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Error! Reference source not found. Error! Reference source not found. Page 1 of 29 Lesson 3: Prismatic Milling Objectives Through completing the exercises in this lesson, you will be able to: Section Topic Exercise 3.1 Create Stock Exercise 1 - Creating Stock 3.2 Manufacturing Environment Exercise 2 - Starting a New Machining Sequence 3.3 Select and Create Tools Exercise 3 - Creating a New Tool 3.4 Face Milling Operation Exercise 4 - Face Milling Operation 3.5 Viewing the Toolpath 3.6 Editing a CAM Instruction Exercise 5 - Editing a CAM Instruction 3.7 Profiling Operation Exercise 6 - Profiling Operation 3.8 Roughing Operation Exercise 7 - Roughing Operation 3.9 Machining Holes Using the Drill Cycle Exercise 8 - Drill Cycle 3.10 Moving/Copying/ Inserting a Machining Instruction Exercise 9 - Moving and Inserting CAM Instructions 3.11 Flat Land Finishing Exercise 10 - Flat Land Finishing Operation Use the right-hand column to tick off those lessons or exercises you have completed. Before You Start Before you begin work on the following exercises, make sure that you display the following toolbars on the screen: Standard toolbar, Main toolbar. Tooling toolbar, Edit Toolbar. Input Options Toolbar, Browser window.
Transcript
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Lesson 3: Prismatic Milling

Objectives

Through completing the exercises in this lesson, you will be able to:

Section Topic Exercise

3.1 Create Stock Exercise 1 - Creating Stock

3.2 Manufacturing Environment Exercise 2 - Starting a New

Machining Sequence

3.3 Select and Create Tools Exercise 3 - Creating a New Tool

3.4 Face Milling Operation Exercise 4 - Face Milling

Operation

3.5 Viewing the Toolpath

3.6 Editing a CAM Instruction Exercise 5 - Editing a CAM

Instruction

3.7 Profiling Operation Exercise 6 - Profiling Operation

3.8 Roughing Operation Exercise 7 - Roughing Operation

3.9 Machining Holes Using the Drill

Cycle

Exercise 8 - Drill Cycle

3.10 Moving/Copying/ Inserting a

Machining Instruction

Exercise 9 - Moving and Inserting

CAM Instructions

3.11 Flat Land Finishing Exercise 10 - Flat Land Finishing

Operation

Use the right-hand column to tick off those lessons or exercises you have completed.

Before You Start

Before you begin work on the following exercises, make sure that you display the

following toolbars on the screen:

Standard toolbar, Main toolbar.

Tooling toolbar, Edit Toolbar.

Input Options Toolbar, Browser window.

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Overview of the Lesson In this lesson, you will learn the milling techniques required to machine the following

component:

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Lesson 3.1 - Creating Stock Page 3 of 29

Lesson 3.1 - Creating Stock Before you can machine a component, you would typically create the stock to represent

the material (or billet). The stock envelops the component outline and is used in

EdgeCAMs Simulator to display the removal of material as the machining instructions

are simulated.

Exercise 1 - Creating Stock

1. Open the component „Packing Adapter_Metric.ppf''. The image should look like

this:

2. Select the Stock/Fixture option from the Geometry menu. You see the Stock

dialogue.

3. Enter the following stock specifications:

automatic Stock checked Shape Box

X & Y Offsets 5mm Z Max offset 5mm

Z Min offset 15mm Layer Stock

Color White

4. Save the Part as „Packing Adapter_Metric.ppf‟ to your X:\ drive.

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Lesson 3.2 - Manufacturing Environment EdgeCAM manufacture mode allows you to specify tooling and machining commands to

manufacture components.

The first time you enter manufacture mode, you must enter details on the type of

machining you want to perform, for example milling or turning. The first dialogue is the

Machining Sequence dialogue:

Exercise 2 - Starting a New Machining Sequence

1. Ensure the part file „Packing Adapter_metric.ppf‟ is opened.

2. Select the Manufacturing Icon.

3. If this is the first time you have used the Manufacturing Environment - you will see

the Machining Sequence dialogue box.

4. Fill in the following parameters:

Sequence Name „First Operation‟

Discipline „Mill‟

Initial CPL „Top‟

Machine Tool „pf-3x-mc.mcp‟

All remaining modifiers can be ignored.

5. Dismiss the Dialogue box by selecting „OK‟.

6. You may edit any of the above information by clicking the right-hand mouse button

over the Sequence Name in the Instructions Browser and select „Edit‟.

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The ‘Sequence Window’ displays a list of manufacturing commands. You can copy, move, edit and delete commands within this ‘Window’.

7. You will observe the following dialogue box:

8. The above information can be altered at any time during the Manufacturing

procedure.

Lesson 3.3 - Creating CAM Instructions Essentially, you have two methods of creating machining instructions in EdgeCAM.

Firstly you may adopt a „Manual‟ method which relies entirely on the users‟ knowledge

and skill of the software. Each individual CAM instruction will be created by the user.

Alternatively, you can choose to work in a more „Automated‟ manner which allows the

software to make more machining decisions for you and the physical creation of each

CAM instructions are faster.

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Machining Process for Packing Adapter Component

Exercise 3 - Creating a New Tool

In this exercise, you will create a new tool, which will be used during the machining

process, on the current component. Specifically, the tool is a 40mm dia. Face Mill. The

tool will be used to remove surplus stock material from the component.

1. Before proceeding ask Mr. Carron to setup your ‘TOOLSTORE DATABASE’.

2. We wish to create a permanent record of this item within the ToolStore. Select the

„ToolStore’ icon.

3. Filter the current amount of tools on display by selecting „Facemill‟.

4. Create a new “40mm Face mill” - select “Create”.

Process CAM Instruction

Work Content Tool Description Tool No.

1 Facemill

Operation

Face off component 40mm x 15° Approach Facemill 1

2 Profiling

Operation

Rough-out external

features

40mm Dia. Endmill - Long Series 2

3 Roughing

Operation

Rough-out two

Pockets

16mm Dia. Solid Carbide Endmill - Long

Series

3

4 Hole Cycle Drill Through 2 x

8mm Dia. holes

8mm dia. HSS Drill 4

5 Hole Cycle Counterbore the 2 -

8mm holes

16mm dia. Flat bottom “peg” drill or Slot

drill

5

6 Flatland

Finishing

Operation

Finish and „size‟

both Pocket

Features

12mm dia. standard Endmill 6

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5. Enter the tool Description - „40mm Face Mill‟.

6. Enter the following values in the „Geometry‟ tab.

Face Mill specifications:

Diameter 40mm

Flute length 10mm

Hand of Tool Right

Included angle 15°

teeth/flutes 5

Shank Length & Diameter 15mm

What happens by default if you do not enter a shank diameter?

4. Rotate and Pan the image of the Face Mill. Double click the left-hand mouse key in

the Graphics port to Zoom Extents the image of the Tool.

5. The tool should now be displayed. Select „Cancel‟ to exit the ToolStore.

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Lesson 3.4 - Face Milling Operation In this lesson, you will learn how to use the basic 2½D milling CAM instructions to

machine the component. Furthermore, you will learn how to Simulate the machining

sequence- using EdgeCAM Simulator.

Process One

Process CAM Instruction

Work Content Tool Description Tool No.

1 Facemill

Operation

Face off component 40mm x 15° Approach Facemill 1

Exercise 4 - Face Milling Operation

The first step in milling the example part is to prepare the top surface of the component

before using any other machining processes. You can facemill the top area of a

component.

Face mill can be performed manually by using Rapid & Feed movements. However, it is

obviously better to employ EdgeCAMs commands - in this instance Facemill Operation.

1. Select the Face Mill Operation either form the menu, or from the toolbar.

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2. Observe the command prompt - ‘Select Boundary Entities (Finish for None)’ Re-act

to the prompt by the chaining the 2D profile representing the stock.

3. You will now observe an interactive dialogue box, which runs a „video‟ of the tool

movements. As you tab through the various commands, the display will be altered in

order to allow the user to visualize the influence of that particular command.

4. Digitize the „?‟ symbol - EdgeCAM will display a miniature „Help‟ menu which will

allow the user to fully interpret the command.

5. Assign the following General Parameters:

Mill Type Climb Angle 0º %Stepover 65

Lead Length 25mm Stock Offset 0mm

6. Assign the following Tooling Parameters:

Select „Find’ and choose the 40mm Face Mill

Position 1

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7. Assign the following Depth Parameters:

Clearance 20mm Level 5mm

Depth -5mm Cut Increment 2.5mm

8. Dismiss the dialogue box by selecting „OK’.

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Lesson 3.6 - Profiling Operation Page 11 of 29

Lesson 3.5 - Editing a CAM Instruction

Exercise 5 - Editing a CAM Instruction

1. Observe the Sequence Window, containing the CAM Instructions. Select the „+‟

symbol alongside the Face Milling Operation.

Why do you think the Face Mill Operation has selected miscellaneous functions such as Coolant and Spindle commands? Investigate what influence does the ‘Operation Preferences’ have over the Face Mill Operation.

2. If you are not entirely satisfied with the toolpaths produced by the Face Mill

Operation you may edit the operation. Position the cursor over the entry called „Face

Mill Operation‟ and click the right mouse button - select „Edit‟ you will observe the

following dialogue box.

3. If you check the „Coord Input‟ box, you will be offered the opportunity to reselect

CAD geometry. Ignoring the „Coord Input‟ box and selecting „OK‟ - you will be

offered the opportunity of re-specifying the various information that was originally

entered into the Face Mill Operation dialogue box.

4. Try changing some of the original data:

Mill Type Climb Stepover 25%

Angle 45° Cut Increment 2mm

Lead Length 25mm

5. Select „OK‟ to dismiss the Dialogue Box and observe the alterations in the toolpaths.

Observe how the Operation

contains individual CAM

instructions.

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Lesson 3.6 - Profiling Operation Page 12 of 29

Viewing the Operation

6. Expand the Face Mill Operation by digitizing the „+‟ symbol. Place the cursor over

the CAM instruction called „Face Milling‟ and click the right hand mouse button.

Select „Edit‟ from the drop-down menu. You are now specifically editing the

individual cycle.

7. Observe the numerous commands contained within the dialogue boxes - in particular

look at the Lead parameters.

Do Not alter any of the information found within the Dialogue boxes.

8. If we had chosen to create our CAM instructions using the „Manual‟ method we

would have used a Face Milling Cycle.

9. Dismiss the dialogue box by selecting ‘CANCEL’.

When viewing CAM Instructions and parameters born out of an Operation - you must dismiss the dialogue box by the ‘Cancel’ command. Otherwise you will ‘Collapse’/’Explode’ the Operation.

10. Select „Preferences’ from the Operations Menu.

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Lesson 3.6 - Profiling Operation Page 13 of 29

11. Activate the „Disable M-Functions’ command.

Operation Preferences influence the behavior of the CAM instructions (and its toolpaths) created from an Operation.

12. Save the file. If you have already saved the file you will not be prompted for a

file name nor Folder.

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Lesson 3.6 - Profiling Operation Page 14 of 29

13. Activate the „Last‟ option found in the Mode command (View Menu). This will have

the effect of allowing EdgeCAM to only display the last toolpath and thus make the

screen less cluttered.

Lesson 3.6 - Profiling Operation

Exercise 6 - Profiling Operation

Process CAM Instruction

Work Content Tool Description Tool No.

2 Profiling

Operation

Rough-out Outside

Profile

40mm Dia. Endmill - Long Series 2

The next stage is to rough out the surplus material found on the outer regions of the

component. There are obviously several methods that could execute this work - the

Profiling Operation is one of several options.

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Lesson 3.6 - Profiling Operation Page 15 of 29

1. Select „Profiling Operation‟ from the Operation Menu.

The characteristic of all Operations is determined by the ‘Preferences’ settings.

2. Observe the command prompt „Digitize Profiles’ - chain the outer profile of the

component. Move through to the next command prompt by clicking the Right-hand

mouse button.

3. Observe the command prompt „Digitize new Start Point for Profile Chain’

EdgeCAM is offering you the opportunity to determine the entry/exit point of the

cutter in relationship to the profile. As you left-hand mouse key click around the

profile, notice how the arrow symbol is positioned. Move through to the next

command prompt by clicking the Right-hand mouse button.

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Lesson 3.6 - Profiling Operation Page 16 of 29

4. You may ignore the final command prompt - „Select Boundary Entities (Return for

None’) - by clicking the Right hand mouse button.

5. You will now observe an interactive dialogue box, which runs a „video‟ of the tool

movements. As you tab through the various commands, the display will be altered

in order to allow the user to visualize the influence of that particular command.

6. Digitize the „?‟ symbol - EdgeCAM will display a miniature „Help‟ menu which

will allow the user to fully interpret the command.

.

Mill Type Climb Mill

Tolerance 0.01mm

Offset 0mm

Compensation Geometry

None - no compensation G Codes are placed in the CNC program. The X & Y

positional output within the program is based on the tools centerline.

Centerline - as above expect compensation G Codes are placed in the CNC

Program.

Geometry - The X & Y positional output within the program is based on the

geometry of the profile. Compensation G Codes are placed in the CNC

Program.

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Lesson 3.6 - Profiling Operation Page 17 of 29

Lead Radius 4mm

The tool will “Roll” into the sidewall of the profile as it enters the cut.

7. Move onto the „Tooling‟ Tab.

Position 2

Select the „Find’ button and browse the ToolStore - selecting „40mm End

Mill‟.

8. Move to the „Depth’ Tab

Clearance 5mm Level 0mm

Depth -33mm Cut Increment 10mm

Cusp blank

Lead Radius - radius compensation is

applied along the Lead In section of the

toolpath.

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Lesson 3.6 - Profiling Operation Page 18 of 29

9. Dismiss the dialogue box by selecting „OK’.

10. Observe the resultant toolpath - referring to the previous exercise, use the Simulate

Toolbar to „play‟ and view the toolpaths.

11. Open the „Simulator‟ and observe the toolpaths.

When the Simulator is launched, select the Start icon from the toolbar:

You can change the speed by adjusting the speed slider bar:

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Lesson 3.6 - Profiling Operation Page 19 of 29

Quit the Simulator and return to EdgeCAM.

Refer to ‘Lesson 4.2 - EdgeCAM Simulator’ section of this training guide for information about the Simulator software.

12. Observe the Sequence Window, containing the CAM Instructions. Select the „+‟

symbol alongside the Profiling Operation.

Why do you think that the Profiling Operation has selected the Tool Change command?

13. If you are not entirely satisfied with the toolpaths produced by the Profiling

Operation you may edit the operation. Position the cursor over the entry called

„Profiling Operation‟ and click the right mouse button. You will observe the

following dialogue box.

Observe how the Operation

contains individual CAM

instructions.

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Lesson 3.6 - Profiling Operation Page 20 of 29

14. If you check the „Coord Input‟ box, you will be offered the opportunity to reselect

another Feature or Profile. Ignoring the „Coord Input‟ box and selecting „OK‟ - you

will be offered the opportunity of re-specifying the various information that was

originally entered into the Profiling Operation dialogue box.

Viewing the Operation

15. Expand the Profiling Operation by digitizing the „+‟ symbol. Place the cursor over

the CAM instruction called „Profiling‟ and click the right hand mouse button. Select

„Edit‟ from the drop-down menu. You are now specifically editing the individual

cycle.

16. Observe the numerous commands contained within the dialogue boxes - in

particular look at the Start/End parameters.

Do Not alter any of the information found within the Dialogue boxes.

17. If we had chosen to create our CAM instructions using the „Manual‟ method we

would have used a Profiling Cycle.

18. Dismiss the dialogue box by selecting ‘CANCEL’.

When viewing CAM Instructions and parameters born out of an Operation - you must dismiss the dialogue box by the ‘Cancel’ command. Otherwise you will ‘Collapse’/’Explode’ the Operation.

19. Re-Save the part.

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Lesson 3.7 - Roughing Operation

Process CAM Instruction

Work Content Tool Description Tool No.

3 Roughing

Operation

Rough-out two

Pockets

16mm Dia. Solid Carbide Endmill - Long

Series

3

Exercise 7 - Roughing Operation

Now that you have experienced setting up an Operation - you should find the next

exercise slightly easier.

Remember, an Operation is creating the CAM instructions for you. You will be shown later on how to create these Instructions manually.

1. From the Operation menu, select „Roughing‟. Observe the command prompt

„Digitize Geometry to machine’ - Chain both pocket profiles.

Think - what CAM instructions are created by the Roughing Operation?

2. Observe the next command prompt „Select Boundary Entities (Finish for None)‟

You may ignore this prompt - a boundary is only used when you wish to restrict the

positions of the toolpath.

3. Observe the „Video‟ window and read the interactive Help. Set the following

modifiers:

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Mill Type Climb %Stepover 50%

Offset 1mm Z Offset 0mm

Tolerance 0.1mm

The value inputted for ‘Offset’ is 3D - applied to X,Y & Z axis.

4. Move into the „Tooling‟ tab and set the following.

Tool Number 3

Tool Type 16mm Long Series End Mill

5. Move into the „Depths‟ tab and set the following:

Clearance 5mm Level 0mm

Depth -15mm Cut Increment 5mm

6. Dismiss the dialogue box by selecting „OK’.

7. Observe the resultant toolpath - referring to the previous exercises, use the Simulate

Toolbar to „play‟ and view the toolpaths.

8. Open the „Simulator‟ and observe the toolpaths.

Refer to ‘Lesson 4.2 - EdgeCAM Simulator’ section of this training guide for information about the Simulator software.

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9. Observe the Sequence Window, containing the CAM Instructions. Select the „+‟

symbol alongside the Roughing Operation.

Consider why EdgeCAM has created a ‘Move to Too Change’.

10. Re-Save the Part.

Lesson 3.8 - Machining Holes Using the Hole Cycle You can produce different drilled hole specifications by selecting the appropriate tool

and specifying the relevant modifiers for the cycle. For example, you can create a main

hole and its countersink by creating two hole cycles, each with different tool, depth and

dimension specifications.

The method described herein represents the ‘Manual method’ of creating CAM instructions. Therefore, unlike the previous exercises - you will not be using Operations.

Process Four

Process CAM Instruction

Work Content Tool Description Tool No.

4 Hole Cycle Drill Through 8mm dia. HSS Drill 4

5 Hole Cycle Counterbore the 2 -

8mm holes

16mm dia. Flat bottom “peg” drill or Slot

drill

5

Exercise 8 - Drilling the Holes

Complete machining of the drilled and counter bored holes.

You will now learn how to create a Hole cycle. For this particular component, you will

have to produce two cycles to completely machine the drilled hole feature.

Drill - through the component with a 8mm dia. HSS Drill.

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Counterbore - 16mm Dia. X 5mm deep with a 16mm Slot Drill .

1. The Endmill from the previous machining instructions requires placing back in the

tool carousel/turret. Execute a Toolchange command.

Consider why it wasn’t necessary to use a ‘Toolchange’ command during the previous machining transactions.

2. Define/select tool number four - 8mm diameter drill.

3. Open the Hole Cycle Command. You see the Hole Cycle dialogue:

4. Set the following Parameters:

Subroutines Controller Longhand No

Feature Name Holes Optimize Path None

5. Set the Depth Parameters:

Clearance 10mm Level 0mm

Depth -35mm

Use „Feature Name‟ in order to

lessen the amount of digitizing.

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Multilevel and Multi Depth are used where the same Drill is to be used on various holes features each possessing different Level and depth.

6. Step parameters are used when Peck Drill or Deep Hole Drilling Cycles are required.

7. Filtering can be used for refining the cycles. For instance where a drawing possesses

numerous arcs that represent hole positions, one can force the cycle to drill arc

entities that match the drill diameter.

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8.

9. Dismiss the Dialogue box by selecting „OK‟ The command prompt will read „

Digitize location for hole centre‟ In the case of the component in hand, select the

centre point(s) of the arc(s) you want to drill, then right-click to end the hole

command.

Use Intellisnap to guarantee that you have selected the correct position.

To select the centre of an arc, position the cursor over the arc centre and wait until the

„Entity Tooltip‟ appears. Select the Centre-point option from the shortcut menu, then left

hand click to select the required position.

Refer to Getting Started with EdgeCAM Lesson 2.5 ‘Selecting Entities’.

9. Having digitized the two positions, EdgeCAM creates and displays the toolpath(s) for

the hole cycle.

10. Move the Tool to the Tool change position.

11. Save the file. If you have already saved the file you will not be prompted for a

file name nor a Folder.

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Process Five

Process Cycle Work Content Tool Description Tool No.

5 Drill Counterbore the 2 -

8mm holes

16mm dia. Flat bottom “peg” drill or Slot

drill

5

12. Select or create a 16mm End Mill.

13. Create a second Hole Cycle - Pay special attention to the depth modifiers.

14. Remember to use Feature Name. EdgeCAM will remember the name used in the

previous hole drilling cycle. On this occasion you will not have to digitize the hole

centers:

15. Move the drill back to the toolchange.

position.

Lesson 3.9 - Moving/Copying/ Inserting a Machining Instruction

Exercise 9 - Moving and Inserting CAM Instructions

Moving a CAM Instruction

The following information will demonstrate how to create further CAM instructions

AFTER a machining process has been completed.

The method used to move and copy a CAM instruction is identical to that used in

Microsoft©. Windows® Explorer for move Files and/or Folders.

1. Position the Cursor over the target CAM Instruction, click the left hand mouse

button and hold the button down. Using the “Drag and Drop” method, slide the

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mouse/cursor up and down the CAM Browser. You will observe a black line

appearing, this indicates the new position for the instruction.

2. Release the Left Hand mouse button the CAM Instruction is moved/Copied.

To Copy a CAM instruction, repeat the above procedure whilst holding down the ‘Control’ Key.

Inserting a CAM Instruction

To Insert a CAM instruction:

3. Right-hand mouse key click over an Instruction and select „Insert‟.

4. An arrow marker will appear next to the instruction. All new instructions will be

placed Before the „marked‟ instruction.

5. Having created the new CAM Instructions - switch off „Insert‟ by right hand click

over the CAM Instructions, and un-check „Insert‟.

Lesson 3.10 - Flat Land Finishing Operation

Process Six

Process CAM Instruction

Work Content Tool Description Tool No.

6 Flatland

Finishing

Operation

Finish and „size‟

both Pocket

Features

12mm dia. standard Endmill 6

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Exercise 10 - Flat Land Finishing Operation

Flat Land Finishing Operation

The Flat Land Finish cycle is capable of finish machining the base and sides of the two

pocket features. Without this cycle, one would have had to use a Roughing cycle (with

the cut increment deactivated) plus a Profiling cycle.

The exercise herewith uses the automatic method of creating CAM instructions. Therefore, you will use the Flat Land Finishing Operation.

1. Select Flat Land Finishing Operation from the Operations Menu.

2. Observe the command prompt - „Digitize Geometry to machine’ - chain the two

profiles that represent the pockets.

3. Ignore remaining prompts.

4. Set the Step-Over 35% and select a 12mm Dia. Endmill from the ToolStore

5. Set the Depth parameters to:

Clearance 5mm Level 0mm Depth -15mm

6. Observe how the tool machines the surplus material on the base of the pockets as

well as the side walls.

7. Re-Save the part as „Packing Adapter.ppf‟.