setups,

Features and Operations

Learning 2 Axis Mill Basics 1-7

The Machine dialog box displays the Machine tab

The default machine is specified in the Technology Database

Mill–mm is the default machine used for the metric parts in this manual

When you use CAMWorks to machine your own parts,

select the machine tool you want to use to machine the part

Machine tools are set up in the Technology Database

Before using CAMWorks to machine your parts,

make sure you define the machine tools available in Machine tab of Machine Dialog Box your facility

For more information,

In the Available machines list,

highlight Mill–mm and click the Select button

Click the Tool crib tab and make sure Tool Crib 1 (metric) is the Active tool crib

The Tool Crib page allows you to choose a Tool Crib,

which is a set of tools or tool assemblies that are used with the machine you have chosen

These are not all the tools that are available,

but a subset that you can modify to represent the actual set of tools that the machine has loaded

Tool Crib 1 (metric) is a default tool crib that has been set up for the sample Mill machine

When you define your machine tools in the Technology Database,

you can set up your own tool cribs

Tool Crib tab of Machine Dialog Box

Click the Post Processor tab

This tab allows you to select the internal post processor or the APT CL option to output a CL file

The list that displays depends on the post processors that are installed on your system

CAMWorks is supplied with several tutorial post processors

Contact your CAMWorks reseller for more information on obtaining and/or customizing post processors for your machine tool

If the post processors do not display,

use the Browse button to locate the folder containing the files (*

If M3AXIS-TUTORIAL (the tutorial post processor) is not the Active post processor,

highlight it in the list and click the Select Post Processor tab of Machine Dialog Box button

This post processor is used for exercises in this manual

When you use CAMWorks to machine your own parts,

you can select your machine tool controller or post processor

Information displays about M3AXIS-TUTORIAL

A short description displays in the window

This window contains information only if an optional file has been created for the post processor

Click the More button

A longer description is displayed

The More button is activated only if a second optional file has been created

This information is intended for use in training or as a detailed description of post processor attributes that can be created

Information files are provided for the sample post processor that is used for the exercises in this manual

Your CAMWorks reseller or your company manager may be able to supply these files if they are available for your post processor

If files are not available,

you can create post information files as explained in the online Help

Click the Posting tab

The parameters on this page are used for the following: − To provide information required to generate the NC program

The parameters are machine-dependent and different parameters may display for your controller

The value for a parameter is output in the NC code if the machine requires it

Learning 2 Axis Mill Basics 1-9

− To provide information for the Setup Sheet,

a file that is created when the NC program file is generated

All of the controller parameters are included in the Setup Sheet

Type 1001 for the Program Number and press the down arrow on the keyboard to shift the focus to the Part Thickness field

Type 40mm for the Part Thickness and click OK

Posting tab of Machine Dialog Box

Step 4: Define the Stock The stock is the material from which the part will be machined

The default stock is the smallest cube (bounding box) that the part will fit into

Typically,

this is not the size of the stock you will be using

You can change the stock definition either by offsetting the bounding box from the part or by defining the stock from a sketch and a depth (extruded sketch) or from an STL file

In this exercise,

you define the stock as a box offset (bounding box) from the part

Double click Stock Manager in the CAMWorks Feature tree

The Manage Stock dialog box is displayed

For the Bounding box offset,

type 1 for X+ and click the X+ button (Uniform X)

Repeat step 2 for Y+ and Z+

To set these entered values as default values for future jobs,

click on the Set default button

Use the Get default button to set the Manage Stock Dialog offset values to pre-defined default values

Select 304L as the material from the Material dropdown list

Click OK to close the dialog box

Step 5: Define Machinable Features In CAMWorks,

machining can be done only on machinable features

You use the following two methods to define machinable features: • Automatic Feature Recognition (AFR) Automatic Feature Recognition analyzes the part shape and attempts to define most common machinable features such as pockets,

Depending on the complexity of the part,

AFR can save considerable time in defining two-dimensional prismatic features

Did You Know

You can select the type of 2

Open the Options dialog box

You can select the type of features to be recognized by selecting the desired features in the Feature Types group box on the Mill Features tab of this dialog box

Interactively created features If AFR does not recognize a feature you want to machine,

you need to define the feature interactively using the Insert 2

If you have 3 Axis Milling,

multi-surface features can be defined using the Insert Multi Surface Feature command

How AFR analyses a solid part The idea of AFR is to analyze the part for features that can be machined

This process is much the same as what you would do if you were to pick up a part that you had to machine

You would look it over,

and begin deciding how to define areas or features to machine and what machining processes you would need

CAMWorks does not machine the SolidWorks or CAMWorks Solids features directly

Instead,

it creates a separate list of Machinable Features

This is because a single SolidWorks feature may have several areas that need to be machined in different ways with different tools

For example,

SolidWorks would see the part on the right as having an extruded cut for the whole pocket and an extruded boss for the ribs

That works well for modeling parts in SolidWorks,

but not for machining purposes

There are actually 5 pockets of 3 different types to machine here

After AFR is run on this part,

the CAMWorks Feature tree would look the one given on the right

There are 3 Machinable Features in the list: one for the large pocket on top,

and 2 for the two different types of pockets around the ribs

This gives you more flexibility for machining

Learning 2 Axis Mill Basics 1-11

Using Automatic Feature Recognition (AFR) Defining machinable features automatically: 1

Select one of the following methods to automatically extract features: In the Feature tree,

right click CAMWorks NC Manager and select Extract Machinable Features on the RMB shortcut menu OR Click the Extract Machinable Features button on the CAMWorks Command Manager

Executing EMF command Extract Machinable Features icon

The CAMWorks Message Window displays automatically to report the progress and status of the process

You can control whether this window displays temporarily or permanently by selecting the Options command on the CAMWorks menu and checking the Message Window option on the General tab in the Options dialog box

CAMWorks Message Window

General Tab of CAMWorks Options dialog

CAMWorks generates the Mill Part Setup and machinable features

The items display in the CAMWorks Feature tree

The Mill Part Setup is the 2 axis plane that the tool movement will be based on

It has an origin location,

The Mill Part Setup is created automatically

and change the direction and angles of the X and Y axes

A Mill Part Setup is created for each different tool orientation

There is only one Mill Part Setup for this part because all features can be machined using a single tool orientation

For each Mill Part Setup,

the machinable features are listed in the order in which they were recognized

The Feature tree allows you to: − Copy,

delete and combine machinable features − Change machinable feature parameters − Change the order in which the features are machined − Insert 2

Did You Know

Features display in a different color when they have no operations generated

Once operations are successfully generated,

If operations are not generated for certain features (this occurs when feature conditions have not been defined in the Technology Database),

then they retain their original color indicating non-generation of operations

You can set the color on the Display tab in the Options dialog box

Most feature parameters are fixed

some parameters can be changed using the Parameters command on the feature’s RMB shortcut menu

Right click Hole Group1 in the tree and select Parameters on the shortcut menu

The Hole Parameters dialog box displays the number of components and the hole parameters

Since there is no physical information about the type of hole,

CAMWorks allows you to define a Strategy for the hole (Drill,

Thread or a user-defined Strategy)

Click the down arrow next to Drill to see the choices

Click Thread in the list

The figure changes to reflect your choice and the Thread parameters are enabled

Click the down arrow next to Thread and select Drill again,

then click OK to close the dialog box

Click the next to Hole Group1 in the CAMWorks Feature tree

The tree expands to display each individual hole

Click the next to Hole Group1

The tree collapses hiding the individual hole features

Hole Group Click the Options button the CAMWorks Command Manager

Note that you can also select the Options command from the CAMWorks menu bar or from the RMB context menu of the CAMWorks NC Manager in the tree

Learning 2 Axis Mill Basics 1-13

The Options dialog box is displayed

On the General tab,

make sure the Save/Restore part option is checked

Click OK to apply the settings and close the dialog

If this Save/Restore part option is checked,

when you save and close a part document,

the machining data is saved and restored with the part design information when the part document is reopened

If this option is not checked,

when you save and close a part document that contains at least one Setup,

a message indicates that Save/Restore is disabled

If you click Yes,

CAMWorks saves all machining data before closing the file

If you click No,

CAMWorks closes the part and discards any new machining data since the last save

Select Save As on the File menu

Browse to the location where you wish to save the file

In the Save As dialog box,

type cwex1 and click the Save button

SAVE FREQUENTLY

you are actually working on a copy of the file

The original is still stored on disk

Periodically saving your file ensures that your latest work is retained

− CAMWorks provides an Auto save option on the General tab in the Options dialog box for automatically saving your CAMWorks data

− Frequent saves prevent having to redo a time-consuming model or CAM operation

If a power failure occurs,

you will lose whatever you have been working on

Defining Features Interactively Automatic Feature Recognition can save a significant amount of time

AFR does have limitations

AFR cannot recognize every feature on complex parts and does not recognize some types of features

To machine these areas,

you can define machinable features interactively using the Insert 2

For some parts,

Face Features can be recognized by AFR by selecting the Face option under the Feature Types group box on the Mill Features tab in the Options dialog box

For learning purposes,

you will insert a Face Feature so that you can face the top of the part

In order to define a Face Feature,

you select a face on the SolidWorks part that is at the depth you want to face the part to

Right click Mill Part Setup1 in the CAMWorks Feature tree and select Insert 2

Click the down arrow next to the Type list box and select Face Feature

Pick the main face

The outline of the face is highlighted on the part and Face displays in the Entities selected list

Click the Next button

This dialog box allows you to determine how CAMWorks calculates the depth of the feature and select a Strategy that defines a unique machining sequence

Leave the End condition Type set to Upto Stock

Leave the Strategy set to Coarse

Click Finish

Click Close to close the 2

Definition dialog Face Feature1 is displayed in the CAMWorks Feature tree

You have now defined all the machinable features in this part and you are ready to generate the Operation Plan

Interactively inserted Face Feature

Step 6: Generate Operation Plan and Adjust Operation Parameters The Generate operation Plan Command An Operation Plan contains information on how each machinable feature is to be machined and how the NC code will be output

When Generate Operation Plan is run,

operations for each machinable feature are created automatically based on information in the Technology Database

In some situations,

the operations defined for a feature in the Technology Database may not be sufficient and additional operations may be required

You can insert operations interactively using the Insert 2 Axis Operation,

Insert Hole Operation and Insert 3 Axis Operation commands

These commands are explained in the CAMWorks online Help

Select one of the following methods to generate an operation plan: Right click Mill Part Setup1 in the CAMWorks Feature tree and select Generate Operation Plan on the shortcut menu

Learning 2 Axis Mill Basics 1-15

or Click the Generate Operation Plan button on the CAMWorks Command Manager

Generate Operation Plan button in Command Manager or Right-click on CAMWorks NC Manager and select Generate Operation Plan command from the RMB shortcut menu

• If you execute the Generate Operation Plan command from the Command Manager or the CAMWorks NC Manager level,

then operations will be generated for all prismatic features in the tree,

regardless of the active item in the tree

Generate Operation Plan command executed at CAMWorks NC Manager level

• If you execute the Generate Operation Plan command from the Mill Part Setup level,

then operations will be generated only for those prismatic features listed under the given Mill Setup

• If you execute the Generate Operation Plan command at the feature level (by rightclicking on a feature listed in the Feature tree and executing Generate Operation Plan command from the RMB shortcut menu),

then operations will be generated only for the selected feature

CAMWorks generates the operation plan for all the machinable features in Mill Part Setup1

The operations are listed in the CAMWorks Operation tree,

The Operation tree can also be accessed by clicking the CAMWorks Operation Tree tab

The CAMWorks Operation tree provides an outline view of the operations for the machinable features

Operations are listed under the Mill Part Setup in the same order as the machinable features

At the top of the tree is the NC Manager

The Stock Manager and Machine items are the same as in the CAMWorks Feature tree

You can change the stock size and shape and the post processor used by CAMWorks to produce G-code

The CAMWorks Operation tree allows you to: − Insert,

and delete operations − Change operation parameters − Combine operations − Sort operations 1-16 Learning 2 Axis Mill Basics

− Change the machining order − Generate toolpaths − Simulate toolpaths − Post process the toolpaths − Hide or show toolpath display − Search based on item name To the left of each toolpath operation is a plus sign (+)

Clicking a plus sign displays the name of the Machinable Feature that this operation is going to machine

These Machinable Feature items can be used to view geometric information and to modify the machining depth of the feature

Did You Know

If an operation displays in a color other than black,

then it indicates that toolpaths have not been generated for that particular operation

This occurs when you insert a new operation interactively,

you insert a new feature interactively and generate operations for the new feature,

or CAMWorks cannot generate the toolpath for an operation because of an error in the toolpath algorithm or a parameter is not correct

You can set the color for operations without toolpaths on the Display tab in the Options dialog box

Operations generated on executing GOP command

Display tab of Options dialog

Adjusting Operation Parameters The operations that are generated by CAMWorks are based on information stored in the Technology Database

These operations are intended to be used as a starting point

Each operation contains operation parameters that affect how the toolpath is created and specific parameters that will be output to the NC program

These parameters can be edited before generating the toolpaths and post processing the part

Learning 2 Axis Mill Basics 1-17

Edit operation parameters: 1

Double click Rough Mill2 (the operation generated for Irregular Pocket2) in the CAMWorks Operation tree

Alternatively,

you can right-click on Rough Mill2 and select Edit Definition on the shortcut menu

The Operation Parameters dialog box is displayed

This dialog box gives you access to all the parameters used to define the toolpath

General parameters for the type of toolpath include the method of machining,

This dialog box also gives you access to the parameters for the tool you are using and allows you to select a different tool

Click the Roughing tab and change the Pocketing Pattern to Zigzag

Click the Feature Options tab and change the Entry Method to Roughing tab of Operation Parameters dialog Entry Hole

Click OK to close the dialog box

Step 7: Generate Toolpaths CAMWorks calculates toolpaths using the operation parameters and the feature's size and shape

After toolpath is generated for a particular operation,

that operation is displayed in black-colored font in the Operation tree

Observe the CAMWorks Operation tree

Notice that the toolpaths for Center Drill and Drill operations were created automatically for Rough Mill2 operation because you set the Entry Method to Entry Hole

When using the Entry Hole method,

control is provided to: − Specify any number of machining processes in the Technology Database to machine the entry hole (i

Center Drill and Drill)

− Tool type selection is based on what each operation supports

− Tool diameter selection can be customized in the Technology Database

− Operation parameter defaults can be defined in the Technology Database

Select one of the following options to generate toolpaths: Click the Generate Toolpath button on the CAMWorks Command Manager

or Generate Toolpath command in CAMWorks Command Right-click Mill Part Setup1 in Manager the CAMWorks Operation tree and select Generate Toolpath command on the shortcut menu

CAMWorks calculates the toolpaths for each operation in the Mill Part Setup

Note: Just like the Generate Operation Plan command,

the scope of the Generate Toolpath command too depends from which level the command is executed

• Executing this command from the CAMWorks NC Manager or Command Manager level generates toolpaths for all the operations

• Executing this command at Mill Part Setup level generates toolpaths only for operations listed under the given mill setup

• You can also generate toolpaths for each operation individually by right-clicking on an operation and executing Generate Toolpath command on the shortcut menu

Highlight the first operation in the Operation tree,

then highlight the last operation

This action displays the toolpaths for all the operations on the part (in the graphics area) showing the centerline of the toolpath

Click an operation in the CAMWorks Operation tree

− The toolpath for that operation is displayed

− As you click each operation,

Cam

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