basisseminar engl

Training course leader: Tobias Weber i-mes GmbH, Im Leibolzgraben 16, D-36132 Eiterfeld, Tel.: +49 66 72 / 892-218, Fax: +49 66 72 / 898-222, eMail: [email protected]

isy CAM 3.0

Training Course Document

Basis Seminar

isy CAM 3.0: Basis Seminar, i-mes GmbH, www.i-mes.de 2

Contents 1 Introduction 1.1 Screen Arrangement 2 1.2 Basic Rules 2 2 CAD-Examples 2.1 Exercise 1a: Object Structure 5 2.2 Exercise 1b: Generate Macros 6 2.3 Exercise 2 : Import of 2D DXF-Data 7

Trims 9 Milling Zero Point (Point Markers) 12 2D-Contour roughing 13 2D-Contour Finishing 15 2.4 Exercise 3 : 2D-Construction 17 Numerical input of coordinate 18 Contour Cut Open, Trims and Contour Generation 20 2.5 Exercise 4: 2D-Engraving "Simple Sign" / Pocket Milling 22 2D-Pocket Milling 24 2D-Pocket Milling Remaining Material Recognition 25 2D-Pocket Milling Finishing and Carving 26 2.6 Exercise 5: Simple 3D Construction / 3D Milling 27 3D Construction: 2D => 3D 28 Roughing 3D Z constant 30 Finishing 3D Z constant 32 Finishing 3D 33 Graphic Simulation of the milling paths 34

isy CAM 3.0: Basis Seminar, i-mes GmbH, www.i-mes.de Screen Arrangement 3

1 Introduction 1.1 Screen Arrangement Text Menu Menu Modes View Main Window Menu Sub Menu Command Line or Status Line 1.2 Basic Rules a) Active Object

An active object is a lastly drawn object or an object, which was selected or marked with a selection function. Active objects can be visibly switched with the function "Highlight active object On/Off " Active objects can be changed with the buttons, which are marked by a yellow-red asterisk, e.g. shifting, rotate, mirror, scale.

b) Coordinate System The coordinate system will be switched on by accompanying button "axis markings in-/-fade out ". Drawing constructions should be developed if possible related to 0/0/0. If no other point of reference is indicated in the CAM technology block, then the coordinate origin is embodied as milling zero point automatically.

c) Colour Snap About the graphic toolbar the object resting itself to elements of certain colours. That is particularly helpful if other selection methods fail (e.g. with overlays of elements) or if you want to delete from a general drawing only objects of a certain colour.

isy CAM 3.0: Basis Seminar, i-mes GmbH, www.i-mes.de Basic Rules 4

d) Visual Aids: VIEW and ZOOM About the menu "View "3D-Objects can be regarded in different projections. After the installation the appropriate toolbar is put at the edge of the view window automatically. The indication sheet can be of any size. This is reached by the ZOOM function, which makes any cut out enlargement possible. Correct handling with the ZOOM function is a prerequisite for the precise construction.

e) Number Input and -Representation Please note that isy CAM numbers with right-of-comma positions not with ",", but with a decimal point ". " are entered. A comma always serves the separation from several numerical values, e.g. with a pair of coordinates X,Y.

f) Command Line Editing, Command Stack The keys , , , , , serve the editing and cursor control within the command line. The keys and/or permit a leafing through the command stack (command repeating memory) towards sooner or later entered commands.

g) Key Functions get older command from stack get new command from stack set cursor one position to the left set cursor one position to the right set cursor to start of line set cursor to end of line delete sign left of the cursor delete sign left of the cursor + sign left from the cursor is marked, cursor jumps a sign to the left (sequentially with longer pressed arrow key) + sign under the cursor is marked, cursor jumps a sign to the right (sequentially with longer pressed arrow key) + marked signs are copied in the clipboard (intermediate file)

isy CAM 3.0: Basis Seminar, i-mes GmbH, www.i-mes.de Basic Rules 5

+ red marks for positioning of the cursor to the past system messages and stack commands to the assumption in the clip board Note: Naturally the cursor can be placed also with the help of the showing equipment. If one drives e.g. with pressed left mouse button over the command line, the signs which are under it are marked. If the pointer of mouse is in the command window, a menu appears for copying, after pressure the right mouse button. + contents of the clip board are inserted at the current cursor position + marked signs are shifted into the clipboard (cut out)

isy CAM 3.0: Basis Seminar, i-mes GmbH, www.i-mes.de Exercise 1a 6

2 CAD-Examples 2.1 Exercise 1a: Object Structure A short overview, how isy-CAM administers geometry data, you receive by the following exercise: Proceeding:

a) Draw a 2D line from left above to the right down An object was produced by this function, which consists of one element only.

b) Put in ,edit in the status line and confirm with Enter.

c) Now you are in the editor, which indicates the geometry data of the stored line. In order to be able to produce the object, isy-CAM needs six internal commands. In this alphanumeric form isy-CAM puts all designs down in the vector listing. Description of the short instructions used here:

os Object start - obj1 is the object name, which isy automatically assigned. You can change it:

ob Object box - each object is coated by (not visible) a rectangle. The box is generated automatically during the object production. The new calculation of all existing object boxes is possible with the command box all

co Object colour - here 2=green - change the colour value (2 to 32), so the colour of the object at the drawing object changes

ma move absolute - moves the virtual pin, here on the position 100,400. If you change the coordinates, then the line beginning shifts

da draw absolute - a line from the current point draws to 400,100 with the virtual pin. If you change the coordinates, then the line end shifts

oe Object end

isy CAM 3.0: Basis Seminar, i-mes GmbH, www.i-mes.de Exercide 1b 7

d) Now construct a second line in another colour and

change with "edit" into the editor. Now in the editor the second object is to be seen behind the first directly. The clips right show os and oe of an object.

2.2 Exercise 1b: Generate Macros A macro (or macro object) is the summary of several objects to a whole one. Also called grouping of several objects. The partial objects remain and be able thereby to be manipulated individually. The macro object has its own object box, which coats all single objects. a) Select first the button in menu " object structuring ", and enter a meaningful

name in the appearing dialogue. b) After that choose function in the same menu.

Select both objects (lines) now. With the right mouse button the selection is terminated and the macro is generated automatically.

Tips & Trick: - The macro function should not be used by summarizing

individual objects to a closed contour (prepare the contours for milling, a preparing of the contours for converting in 3D-objects). Select instead of its the functions "contour generation " in the menu " curves "!

- Proceed during the macro formation systematically, as macros are not visible in the design. Too deeply interlocked macros are difficult to seize.

- macros can be selected with accompanying switching surface.

- with this function macros can be deleted again.

isy CAM 3.0: Basis Seminar, i-mes GmbH, www.i-mes.de Exercise 2 8

2.3 Exercise 2: Import of 2D-DXF-Data This exercise is to point practical handling and a preparing of 2D-DXF-data for milling. Here you find among other things the functions, " deletion ", " trims " and " macro ". Proceeding: a) Import the file KONTUR.DXF from the training course disk (or from an appropriate

listing). Select for this menu " file " => " import". In isy in the CAM file manager select the filter " *.DXF " under type of file.

b) Confirm with OK. Activate the small box

" import as 2D drawing ", otherwise the drawing will be written in a 2D drawing. This would have the consequence that no 2D function could be used.

An error message with a warning appears after converting in most cases. This continues to be not tragic, because only a conflict exists with the shifting of the used character font. The desired character font can be adapted by a writing filter to a foreign format.


c) In this exercise the red contour with a 3 mm - cylinder drill from an aluminum plate 100 x 100 x 4 mm is to be milled centrically out. Delete first the green dimensioning lines and the white coordinate cross X/Y. Adjust the colour resting as follows:

Click first with the left mouse button on the colour resting green, afterwards with the combination [ Strg ] - key / left mouse button on the colour snap white.

d) Select now the button " multiple deletion of objects ". Click now with the left mouse button (once short) left above into the drawing surface and pull a window over all objects to the right lower corner. Click again the left mouse button, so that all objects are deleted. The function is terminated with the confirmation of the right mouse button.

e) Place back again the colour snap "Snap to all colours".

f) Analyze the imported data: Select for this the individual objects, so that you recognize how the contour is created. It occurs very frequently that errors are present in the construction, which when milling or processing can lead to problems e.g. by objects lying one above the other or badly trimmed objects. Use the accompanying buttons for analysis. Select for example on the middle line.

g) As you can recognize now, the line of the outer contour runs inward.

With the function " trim both elements " the supernatant part of the line "is trimmed. Proceed here as follows:

Click in each case at the outer contours (look pictures above). Select not first at the middle line. With the right mouse button the function is again terminated.


Basic Rules For Trims For trimming of elements (an object) the following rules are valid: 1. The object selected first will change. 2. In the place, where it is selected, it remains visible at the screen. 3. It is to be selected in the proximity of the intersection which can be expected. 4. Store drawing before...

Examples of trims of line with line: At 1. element Both elements

Examples of trims of line with circle: At 1. element Both elements


Examples of trims of circle with circle: At 1. element Both elements

h) Construction of the aluminum plate 100 x 100 mm:

Select the function " numerical rectangle: enter width, height & centre (hatched also) ". Follow the references in the dialogues and enter for the width and the height the number of 100. For the centre enter 0,0. The coordinate origin is placed exactly into the centre of the rectangle. Note: Perhaps more meaningfully is to put a corner of the rectangle into the coordinate origin. However a mark point is to be placed later into a corner when milling, which corresponds to the milling zero point.

i) Select the button " zoom all ", so that all objects are format-filling indicated.

j) Move and adjust the red contour within the rectangle: Red contour combine into a macro: Because the red contour consists of individual objects, all objects must be combined first into a macro. In the exercise 1b we already learned the function macro. The practical conversion has to be practised. After select the button "Concatenate objects to a macro/extend macro" first award a meaningful object name. After that select all objects of the red contour either by individual clicks with the left mouse button or by drawing a large catch window up over all objects. With the right mouse button the function is terminated. Note: The function " generate macro " is not to be equated with the function "contour generation "The macro function is treated in this example, so that the following shifting function does not fail. Here is pointed out again expressly that the function "contour generation" has a higher priority in relation to the macro function. Use always an contour generation for subsequent treatment of contours.


k) Move and adjust the red contour into the centre of the rectangle: isy CAM offers naturally several adjust and moving functions, e.g. the function "move object by relative coordinates" applies often. For our example we would like to use however the function " object on the centre of the reference object ", in order to place the red contour centrically into the rectangle. You find the function in the menu "Adjust". Follow for this the defaults in the command line and select first the red contour and then the adjust object (rectangle). Did this action work? Surely only one object of the red contour was moved! As already in chapter 2.2, exercise 1.b (page 6) mentioned, the partial objects at a macro remain and can be manipulated individually. If the catch function starts however with the combination of [ SHIFT ] - key and left mouse button at the red contour, isy CAM recognizes automatically that there are further objects for selection now. Either you pull a catch window over the whole red contour or you extend the selection with the operation of [ F10 ] - key. isy CAM finds the macro, which belongs to the red contour. With the right mouse button the object selection is terminated and with the left mouse button the rectangle (adjust object) will be selected finally. The red contour is in the centre of the rectangle now. Tip: The selection in connection with [ SHIFT ] - key can be used at all functions, where an object selection is necessary. Note: Try an adjusting of the objects without grouping the objects to a macro before. Now you will understand, why the macro function in the example was used.

l) Choose button zoom all, so that all objects are format-filling indicated.

m) The CAD part and the preparing of the drawing for milling is finished for this milling part hereby.

But first we would like to place the milling zero point with the function set 2D point markers into a corner of the contour, e.g. left down.

This point corresponds to the work piece zero point of the machine later, that means with the x/y/z axis the upper edge of the aluminium plate is touched in the position left lower corner


n) CAM-modul: contour milling (internal contour): With the accompanying button a new technology block " 2-D contour " will be created. In a technology block (block) all important parameters for treatment and for the machine are specified. A block consists in its structure of the ranges " geometry ", "edit, "approach / remove " and " program origin ". If you like to accomplish changes in a block, then activate the button "edit block". Important: With possible changes in a block please do not select again the function " 2-D - contour " (or accordingly different milling strategy function), otherwise isy CAM produces a new block automatically. As you surely know, the program isy CAM with its function varieties is completely identical to the "complete version" Pictures by PC from Schott Systeme, but with a restriction: The NC-expenditure is limited to the isel NCP- format " only ". On the next pages all important parameters are described, which are necessary for the NC-calculation. Internal Contour " roughing ":


1: Please assign here a meaningful name, so that you can recognize later, what is calculated in this block. 2: With the button you select the contour, which should be milled, with a click at the left mouse button. With the right mouse button you will be back at the block again. 3: Entry 0 mm corresponds to the work piece upper edge, Z = 0, which is touched in at the machine with the cutter peak. 4: Depth at Z- = 4 mm related to Z = 0 (work piece upper edge). 5: Lay in new tools, look at the next page too. Edit existing tool. Select existing tool from list. 6: Activate the small box "to" always. The programmed insertion depth speed into the work piece will be reduced automatically to 20% of the programmed feed speed. 7: Specify milling strategy: Inside and outside refer to "closed contours", left and right refer to "open" contours. Contour means, the cutter drives on the centre course (=>engraving) directly. 8: Oversize: The cutter drives during roughing not directly to the contour, but leaves untouched a oversize (remaining material) of 0.2 mm. This remaining material will be milled away during Finishing, so that a Finishing wall appears (e.g. so the setting depths during increment milling will be put away). 9: The depth increment is the maximum permissible setting depth of the used cutter into the work piece, in our example 0.5 mm. 10: With a new cutting zero point (work piece zero point) will be established in the block. Select in the appearing dialogue "Change CAM-origin " 2D-position.Then, select the before placed mark point in the left lower corner of the red contour in the drawing. If no milling zero point is established in the block, then isy CAM selects automatically the absolute origin of the drawing as milling zero point.


Tools: 1: Please assign here also a meaningful tool name too. 2: Select cutter, which you would use, here: cylinder cutter. 3: Enter cutter diameter. 4: Tool number: By using a automatically tool changer then this corresponds to magazine position 1. Also the tool change instruction is written into the NC-Program. 5: Feed speed during milling in mm / min. 6: Number of revolutions of the main spindle drive. In the case of use of the CNC-machines series CPM / GFM or C142-control the number of revolutions is not adjustable by this software parameter. Thus a number of revolutions of 1 would be sufficient here, so that at least the milling spindle is switched on automatically.

o) Internal contour "Finishing": For Finishing create again a new block with the button "2-D contour Opposite block 1 "roughing " only three parameters change: 1: The designation of the block now is: "internal contour Finishing" 2: The oversize is changed in 0 mm and 3: the indication of the depth increment is void. When Finishing the cutter drives with a feed motion to the depth Z = -4 and works at the contour.

p) Before transferring the NC-data to the machine, the generated technology blocks

are tested on their function, that means the milling paths are simulated. We use for this the accompanying button. In the dialogue "show path" select both blocks from the list. With OK the simulation is started. Tip: Are the milling paths simulated too quickly? With the two keys [ picture up ] and [ picture down ] the simulation speed can be affected.

q) The last step is now the so-called " post process ", that means the calculated and simulated milling paths are stored in the NCP format on the non removable disk. Select the appropriate function and follow the defaults in the following dialogues.


Technology-Parameters at the Machine

depth

safe

ty h

eigh

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wor

k pi

ece

uppe

r edg

e: p

lane

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stop b

ars

retr

actio

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safe

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work piece zero point

machine zero point (referene point)


2.4 Exercise 3: 2D-Construction This exercise is to show the typical proceeding to construct a 2D-contour, which is to be milled directly or be used for further processing in 3D. With the basic geometry objects and the use of " numeric coordinate input" the expected contour will be indicated first. By the assistants of "cutting open", "trims" and "contour generation" the resulted contour will be generated then.

isy CAM 3.0: Basis Seminar, i-mes GmbH, www.i-mes.de Exercise 3

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Proceeding: a) Basic rule no. 1: Activate the buttons "active object mark on/off" and "Show /

Remove axis-marks from screen". b) Construction of the three outside circles by means of "numeric input of coordinates":

Select the function "circle with num. radius and interactive centre". In the dialogue "circle or arc" enter the radius of the left outside circle of 50 mm. The circle centre has to lie in the absolute origin 0/0. Press in addition, while the circle as "rubber band line" is to be seen at the curser, the key [ n ].

By using the button "apply" in the dialogue "numeric coordinate data" the coordinates X/Y = 0/0 (absolute) for the circle centre are taken over.

c) Repeat the function "circle with num. radius and interactive centre" for construction of the second circle left with the radius of 25 mm.

d) The right circle (radius 75 mm) will be constructed with the same function and the assistant of the numeric indication of coordinate. Please enter for the x-coordinate 300 mm absolutely. With "apply" the dialogue is terminated.

e) The two outside circles are connected with two lines with the function "tangents to

two circles". Follow the instructions in the command line (1. / 2. ellipse (circle(-arc)) select). Select successively the two outside circles.

f) Construction of the two parallel lines in the distance of 20 mm of the two outside

lines, which end tangential in the large circles: Select the function automatic offset of multiple objects.... - In the dialogue automatic contour enter 20 for the distance. - Select the 1. object with the left mouse button, e.g. upper line, - after that select the 2. object with the left mouse button (lower line), - then press right mouse button to terminate the selection. - Click with the left mouse button below the upper line (the upper line- line selected first - marked by two triangles). With a left mouse-click the position will be specified now (select distance/position).-


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g) Construction polygon (hexagon): The centre point and the radius are well-known by the construction design. Select the function " regular polygon on centre point...". Enter the following values in the appropriate dialogue:

The centre point of the polygon can either be selected with the left mouse button, because the curser locked automatically in the circle centre point of the right circle, or enter the distance of 300 mm of the absolute origin with the function "numeric coordinate instruction" (key [ n ]).

h) Construction of the four internal circles, which in each case are attached tangential to two neighbouring objects. In the menu "circles" select for this the function "tangential circle at two elements with numeric input of the radius". First you are requested to enter the radius (for the left internal circles " 20 " and for the right internal circles " 25 "). Select, as to be seen in the two pictures, with the left mouse button the two elements, at which the circle is to be tied up tangential. Repeat the function for all internal circles.

i) The construction of all " basic geometry objects " is therefore terminated. Now the actually difficulty but also the important part of the construction will start : With the functions "cutting open", "trims" and " contour tracing" the resulted contours will be produced.


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Cut open: The outside contour will be cut open in the points, as to be seen in the lower drawing 1 , with the function "cut a part out of a single element ". Note: - Please consider that the selection of the intersections always have to be made against the clockwise direction. - Do not put the selection points directly within the range of the intersections too neighbouring elements, but hold sufficiently distance (generous selection). The supernatant partial elements will be removed later with the function "trims". - Place the selection points one time per element only. Will be several points selected or at the wrong place, the later "contour generation" can be failed.

j) Trims: After Cut open the remaining partial elements with the function " trims of both elements (to extend and/or shorten)" are removed => 2.

Trims: 1. mouse click Trims: 2. mouse click Please consider also the "basic rules for trims" at page 10.

k) Contour generation:

- Switch on a new drawing colour, e.g. white. - Contour first the outside contour with the function "interactive 2D-contour -generation duplicate". Tip: Switch out the button "active object mark on/off", that the selected objects are seen clearly. In the dialogue Contour the following small boxes will be activated: Explanation: - an object for each contour: is activated, if several contours are marked with a window. The program generates automatically several individual contours. - the created contour is generated automatically as NURBS curve. - a curve for each contour means that e.g. a contour consisting of four straight lines will be generated as a curve.

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first cut open, then


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- Select gradually all elements, which belong to the outside contour. After you have selected the fourth element, terminate the function with the right mouse button. The new contour is drawn automatically over the origin elements. - Repeat now the contour generation with the internal objects (together eight elements). The left small circle, as well as the polygon will not be considered by creating contours naturally. Tip: Use for assistance during creating contour the zoom functions, e.g. accompanying button.

l) Production of the resulting contour(s): Switch on the colour snap to the origin indication colour (the colour, in which the individual objects were drawn before contour generation), e.g. green.

After selection of function " multiple deletion of objects " pull a catch window over all objects now, in order to delete the objects, which are no longer needed for the subsequent treatment. If necessary you must construct again the screen with the function (right mouse button), that the white objects can be seen.


2.5 Exercise 4: 2D-Engraving Simple Sign / Pocket Milling The emphasis of this exercise is the construction of the CAM-data. First a relatively simple sign with the 2D-drawing functions will be constructed. The type has to stand, after the calculation of the milling paths, "raised" afterwards. The contour of the type will be Finishinged with the " Out pointed function ", so that a clean edge appears.


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Proceeding: a) Construction of the outside rectangle with width of 100 mm and a height of 70 mm.

Draw the rectangle with the accompanying button. Press, after the selection of the function, the key [ n ] directly, in order to construct the rectangle with help of the indication of coordinate. 1. Point: X/Y = 0/0 absolute 2. Point: X/Y = 100/70 absolute

b) Select function at text menu EXTRAS. In the dialogue "type font" a contour type will be selected now , e.g. " PostScript 7 ". Type height is not relevant for this example, because the text will not be placed punctually.

c) With the function "enter text + scale lable into window proportionally" the text will be established generously with a catch window. Press in each case in the corners two clicks with the left mouse button.

d) For the " beauty " we can place the text centrically with the accompanying button.

Follow here the data in the command line and select first the text in the left lower corner (object) and then the outside rectangle (orientation object). Note: Types can be selected in the left lower corners only. curser

This point is the starting point of the type. Starting from this point the entered text will be drawn in x- and y- direction. With the following possibilities types can be selected also in other places than the left lower corner: 1) Object snap Activate the small box text in the attitudes Object snap. Now the curser snaps in any place of the text base line, look at the picture.


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2) Types convert With the function "hatches and texts convert," a type will be converted in lines and Bezier curves after confirmation of the conversion tolerance of 0,01 (command line). This function makes it possible on processing the type within the artistic range (e.g. with the function "move point to a new position ") and on the other side now the selection is possible in any place of the type. 3) Colour snap Select before placing the type a drawing colour, which is not the same as the other objects in the drawing. Use now the possibility of the function "colour snap", look also for this at the information on the page 9. 4) Selection with window With the function " selection by means of windows " you can draw "generously" a catch window up over the text which should be selected.

e) Preparing of the CAM blocks For milling you need three technology blocks, in order to engrave the text " raised ": Block 1 pocket milling: pre-rough Block 2 pocket milling: after-rough with remaining material recognition Block 3 contours milling: Finishing the contour with cut out function

f) Block 1 Pocket Milling: pre-rough

First the 1. technology block "pocket milling" will be constructed. The following parameters are necessary for the calculation of the milling paths:


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1: Enter block designation, here: pre-rough 2: With the button the text, which should be milled, will be selected by pressing the left mouse button. With the right mouse button you will be back again into the block. 3: With the button also the outside edge will be selected. It is obtained by the additional selection of the contour that the construction unit is milled beyond the edge, so that the text remains standing " raised ". 4: Entry 0 mm corresponds to the work piece upper edge, Z = 0, with the peak of the milling tool will be teach on. 5: Depth in Z- = 1 mm regarding to Z = 0 (work piece upper edge). 6: Create new tool: 10 mm Cylinder cutter 7: Always activate the small box "To". The programmed immersing speed into the work piece is reduced automatically to 20% of programmed feed speed. 8: Oversize: The cutter drives during roughing not directly to the contour, the cutter leaves untouched an over measure (remaining material) of 0.3 mm still. The remainder is then removed in the following two technology blocks. g) Block 2 Pocket milling: after-rough with remaining material recognition

1: Enter block designation, here: after-rough with remaining material recognition 2: With the button the text, which should be milled, will be selected by pressing the left mouse button. With the right mouse button you will be back again into the block. 3: With the button the outside edge will be selected. 4: Entry 0 mm corresponds to the work piece upper edge, Z = 0, with the milling point will be teach on. 5: Depth in Z- = 1 mm regarding to Z = 0 (work piece upper edge). 6: Create new tool: 2 mm Cylinder cutter


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7: Always activate the small box "To". The programmed immersing speed into the work piece is reduced automatically to 20% of programmed feed speed. 8: Oversize: The cutter drives during roughing not directly to the contour, the cutter leaves untouched an oversize (remaining material) of 0.2 mm still. The remainder is then removed in the Finishing blocks. 9: In the field "pre-roughing" the technology block 1will be selected. But this works only if the complete block is closed first by pressing the OK button. Only after renewed calling with the function "block work on" the block 1 can be selected from the list. It is obtained by this parameter that only the remaining material with the 2 mm - cylinder cutter is milled, which block 1 (pre-roughs) with the 10 mm - cylinder cutter stand left.

h) Block 3 Contour milling: finishing and carving

1: Enter block designation, here: Finishing and cut out 2: With the button the text, which should be milled, will be selected by pressing the left mouse button. With the right mouse button you will be back again into the block. 3: Entry 0 mm corresponds to the work piece upper edge, Z = 0, with the milling point will be teach on. 4: Depth in Z- = 1 mm regarding to Z = 0 (work piece upper edge).

5: Create new tool: 0,3 mm engraving tool 6: Always activate the small box "To". The programmed immersing speed into the work piece is reduced automatically to 20% of programmed feed speed. 7: Select milling strategy "outside". 8: Activate small box Engrave. 9: Oversize: The cutter drives now during finishing directly to the contour.


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2.6 Exercice 5: Simple 3D Construction / 3D Milling We would like to convert the produced 2D-contour of the training example 3 into a 3D solid and mill it afterwards. Here you will learn to know the simplest 3D milling strategies, which you can use at the most 3D models.


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Proceeding: a) Construction of the contour like exercise 3, and/or load before secured drawing.

b) The exercise 3 was concluded with the most important function for preparing 2D

contours, the contour generation. A " lightning-clean " contour is the basis, in order to get later no difficulties in 3D with the different 3D functions, for example by creation of 3D solids with volume operations (Bool' arithmetic operations). First all objects of the drawing are converted in 3D objects, but without data of the solid height. For this select the function "convert active object to 3D object" from the menu "conversion". As you can see on the button, the object which has to be converted must be selected first. Unfortunately all objects cannot be converted together. Use therefore the conversion steps for each object individually.

c) With the view function "Isometrical view" all objects in the 3D space can be displayed now.

d) With the following steps a 3D solid will be constructed:

First all objects are extruded successively with the function "Extrusion of a plane contour by...", i.e. allocated a solid height. In the appearing dialogue enter for the height 40 mm. Subsequently, select the object which can be changed. Repeat this procedure for all contour objects.

e) With the shading view 3D objects

can be displayed visually now. Of course you can see the largest object only, because all the others are placed inside Switch the shading view off again.

f) With the "Volume-operations " all internal objects are subtracted from the outside object now. Select the outside object (1st object) in each case and then an internal object (2nd object). Tip: Before switch off "active object mark,,,".

g) Now the 3D solid with the shading view can be visually visibly displayed. With the view function " dynamic view-rotation,,," you can view the solid from all sides optional.


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h) So that we can use the 3D milling strategy later meaningfully, we would like to provide all solid edges with a blend radius of 8 mm. Tip: First leave switched off and/or on "active object mark,,,".

Select function Blend Standard. With a starting and end radius of 8 mm all edges will be selected after another. Start first again with the outside contour (edge). If all four edges of the outside contours are found, then you terminate this action with the right mouse button. Now in the following the internal edge are blended, then the circle and at the end the polygon.

Tip: Use during this function generously

the zoom and the dynamic rotation function, so that the solid edges are taken surely. Is inadvertently because of an unfavourably set of the drawing view not the correct edge or an adjacent surface is not selected, then press directly the left mouse button here again, so that the edge or surface marked before, is end marked again. If all solid edges were successfully blended, then the 3D solid should look in a shadowing view as follows:


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i) Before we start with the providing of the CAM blocks, we still have to define

the blank (existing milling material from which the 3D solid should be milled) and the work piece zero point (milling zero point): Switch on a new drawing colour, e.g. magenta.

j) With the function "over 3D object with block" construct now a simple blank with a distance of for example 2 mm to the solid. In practice naturally the blank, which is available for milling and which will be put in into the work space of the machine later, will be constructed with its accurate dimensions.

k) Definition of the work piece zero point: Here natural a meaningful solid edge will be

selected, e.g. left above in the corner, in which a 3D marking point will be placed first. This point is embodied firmly later in the CAM block and defined as workpiece zero point. Preparing of the CAM blocks For 3D milling you need three technology blocks: Block 1: roughing 3D Z-constant Block 2: Finishing 3D Z-constant Block 3: Finishing 3D

l) Block 1: roughing 3D Z-constant In most cases, respectively at nearly all 3D models, which should be milled, select the CAM technology "roughing 3D Z-constantly". The following parameters are important for the creation of the NC-paths:


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1: Enter block designation, here: roughing 2: with the button the 3D model will be selected by pressing the left mouse button. With the right mouse button you will be back again into the block. 3: With the button an additional blank (here: magenta) will be selected. Tip: The size and the form of the blank limits automatically the milling range! 4: Create new tool: 6 mm cylinder cutter 5: Always activate the small box "To". The programmed immersing speed into the work piece is reduced automatically to 20% of programmed feed speed. 6: Depth increment: The depth increment is the maximum permissible setting depth of the used cutter into the work piece, here: 2 mm. 7: Steps: Always indicate! In the range of a "finished" depth increment will be worked on backwards with the same cutter step by step. Advantages: - This optimisation affects very favourably for the following Finishing cutter, because the heights of the " stairway steps " will be minimized. - We talk also of a Finishing cycle during roughing with the same tool (tool change not necessary). 8: Oversize: The cutter drives during roughing not directly to the contour, the cutter leaves untouched an oversize (remaining material) of 0.3 mm still. 9: With a new milling zero point (work piece zero point) is embodied in the block. Select in the appearing dialogue "zero point work on" "3D-Position". After that, select the 3D marking point, placed before, in the corner of the blank.

Note: If no milling zero point is embodied in the block, then isy CAM selects automatically the absolute origin of the drawing as milling zero point.


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m) Block 2: Finishing 3D Z-constant

Finishing will be divided in two technology blocks. With the strategy "Finishing Z-constant" the steep ranges of the model and afterwards with the strategy "Finishing 3D" all flat ranges will be milled. Here the milling ranges with different limit angles will be divided. 1: Enter block designation, here: Finishing Z-constant 2: Select model colour for the graphic simulation. Note: please do not use the colour red, because the collision examination is also displayed red. 3: With the button the 3D model will be selected by pressing the left mouse button. With the right mouse button you will be back again into the block. 4: 1. Limit angle: Here the sub range which will be milled is registered over the input of the limit angle. 90 means perpendicular steep edge; 0 a flat horizontal range. Note: The programming of the limit angle is naturally different depending upon the model which will be milled and must be adapted individually. 5: Create new tool: 6 mm ball cutter 6: Always activate the small box "To". The programmed immersing speed into the work piece is reduced automatically to 20% of programmed feed speed 7: Path distance: Define here a meaningful path distance in mm. The more closely the path distance, the surface will become more finely, but the more largely the NCP -file will be. 8: Oversize: Now the cutter drives during Finishing up to the surface directly. 9: Program origin: Select from the list with the cutting zero point, set before.


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n) Block 3: Finishing 3D

Now all flat ranges will be milled. The necessary parameters you can find again in the picture. 1: Enter block designation, here: Finishing 3D 2: Select model colour for the graphic simulation. Note: please do not use the colour red, because the collision examination is also displayed red. 3: With the button the 3D model will be selected by pressing the left mouse button. With the right mouse button you will be back again into the block. 4: 1. Limit angle: Here the sub range which will be milled is registered over the input of the limit angle. The ball cutter should mill all flat ranges up to an inclination of 45 in this example. Naturally the graduation of the limit angle must be divided too here related to the respective model meaningfully. 5: Select 6 mm ball cutter (shere) from the list with 6: Always activate the small box "To". The programmed immersing speed into the work piece is reduced automatically to 20% of programmed feed speed. 7: Path distance: Define here a meaningful path distance in mm. The more closely the path distance, the surface will become more finely, but the more largely the NCP -file will be. 8: Oversize: Now the cutter drives during Finishing up to the surface directly. 9: Program zero point: Select from the list with the cutting zero point, set before.


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o) graphic simulation of the milling paths

Before the milling paths for the CNC-machine will be generated, we use the advantage of the graphic simulation still. With this function we can recognize whether with the selected milling parameters a good milling quality of the model can be really achieved. In our example the adjusted milling parameters are sufficient. With another model better values must be found however if necessary. For example if a 3D model in Aluminium will be milled, then special start / departure or sort strategies must be selected still. Proceeding: We examine now successively each technology block individually and store in each case the milled simulation picture. Start now with the accompanying button the simulation. In the dialogue "CAM simulation parameters" are listed all provided technology blocks in the left field ("simulated blocks"). Because we would like to simulate first the block 1 only, select successively block 2 and block 3 and afterwards press "removing", so that the two blocks appear now right in the field "other blocks", look at the picture. You terminate the dialogue with "continue". Tip: With one double click on the blocks left which should be removed, they could also be shifted to the right side. Now the program requires the indication of the simulation blank. This indication is particularly important. You can indicate for example all fixing elements for fastening the model on the machine table and simulate possible collisions. It is sufficient in most cases to select the blank (colour magenta) from the drawing.


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Click and select the object. With Finish confirm all selected parameters.

p) The calculated milling paths are represented in a new window now.

Before the graphic simulation will be started now, set before the view meaningfully, in order to be able to analyse critical ranges, e.g. sub range zoom largely or rotate model.

With simulation will be started now.

q) After completion of the

roughing paths, store the current view. Select a meaningful file name,

e.g.. TEST_1.

r) Now repeat the simulation steps o) to p) with the two Finishing blocks.

Open the simulation picture stored before and restart the simulation.

s) At the end the NCP file will be written on the non removable disk. Select the accompanying button and follow the instructions in the dialogues.

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