FeatureCAM 15.

Getting Started
By Delcam plc

Release Issue 1

Disclaimer Delcam plc has no control over the use made of the software described in this manual and cannot accept responsibility for any loss or damage howsoever caused as a result of using the software. Users are advised that all the results from the software should be checked by a competent person, in accordance with good quality control procedures. Information contained in this manual is subject to change without notice and does not represent a commitment by Delcam plc. The software described in this manual is furnished under licence agreement and may be used or copied in accordance with the terms of such licence. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose without the express permission of Delcam plc. Copyright 1995-2008 Delcam plc. All rights reserved Acknowledgements This documentation references a number of registered trademarks and these are the property of their respective owners. For example, Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. Restricted Rights Legend The Program and Program Materials are provided with Restricted RIGHTS. Use, duplication, or disclosure by the United States Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software Clause at DFARS 252.227-7013, Manufacturer is the Licensor: Delcam plc. Permission to Copy for Licensed Users Delcam plc grants permission for licensed users to print copies of this manual or portions of this manual for personal use only. Schools that are licensed to use FeatureCAM may make copies of this manual or portions of this manual for students currently registered for classes where FeatureCAM is used. FeatureCAM Version: 15.0 Date: 07/10/2008 13:37

Contents
Introduction 1
How this guide is organized...........................................................................1 Special features in this guide .........................................................................2 Tell us what you think ...................................................................................2

FeatureCAM overview

Why creating toolpaths is so fast ...................................................................4 What's new in this release..............................................................................5 Installing FeatureCAM ..................................................................................5 To install FeatureCAM ..........................................................................5 PAF installation instructions .................................................................7 Using a dongle .......................................................................................9 FeatureCAM maintenance releases .....................................................10 Evaluating FeatureCAM modules .......................................................11 Setting up Flex licensing .....................................................................12 Website ................................................................................................33

Using FeatureCAM

34

Starting FeatureCAM for the first time .......................................................34 Opening a part..............................................................................................37 Closing the Stock wizard .............................................................................39 Creating a simple part ..................................................................................40 Interface tour................................................................................................42 Title bar................................................................................................43 Menu bar ..............................................................................................43 Toolbars ...............................................................................................44 Graphics window .................................................................................53 Steps panel ...........................................................................................58 Part View panel....................................................................................72 Results window....................................................................................74 Assistance bar ......................................................................................75 Feature/Geometry Edit bar ..................................................................75 Status bar..............................................................................................75

FeatureCAM 15.0 Getting Started

Contents i

Saving your work.........................................................................................76 Printing.........................................................................................................77 Keyboard shortcuts ......................................................................................78 Getting help..................................................................................................79

Customizing FeatureCAM

81

Managing your settings................................................................................81 Controlling wizards......................................................................................82 Setting up dynamic viewing options............................................................83 Adjusting colors ...........................................................................................84 Setting up snap and grid options..................................................................86 Customizing toolbars ...................................................................................87

Introduction to 2.5D milling

89

Creating a part file .......................................................................................89 Viewing........................................................................................................93 Toolpaths......................................................................................................94 Order of manufacturing operations..............................................................95 Part documentation ......................................................................................98 Controlling the automation ....................................................................... 100 NC code .................................................................................................... 101 Tool mapping ............................................................................................ 101 Changing post processors ......................................................................... 102 Saving NC code ........................................................................................ 103

Features from curves

104

Getting started........................................................................................... 105 Setting the snaps ....................................................................................... 106 Building circles ......................................................................................... 106 Drawing lines ............................................................................................ 107 Chaining a curve ....................................................................................... 109 Creating a feature from a curve ................................................................ 110 Simulating the part.................................................................................... 111 Modifying the boss feature to contour around the part ............................ 111 Changing the plunge point........................................................................ 112

Introduction to turning

115

Getting started........................................................................................... 115 Create a part file........................................................................................ 115 Making features ........................................................................................ 119 Viewing..................................................................................................... 123

ii Contents

FeatureCAM 15.0 Getting Started

Toolpaths................................................................................................... 124 Ordering of operations .............................................................................. 125 Part documentation ................................................................................... 127 NC code .................................................................................................... 127 Changing post processors ......................................................................... 128 Saving NC code ........................................................................................ 128

Advanced turning and machine simulation 130

Getting started........................................................................................... 131 Setting up machine simulation.................................................................. 131 Adding a subspindle feature ..................................................................... 134 Adding a bar feed feature.......................................................................... 136 Running a subspindle simulation.............................................................. 136 Setting up the second turret ...................................................................... 137 Synchronizing operations ......................................................................... 138 Running synchronized multi-turret simulation......................................... 139

Introduction to turn/mill

140

Getting started........................................................................................... 140 Creating a turn feature .............................................................................. 141 Viewing..................................................................................................... 144 Creating a radial hole pattern on the face ................................................. 145 Engraving on the face ............................................................................... 147 Creating a pattern of wrapped slots .......................................................... 149 Simulating a turn/mill part........................................................................ 149

Creating features from 3D CAD models

151

Getting started........................................................................................... 151 Importing the CAD model ........................................................................ 152 Aligning the model ................................................................................... 154 Shading the part ........................................................................................ 156 Automatic feature recognition .................................................................. 157 Recognizing holes..................................................................................... 158 Recognizing pockets ................................................................................. 160 Creating a slot feature ............................................................................... 162 Creating a side feature .............................................................................. 163 Simulating the entire part.......................................................................... 165

Introduction to 3D milling

167

Getting started........................................................................................... 167 Creating the bottle surface ........................................................................ 170

FeatureCAM 15.0 Getting Started

Contents iii

Viewing..................................................................................................... 171 Creating a surface milling feature............................................................. 173 Simulating the entire part.......................................................................... 175

Advanced 3D milling

176

Importing the part ..................................................................................... 176 Selecting toolpath strategies ..................................................................... 178 Simulating the toolpaths ........................................................................... 180 Cleaning up the fillets ............................................................................... 182 3D toolpath strategies ............................................................................... 184

Introduction to 5-axis simultaneous

189

Getting started........................................................................................... 189 Creating a surface milling feature............................................................. 190 Importing geometry .................................................................................. 193 Adding flowline operation ........................................................................ 194 Recognizing holes..................................................................................... 198 Recognizing side features ......................................................................... 199

Solid modeling basics

202

Getting started........................................................................................... 203 Creating the initial solid............................................................................ 203 Hidden line graphics ................................................................................. 207 Creating the curved lower surface ............................................................ 209 Creating constant and variable radius fillets............................................. 214 Adding thickness....................................................................................... 216 Creating a mold cavity .............................................................................. 218

Introduction to FeatureWIRE

220

Getting started........................................................................................... 220 Creating the profile ................................................................................... 221 Creating a wire EDM feature.................................................................... 223 Simulating a wire EDM toolpath .............................................................. 224 Generating NC code.................................................................................. 226 Adding a taper angle ................................................................................. 226 Creating the second profile ....................................................................... 229 Creating a 4-axis wire EDM feature ......................................................... 231 Modifying the start point .......................................................................... 233 Matching the curves.................................................................................. 234 Simulating the part.................................................................................... 236

iv Contents

FeatureCAM 15.0 Getting Started

Index

239

FeatureCAM 15.0 Getting Started

Contents v

Introduction
This guide is designed to quickly get you up to speed with FeatureCAM. By the time you finish this book, you'll know enough about FeatureCAM to use it straight away. You may also find this guide useful, if you have upgraded your FeatureCAM, and want to learn the new modules. FeatureCAM is very easy to use, and does not require any specialist computing knowledge. However, you need to know how to use the mouse, the keyboard, and the Windows environment. If you want to know more You can find answers to using specific features, in the online help system included with FeatureCAM.

How this guide is organized

This guide contains two distinct parts: General overview of the FeatureCAM range, and common functions; Detailed step-by-step tutorials showing you how to program parts. If you are familiar with the basic FeatureCAM features, you can skim through the introductory pages and go straight to the relevant tutorials. If you are new to FeatureCAM, it's best to read this guide sequentially.

FeatureCAM 15.0 Getting Started

Introduction 1

Special features in this guide

Names of dialogs, menus, toolbars, and the menu options appear in boldface. The menu names are separated from the specific command on that menu with a '>'. For example, a phrase 'select View > Simulation' instructs you to open the View menu and select the Simulation option. Any text that you have to type in a dialog or a text box appears in blue boldface type. Icons This icon draws your attention to something that may not work the way you think it should, and helps you to avoid common errors or hidden pitfalls. This icon is here to save your time, and shows you a more efficient way of doing things in FeatureCAM. This icon tells you how to avoid serious problems.

Tell us what you think

Tell us what you think of this guide. We need your opinion, and want to know what we are doing right, and what we could do better. Email your thoughts to [email protected]. Thank you for choosing FeatureCAM!

2 Introduction

FeatureCAM 15.0 Getting Started

FeatureCAM overview
FeatureCAM is a CAD/CAM software suite that automates machining and minimizes programming times for parts on mills, lathes and wire EDM. Unlike operations-based CAM systems, FeatureCAM generates toolpaths based on the features of the part, and then automatically selects appropriate tools, determines roughing and finishing passes, and calculates feeds and speeds. The selections made can be based on the built-in machining knowledge that Delcam supplies 'out-of-the-box' with FeatureCAM, or from experience captured from your company, project or individual users' preferences. FeatureCAM includes five stand-alone modules: FeatureMILL - 2.5D design and toolpath generation for 2- and 3-axis mills. FeatureMILL3D - 3D surface modeling and 3-axis toolpath generation. FeatureTURN - 2-axis design and toolpath generation for 2axis lathes. FeatureTURN/MILL - Supports lathes with C and Y-axis milling capabilities. FeatureWIRE - 2- and 4-axis wire EDM toolpath creation. The following add-on modules are also available: FeatureRECOGNITION - 3D surface and solid import and the recognition of 2.5D features from solid models. Accelerates making 2.5D and turned parts from solid models. Solid Modeling - Solid modeling and tools for creating molds from solid models.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 3

5-Axis Positioning - Manufacture 2.5D features from 5-axis orientations. 5-Axis Simultaneous - Manufacture 3D features while changing the tool axis. Tombstone - Multiple part manufacturing for horizontal or vertical milling machines with indexers. Native Import Modules - Native data can be read directly from SolidWorks, SolidWorks Assemblies, Autodesk Inventor, SolidEdge, CATIA, Unigraphics, Pro-Engineer, and STEP files. Machine Simulation - Modeling and simulation of a CNC machine. Advanced Turn/Mill - Includes support for FeatureTURN/MILL in addition to support for B-axis (5-axis positioning) and turret synchronization. Network Database and Licensing - Flexible product licensing allows sharing FeatureCAM licenses across a network.

Why creating toolpaths is so fast

FeatureCAM has the unique ability to generate toolpaths and create NC code to run the machines with a minimum amount of user input. Traditional CAM systems are operations-based and require you to program every operation, one at a time, to create your part. FeatureCAM is feature-based; this means the part is created using features that describe that part, from simple holes to complex pockets to turned grooves. Machinable features contain information and rules describing how and where material removal should occur, cutting depths, whether to use climb cutting, whether to spot drill or center drill, and preferred machining strategies for roughing and finishing. This means that after you import or draw the part and identify its features, FeatureCAM automatically: Selects the most appropriate tools and operations; Recommends machining strategies; Calculates speeds and feeds; Generates toolpaths and creates the NC code. This built-in 'intelligence' can be customized to your own style of cutting.

4 FeatureCAM overview

FeatureCAM 15.0 Getting Started

What's new in this release

If you are an existing FeatureCAM user and want to find out about new functionality and other changes to FeatureCAM, see the Whats New section of the FeatureCAM help file.

Installing FeatureCAM
You can install FeatureCAM from CD, or from hard disk if you have downloaded the software from the Internet.

To install FeatureCAM
1. If you have a dongle (see page 9), attach it to your computer's USB port or parallel printer port. 2. Insert your installation CD into your CD-ROM drive. In this example, drive D is used. You must substitute the drive letter where appropriate. 3. If you are installing FeatureCAM from a CD which runs automatically, go to Step 4. If you are installing FeatureCAM from a CD, and it does not automatically run, select Run from the Start menu, and type: D:\FeatureCAM.exe If you are installing FeatureCAM from a hard disk, double-click the file FeatureCAM.exe. 4. Click Continue to start the installation. 5. Read the information in the Welcome dialog, and click Next. 6. Read the terms of the License Agreement before installing FeatureCAM. To accept the terms, click Yes.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 5

7. Choose the folder in which FeatureCAM is installed. The default location is displayed in the Destination Folder field. You can change the location by clicking the Browse button, and selecting a new location in the Choose Folder dialog.

If you are upgrading an older copy of FeatureCAM, you can safely overwrite old versions of FeatureCAM. When you are prompted for the installation directory, use the same directory you did last time. Your part files and customizations are preserved and can be used with this version of FeatureCAM. If you want to continue to run your older copy of FeatureCAM, then install the new version in a different directory. Be aware that your old version may not be able to read files from your new version, but the new version is always backwards-compatible with older versions of files. 8. Click the Next button to continue. 9. Select a program folder. This is the folder in which the FeatureCAM program icons are created. You can: Use a default folder shown in the Program Folders field. Select a different folder from the Existing Folders list. Type a new name in the Program Folders field. 10.Click the Next button to continue. 11.Review the installation settings, and click the Next button to install FeatureCAM on your PC.

6 FeatureCAM overview

FeatureCAM 15.0 Getting Started

12.In the Setup Complete dialog, click the Finish button.

PAF installation instructions

You should have received an email from Delcam with your Product Authorization File (PAF). We ship the software before sending the PAF file to you. It is very possible that you will get the upgrade package before you receive the email with the PAF file. The email with the PAF file could be sent to your supervisor, IT department or purchasing depending on the email address we have on file for your company. If you don't have that email, wait 72 hours before installing the software or contacting support. When you have the PAF file: 1. Save it to the desktop on your computer. 2. Install the 2009 version of FeatureCAM from either your upgrade package or the web. 3. Go to Start > All Programs > FeatureCAM > PAF Directory. 4. If you have any existing *.paf, *.flx, or *.lic files in this directory, please delete them or rename them to dcam.old. 5. Drag the PAF file from the desktop into this directory. 6. Open FeatureCAM.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 7

FeatureCAM should run with no problems. If you do experience any problems, please refer to the Troubleshooting section. Troubleshooting PAF Are you evaluating items that you do not have a license for? 1. Inside FeatureCAM, select File > Evaluation Options from the menu. You must close all files and windows in FeatureCAM before you can access Evaluation Options. 2. Deselect any items that you don't have a license for and click Apply. Did you edit the PAF file in any way? If you open the PAF file in any program other than Notepad, the file can become corrupt. If this happens, delete the file and re-save the original file that you received by email. Is the PAF file being recognized? The file extension must be *.paf, although the name of the file may be different. It is possible that an email program or something else has created or hidden an extension of *.txt. You can check this by looking at the Type of file. To do this, right-click on the PAF file and select Properties. The file Properties dialog displays. The Type of file should be Delcam PAF licence file or PAF file. Is the dongle attached to the computer? In order for FeatureCAM to function, the dongle must be attached to the computer. Do you have the latest Sentinel drivers installed? 1. In FeatureCAM, select File > Evaluation Options from the menu. The Evaluation Options dialog opens. 2. Click Diagnostics. The Dongle Diagnostics dialog opens.

8 FeatureCAM overview

FeatureCAM 15.0 Getting Started

3. Check the value for Dongle. If it reads None, you must update the Sentinel drivers. 4. Click Open Sentinel Driver directory. The directory opens and contains the program file Sentinel Protection Installer 7.4.0.exe. 5. Run this program. 6. Restart your computer.

Using a dongle
A dongle is supplied with FeatureCAM for copy protection. The dongle is a physical device that attaches to one of your computer's USB ports or the parallel printer port. FeatureCAM checks to see if a dongle is present before it generates NC code for your parts or before saving a file. The dongle must remain connected for the entire time you are running FeatureCAM.

If you have a USB dongle, install it on your computer by inserting it into the USB port (or if you don't have USB, insert the parallel dongle into the parallel printer port and screw in the thumbscrews). If you are using a parallel dongle, you may have multiple devices attached to your parallel port. Many computers have a printer attached to that port. If you have any devices attached to the port, you need to chain the devices in sequence and the FeatureCAM dongle should be the first in the stack. You must not connect multiple FeatureCAM dongles to a single parallel port. The dongle is a pass-through device. You can attach your dongle to the computer and the other devices can hook up to the dongle. You may have to experiment with the order of devices to find which sequence works best with your devices. Printers should probably be at the end of the device chain. In general, try to put the FeatureCAM dongle in as the first or second device in the sequence.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 9

Troubleshooting the dongle If, when you start FeatureCAM, you see the Registration dialog with the dongle picture, that means that either the dongle is not plugged into the back of the computer, or that the computer is not recognizing the dongle. Or that you do not have a PAF file installed or it is in the wrong location.

When you close this dialog, FeatureCAM starts in evaluation mode. To fix this problem: 1. Disconnect the dongle from the PC. 2. Download the latest release of the dongle driver from http://www.featurecam.com (under Support > Downloads). 3. When the download is complete, install the software. 4. Connect the dongle to the PC. 5. Restart FeatureCAM. If you come across any errors after following these steps, please email or call your local FeatureCAM dealer.

FeatureCAM maintenance releases

If you have purchased and registered a FeatureCAM version, you are allowed to install maintenance releases free of charge. A maintenance release is any product version with the same first number as the product you are licensed to run. For example, if you have version 14.0.1.36, the first number is 14. To check for a FeatureCAM maintenance release: 1. Make sure you are connected to the Internet, and select Help > Check For New Version.

10 FeatureCAM overview

FeatureCAM 15.0 Getting Started

2. If a newer version is available, you are given the option of updating your version of FeatureCAM.

Evaluating FeatureCAM modules

When you are running FeatureCAM, you can evaluate other FeatureCAM modules. To enter evaluation mode: 1. Run FeatureCAM. 2. If the New Part Document wizard opens, click Cancel. 3. Select File > Evaluation Options from the menu. 4. In the Evaluation Options dialog, select the check boxes for the modules you want to try.

5. Click OK. FeatureCAM is now running in evaluation mode. You cannot save parts or post, but you can create part models and generate toolpaths. When FeatureCAM is in evaluation mode, the word evaluation is shown in the Title bar.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 11

To exit evaluation mode: 1. Open FeatureCAM. 2. Click cancel to any dialogs that display. 3. If the New Part Document wizard opens, click Cancel. 4. Select File > Evaluation Options from the menu. 5. Deselect all Evaluate check boxes. 6. Click OK.

Setting up Flex licensing

Setting up the server You need two files to install the flex license: The license file (*.lic) The server install Delcam Flex3001.msi (sent as a *.zip file) These files are sent to you by email to the address we have on record. To set up the server: 1. Copy the *.lic file to the C:\dcam\config\pass directory. If the path C:\dcam\config\pass does not exist, create the folder structure and copy the file to there. 2. Change the license file name and extension from *.lic to dcam.flx. 3. Open dcam.flx in Notepad so that you can make changes to it. Do not open the file in Microsoft Word or any other program because it will become corrupt.

12 FeatureCAM overview

FeatureCAM 15.0 Getting Started

The file looks similar to this one:

4. At the top of the file, you see the text SERVER flexserver. You must change the text flexserver to be the name or IP address of the server (the computer where the dongle will be installed). You can find the server name by going to Control Panel > System > Computer Name tab. The name has been changed to FCServer in the example below:

If your computer name contains a hyphen (-), use the IP address instead of the name. 5. Save the file. Installing Delcam Flex3001: 1. Unzip ABC10_flex_server.zip and run Delcam Flex3001.msi. The Delcam Flex3001 - InstallShield Wizard opens. Make sure the dongle is not attached.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 13

2. Click Next.

3. Select I accept the terms in the license agreement and click Next.

4. Enter your Customer Information and click Next.

14 FeatureCAM overview

FeatureCAM 15.0 Getting Started

5. Make sure the destination folder is correct and click Next.

6. On the Setup Type page, select Custom and click Next.

7. On the Custom Setup page, click Next.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 15

8. On the Ready to Install... page, click Install.

9. On the final page, click Finish.

10.When asked it you want to restart your system, click No because we will restart shortly.

Managing Delcam Flex3001 1. After installing Flex3001, go to Start > All Programs > Delcam > Flex > Flex3001 > License Manager Tool to start the license server.

16 FeatureCAM overview

FeatureCAM 15.0 Getting Started

2. On the Service/License File tab, make sure Configuration using Services is selected.

3. Click the Config Services tab: a. Select the Service Name. It will probably be FLEXlm Service 1 unless you have other software packages that use flex licensing. b. Enter the Path to the lmgrd.exe file as C:\Program Files\Delcam\Flex3001\sys\exec\lmgrd.exe or Browse to it. c. Enter the Path to the license file as C:\dcam\config\pass\dcam.flx or Browse to it. d. Enter the Path to the debug log file or Browse to it. You can create it anywhere on the server (as long as you have read/write permissions), for example C:\temp\flexlogfile.log. The log file tracks all access to the flex server.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 17

e. Select both the Start Server at Power Up and Use Services check boxes. f. Click Save Service. g. Click Yes when asked if you want to save the settings for the service FLEXlm Service 1. h. Close the License Manager. 4. Restart your computer. The server should start automatically 5. Plug the dongle in. 6. If you receive the following warning message, click Continue Anyway.

If the software and Sentinel driver are installed on the server computer, you can test that it is running by trying to start FeatureCAM after the reboot is complete. If the software is not installed on the server, move onto the section Setting up the client computers (see page 18). Setting up the client computers First make sure that FeatureCAM is installed on all the client computers, then follow these steps: 1. Edit a copy of the server's dcam.flx file so that it only contains the first six lines or open a new Notepad file and enter the following text: line 1: # ... comments line 2: # ... comments line 3: SERVER <server name> DELCAM_ID=<host dongle number> <port number> line 4: DAEMON delcam delcam.exe line 5: USE_SERVER line 6: This is an empty line

18 FeatureCAM overview

FeatureCAM 15.0 Getting Started

There must be at least one blank line as seen below:

- blank line - cursor 2. Save this file as dcam.flx and put it in the C:\dcam\config\pass directory on all client computers. If there is a file named dcam.paf already in this directory, you must rename it to something else (that is, dcam.xxx). If there is a dcam.paf file in the C:\Program Files\Common Files\Delcam directory, that must also be renamed. Check that the file has been saved as dcam.flx not dcam.flx.txt. You can test the flex licensing by opening FeatureCAM on a client computer. When the license expires, you only need to update the server flex file because all the client computers refer to the server's flex file. Notes for computers using a Windows firewall If you are running a Windows firewall, there are some extra steps for setting up Flex licensing: 1. Go to C:\dcam\config\pass and open the dcam.flx file with Notepad. Do not open the file in Microsoft Word or any other program because it will become corrupt.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 19

2. Enter the port number that the vendor daemon will use as below. This can be any port number, for example 1450.

3. Go to Start > Control Panel > Windows Firewall. The Windows Firewall dialog opens. 4. On the Exceptions tab, click the Add Program button:

The Add a Program dialog displays. 5. Click Browse and browse to C:\Program Files\Delcam\Flex3001\sys\exec\delcam.exe. 6. Click OK. 7. Repeat steps 4 to 6, but this time browse to C:\Program Files\Delcam\Flex3001\sys\exec\lmgrd.exe. 8. On the Exceptions tab, click the Add Port button.

20 FeatureCAM overview

FeatureCAM 15.0 Getting Started

The Add a Port dialog displays. 9. In the Add a Port dialog: a. For the Name, enter Vendor Daemon. b. For the Port number, enter the same port number that you put in the dcam.flx file, for example 1450. c. Select TCP.

d. Click OK. Notes for old FeatureCAM network license users To upgrade to the license mechanism in FeatureCAM 2009 (V15.0), you must swap your old purple or black dongle to a new blue one. Your new dongle is included in the upgrade box received in the mail. In order for FeatureCAM to work with the new dongle, you must delete this file: C:\Program Files\FeatureCAM\program\LSAPIW32.dll If you did not use the default installation directory, the file will be in the folder you installed to. In this case, right-click on the FeatureCAM shortcut icon on your desktop and select Properties. You can see the location of the installed files on the Shortcut tab.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 21

Troubleshooting Flex Checking the name and type of the Flex file To check that the name of the Flex license file is correct: 1. In FeatureCAM, select File > Evaluation Options from the menu. The Evaluation Options dialog opens. 2. Click the Diagnostics button. The Dongle Diagnostics dialog opens. 3. Click the Open PAF directory button. The directory opens in Windows Explorer. 4. Check that the name of the Flex license file is correct: a. Right-click on the *.flx file and select Properties. b. Check that the name of the file is dcam.flx. c. Check that the Type of file is FLEX License file or FLX File.

22 FeatureCAM overview

FeatureCAM 15.0 Getting Started

Checking the contents of the Flex file 1. Open the dcam.flx file with Notepad. Do not open the file in Microsoft Word or any other program because it will become corrupt. 2. Check that the name of the server is correct. 3. Ensure that there is at least one empty line at the bottom of the file. 4. Save and close the file. Running Chkpaf If FeatureCAM is still not working after completing the previous troubleshooting steps, run Chkpaf. To do that, follow these steps: 1. In FeatureCAM, select File > Evaluation Options from the menu. The Evaluation Options dialog opens. 2. Click the Diagnostics button. The Dongle Diagnostics dialog opens. 3. Click the Run Chkpaf button.

FeatureCAM 15.0 Getting Started

FeatureCAM overview 23

The text file chkpaf_results.txt opens shortly in Notepad.

- The processor ID# - The license files that have been found on your computer - Specific product error codes - Items that may need attention - General Flex error codes

24 FeatureCAM overview

FeatureCAM 15.0 Getting Started

Flex error codes Error code -1 Meaning Can't find license file What you should check License is specified in license manager, read access, environment variable point elsewhere. Download the file from Delcam's FTP area again. Check network access, firewall settings. Crashed process may have held a license. Check users. Reboot server if necessary. Check the dongle number is being returned correctly - chkpaf on the server. Check Mod file for details. Check latest license file is being used. Flex error -12 -

-2 -3 -4

License file corrupted Cannot connect to a license server Maximum number of users reached No such feature exists No TCP/IP service 'FLEXlm' No socket to talk to server on Bad encryption code l_host failure code

-5 -6 -7 -8 -9

-10 -11 -12 -13 -14

Software expired Bad date in license file Bad return from server No servers specified in license file Bad SERVER hostname in license file

FeatureCAM 15.0 Getting Started

FeatureCAM overview 25

-15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25 -26

Cannot connect to server Cannot read from server Cannot write to server Server does not support this feature Error in select system call Application server 'busy' (connecting) Config file doesn't support this version Feature checking failed at daemon end Server busy/new server connecting Users already in queue for this feature Version not supported at server end Request for more licenses than supported. Cannot read /dev/kmem Cannot read /vmunix Cannot find ethernet device Cannot read license file Start date for feature not reached

Check network access, permission rights, firewall settings. Check network access, permission rights, firewall settings. Check network access, permission rights, firewall settings. Check latest Flex kit is installed. Check Mod file for details. Check latest license file is being used. Check customer maintenance records. License is specified in license manager, read access, environment variables point elsewhere. Check system clock.

-27 -28 -29 -30

-31

26 FeatureCAM overview

FeatureCAM 15.0 Getting Started

-32 -33 -34

No such attr for lm_set_attr/ls_get_attr Bad encryption handshake with server Clock difference too large between client/server We are in the queue for this feature Feature database corrupted in daemon dup_select mismatch for this feature User/host on EXCLUDE list for feature User/host not in INCLUDE list for feature Cannot allocate dynamic memory Server and client clocks must be synchronized. Check time zone settings. Check settings in Flex Options file.

-35 -36 -37 -38

-39

Check settings in Flex Options file.

-40 -41 -42 -43 -44 -45 -46 -47 -48

Feature never checked out (lm_status()) Invalid parameter No FLEXlm key data Invalid FLEXlm key data FLEXlm function not available FLEXlm software is demonstration version Clock check not available in daemon FLEXlm platform not enabled -

FeatureCAM 15.0 Getting Started

FeatureCAM overview 27

-49 -50 -51 -52 -53 -54

Date too late for binary format FLEXlm key data has expired FLEXlm not initialized Server did not respond to message Request rejected by vendor-defined filter No FEATURESET line present in license file Incorrect FEATURESET line in license file Cannot compute FEATURESET line socket() call failed setsockopt() failed message checksum failure server message checksum failure Cannot read license file from server Network software (TCP/IP) not available Not a license administrator lmremove request too soon Bad VENDORCODE struct passed to lm_init()

-55

-56 -57 -58 -59 -60 -61 -62

-63 -64 -65

28 FeatureCAM overview

FeatureCAM 15.0 Getting Started

-66 -67 -68 -69

FLEXlm include file/library mismatch No licenses to borrow License BORROW support not enabled License BORROWing database corrupted Attempted to borrow the same license twice Invalid TZ environment variable 'Old style' vendor keys (3-word) Local checkout filter requested request Attempt to read beyond the end of LF path VMS SYS$SETIMR call failed Internal FLEXlm error -- Please report Version number must be string of dec float FLEXadmin API functions not available FLEXlm file-based operations not linked in FLEXlm serverless data file missing FLEXlm serverless no lm_vsend()

-70 -71 -72 -73 -74

1 -

-75 -76 -77 -78

-79

-80 -81

FeatureCAM 15.0 Getting Started

FeatureCAM overview 29

-82 -83

Invalid PACKAGE line in license file Server FLEXlm version older than client's Incorrect number of USERS/HOSTS INCLUDED in options file Server doesn't support this request Checkout exceeds MAX in options file System clock has been set back This platform not authorised by license Future license file format ENCRYPTION_SEE DS are non-unique Feature removed during re-read This feature is in a different license pool License with incompatible attributes Network connection to host has failed Server machine is down or not responding The desired vendor daemon is down

-84

See server log.

-85 -87 -88 -89 -90 -91 -92 -93 -94

The license file is for a later version of FLEXlm than that currently installed. Check server line host ID. -

-95 -96

Check the host ID on the server line of the license file. Check network connections, firewall settings, environment variables. Reboot server. Check the Flex log file. Try re-reading the license file.

-97

30 FeatureCAM overview

FeatureCAM 15.0 Getting Started

-98

Feature line can not be converted to decimal Decimal format license is typed incorrectly Can not remove a linger license All licenses are reserved for others A FLEXid borrow error occured Terminal server remote client not allowed Cannot borrow that long License server out of network connections Dongle not attached Missing dongle driver Two Flexlock checkouts attempted

-99

-100 -101

Check the Flex options file. Server must be restarted for option file changes to come into effect. -

-102 -103

-104 -106 -110 -112 -113 -114

Check dongle and Sentinel driver. Re-install Sentinel. -

SIGN = Keyword required. License is older than application. Error in public key package CRO not supported on this platform BORROW failed BORROW period has expired. lmdown and lmreread must be run on server. -

-115 -116 -117 -118 -119

FeatureCAM 15.0 Getting Started

FeatureCAM overview 31

-120

Cannot lmdown the server when licenses are borrowed. FLOAT_OK license must have exactly one dongle hostid. Unable to delete local borrow info Returning borrowed license not enabled. Error while returning borrowed license. Attempt to checkout just a PACKAGE Error initializing a composite hostid Hostid for composite host invalid Borrowed license does not match server license Product not authorized on workstation for Flex Not Flexed Clocked machine

-121

-122 -123 -124 -125 -126 -127 -128

-1001

-1003 -2030

This is the same as PAF Error 30 with the same solution. The anti-clocking mechanism can also be triggered by an update to Java installed on the machine. We found that the following two files cause this to happen: C:/Program Files/Java/j2re1.4.2_06/LICENSE and C:/Program Files/Java/jre1.5.0_02/LICENSE

32 FeatureCAM overview

FeatureCAM 15.0 Getting Started

Website
The website www.featurecam.com contains useful information for FeatureCAM users including: New product announcements Comprehensive database of technical tips Maintenance releases User forum Evaluation copies of new software Local dealer information Trade shows where FeatureCAM is being exhibited Software updates

FeatureCAM 15.0 Getting Started

FeatureCAM overview 33

Using FeatureCAM
As with any software program, the key to efficiency is being able to control the program effectively using its interface. This chapter covers FeatureCAM basics, such as starting FeatureCAM for the first time, getting help as you work, mastering different components of the FeatureCAM interface, and following the basic steps to create a part.

Starting FeatureCAM for the first time

1. From the Start menu, select All Programs > FeatureCAM > FeatureCAM. You can also start the program by double-clicking the FeatureCAM icon on the desktop. The first time you start FeatureCAM, it runs the INITDB Initialization program to create the tools and materials database. 2. Click OK to begin the configuration.

34 Using FeatureCAM

FeatureCAM 15.0 Getting Started

The Tool and Material Setup dialog opens.

3. If you want to create a local database, select the On my local computer option. If you want multiple computers to have the ability to use the same tool and material information: a. Select the On another computer that I will access over a network option. b. Click the Browse button, and use the Database Location dialog to select the folder where the database is located. You need to create a database folder on your network first, and then copy an empty MDB database from the FeatureCAM CD-ROM to this location. The default database is created by MS Access, and should be accessed using the MS Jet database driver. You may use a different database type, such as MS SQL Server. For more information, refer to the online help. You need to have the Shared Network Database module to use this option. 4. Click the Next button to continue.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 35

5. Choose the tools to load:

Inch - loads only the inch tools. Metric - loads only the metric tools. Both - loads both inch and metric tools. 6. Click the Next button to continue. 7. If you chose to load both tool types, you are asked which tool type you use more often. Select Inch or Metric, and click Next. 8. Click Finish to initialize the database. The tools database specifies the set of tools used by FeatureCAM to perform manufacturing operations. For best results, use the Tool Manager (available from the Manufacturing menu) to customize the database to reflect the tools in your shop.

36 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Opening a part
When you start FeatureCAM, by default, the New Part Document wizard is the first thing you see.

To open an existing file: 1. Select the Open an existing file radio button in the New Part Document wizard, and click the Next button to continue. 2. In the Open dialog, select a part file to work with.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 37

3. When the part file is selected, click the Open button to bring up that part in FeatureCAM. Double-clicking the part name in the Open dialog (or Windows Explorer) automatically selects the part and starts it in FeatureCAM. This works whether you have FeatureCAM running or not. You can also drag-and-drop a part file into the open FeatureCAM Graphics window to start a part. To create a new file: 1. Select the New file radio button in the New Part Document wizard, and click the Next button to continue. 2. Choose the setup type for your part:

Turn/Mill - for turning that supports live tooling. Milling - 2.5D or 3D milled parts. Select this type for 5-axis positioning as well. Wire EDM - for a 2- or 4-axis wire EDM part. Multiple Fixture - for laying out multiple parts on the table. This indicates that you will be mixing different milled parts for multiple part manufacturing. Tombstone Fixture - for parts that you will mass produce on a horizontal or vertical milling machine. Simulation Machine Design - to create a machine tool model for simulation.

38 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Your choices are limited by the FeatureCAM modules you have purchased. 3. Select the unit of measure for your part (Inch or Millimeter). You can change the default dimension units later, by selecting Options > File Options from the menu. 4. Click Finish.

Closing the Stock wizard

The stock is the initial material from which you cut your part. By default, the Stock wizard (Dimensions page) opens on the screen as soon as you have created a new part. It lets you set the shape and dimensions for the stock, the stock material, part program zero, and the coordinate system for modeling.

To close the Stock wizard, click the Cancel button.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 39

Creating a simple part

Let's create a basic part using default FeatureCAM behavior. This tutorial uses the Milling Setup. The measurements are in inches; the values in millimeters are shown in parentheses. 1. Create the stock. a. Select the Stock step from the Steps panel.

b. In the Stock wizard (Dimensions page), set Width to 4 (100mm), Length to 4 (100mm), and Thickness to 2 (50mm). c. Click the triangle next to the Finish button, and select the Finish option to exit the wizard. 2. Add a hole feature. a. Select the Features step from the Steps panel.

b. In the New Feature wizard, select the Hole radio button in the From Dimensions frame, and click Next. c. Set Diameter to 1 (25mm), Depth to 2 (50mm), and click Next. d. Enter the hole location: X = 3 (75mm), Y = 3 (75mm), Z = 0. e. Click the triangle next to the Finish button, and select the Finish option to exit the wizard. 3. Add a pocket feature. a. Select the Features step from the Steps panel.

b. In the New Feature wizard, select the Rectangular Pocket radio button in the From Dimensions frame, and click Next. c. Set Length to 2 (50mm), Width to 2 (50mm), Depth to 1 (25mm), and click Next. d. Enter the pocket location: X = 0.5 (12mm), Y = 0.5 (12mm), Z = 0, and click Finish.

40 Using FeatureCAM

FeatureCAM 15.0 Getting Started

4. Select View > Principal Views > Isometric from the menu.

5. Select File > Save, and save your part as first1.fm. Your part should looks something like this:

6. Create the toolpaths. step from the Steps panel. The a. Select the Toolpaths Simulation toolbar opens. button, and then click the b. Click the Show Centerline button. Lines are drawn that represent the center of the Play tip of the tool. Rapid moves (G0) are shown in green and lines and arcs (G1, G2, G3) are shown in black. button, and then click the Play c. Click the 3D Simulation button. This style shows a three dimensional shaded rendering of the initial stock and simulates material removal in 3D. Any gouge caused by holder interference or the tool hitting the part during a rapid move is displayed in pink. button, and then click the Play d. Click the 2D Simulation button. For milling this style shows a flat (from the top) view of the part, with each tool being shown in a different color. For turning, this style shows a cross section of the part.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 41

7. To view the generated NC code, click the NC Code tab in the Results window. You are now ready to take a quick interface tour (see page 42).

Interface tour
The FeatureCAM interface contains a number of traditional Windows elements, such as toolbars, dialogs, context menus, and wizards.

- Title bar (see page 43). - Menu bar (see page 43). - Toolbars (see page 44). - Graphics window (see page 53). - Toolbox window with the Steps panel (see page 58) and the Part View panel (see page 72). - Results window (see page 74). - Assistance bar (see page 75). - Feature/Geometry Edit bar (see page 75). - Status bar (see page 75).

42 Using FeatureCAM

FeatureCAM 15.0 Getting Started

As with other Windows programs, you can tell FeatureCAM what to do in several ways: Select a button on a toolbar; Select an option from a menu; Select an option from a context menu; Press a keyboard shortcut. As you master FeatureCAM, try combining several methods of issuing commands to get your work done faster.

Title bar
Like most Windows applications, FeatureCAM has a Title bar at the top. At the left side of the bar is the control icon, and at right side of the bar are three standard icons: minimize , maximize/restore , and close . You can maximize the FeatureCAM window on the screen by double-clicking the Title bar. To restore its previous size and position, double-click it again. The type of part setup is shown in round brackets, for example: (Milling), and the name given to your part file is shown in square brackets, for example: [first1.fm]. When you have any unsaved changes in your part file, an asterisk (*) is displayed next to its name.

Menu bar
The Menu bar contains all commands available in FeatureCAM. Menus are grouped by similar or 'like' functionality. For example, all commands related to features and geometry are located under the Construct menu, all commands related to user assistance are located under the Help menu and so on. When a menu has a right-pointing arrow, such as there is a submenu associated with that choice. When a menu item is followed by three dots, such as dialog or a wizard associated with that choice. , , there is a

FeatureCAM 15.0 Getting Started

Using FeatureCAM 43

You can use the keyboard to navigate around the menus. To do this, press and hold the Alt key, and then press the letters on your keyboard that correspond to the letters underlined on the Menu bar and in the menu options. For example, to rotate your part, press and hold the Alt key, press V for View menu, press V for Viewing Modes, and press R for Rotate. This manual contains a full list of the keyboard shortcuts (see page 78). Typically, use the Ctrl-key shortcuts for standard Windows commands (Ctrl+N to create a file; Ctrl+S to save a file), and the Alt-key shortcuts to execute FeatureCAM-specific commands (Alt+R to refresh the view).

Toolbars
FeatureCAM toolbars provide quick access to frequently-used commands. Every button on a toolbar includes a tooltip, which describes the function the button activates. Bes (see page 75)ides the tooltip, the Assistance bar prompts you for the next step in the process. It senses your context, and helps you design geometry and features. You can rearrange, open and close toolbars: To move a toolbar, click the double-dotted line at the edge of the toolbar, and drag it to a different location. To open or close toolbars, right-click an empty area next to the last toolbar on the screen, and choose from the list of available toolbars, as shown below:

In addition to rearranging the existing FeatureCAM toolbars, you can customize their appearance and content, and create your own toolbars. , a submenu If a toolbar button has a down-pointing arrow, such as toolbar is associated with that choice. Click the triangle to open the menu, and select a specific option. As you move through the menu, additional help is displayed in the Status bar (see page 75). When the option is selected, it becomes the current command and is displayed as a button in the toolbar. To repeat the command, click the button in the toolbar. To choose a different command, click the triangle again.

44 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Some buttons on toolbars let you choose a program mode. For example, to create a circle, you need to be in circle-creation mode. To rotate your part, you need to be in rotation mode and so on. FeatureCAM remains in the selected mode until instructed otherwise. To identify the mode you are in, look at the buttons. A pale grey border around a button indicates that the corresponding mode is currently active. To leave the mode, usually you need to click the button again. Standard toolbar The New Part Document button creates a new part file. You can control how files are created by selecting Options > File Options from the Menu bar, and customizing the settings on the New Files tab. The Open button opens an existing file. You can control how files are opened by selecting Options > File Options from the Menu bar, and customizing the settings on the Existing Files tab. The Save button saves the current file. You can control how files are saved by selecting File > Save Options from the Menu bar. The View menu lets you select viewing modes for your part. Your cursor shows the same icon as the viewing mode you selected. The Principal View menu lets you select one of seven predefined views for your part. The Shade button toggles display of shaded surfaces for solid modeling. You need to have the Solid Modeling module to use this option. The Undo button reverses the effect of the previous command. FeatureCAM remembers a long list of the commands that are performed, so you can undo more than one command. The Delete button erases the object that is selected on the screen. The object is removed from the system. The Select button turns on select mode. When you are in select mode, the mouse appears as a standard arrow pointer in the Graphics window. In select mode, you can click objects to select them.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 45

The Transform button opens the Transform dialog, and lets you move or copy the selected entity. The Options Dialog button opens the Options dialog, and lets you customize FeatureCAM. The Context Help button switches on contextsensitive help. When the cursor has changed to a question mark (?), click a menu item, button or dialog to receive more information. The FeatureCAM Help button opens online help.

Advanced toolbar The Show menu contains the object categories that can be displayed in the Graphics window. The Hide menu contains the object categories that can be hidden in the Graphics window. Hiding objects does not delete them; it only removes them from display. The Curve Wizard button opens the Curve wizard and lets you construct curves. The commands available in this wizard are also available from the Curves and Surfaces toolbar (see page 47). The Surface Wizard button opens the Surface wizard and lets you construct surfaces. The commands available in this wizard are also available from the Curves and Surfaces toolbar (see page 47). The Solid Wizard button opens the Solid wizard and lets you construct solids. This option is available if you have the Solid Modeling module. The Toggle Geometry Bar button toggles the display of the Geometry toolbar (see page 49). The Snap Modes button opens the Snap Modes dialog, which lets you set the locations for point snapping. The New Feature Wizard button opens the New Feature wizard, which lets you create features.

46 Using FeatureCAM

FeatureCAM 15.0 Getting Started

The UCS button opens the User Coordinate System dialog, and lets you create or change existing UCSs. The Setups button opens the Setups dialog and lets you create or edit part program zero.

Curves and Surfaces toolbar The Curve menu lets you use predefined curves, such as ellipses or rectangles. The Curve from Curve menu lets you construct curves from other curves. The Curve from Surface menu lets you construct curves from surfaces. The Surface Primitives menu lets you use predefined surfaces, such as spheres or cylinders. The Surface from Curve menu lets you construct surfaces from curves. The Surface from Surface menu lets you construct a surface from a single surface. The Surface from Surfaces menu lets you construct a surface from multiple surfaces. To construct surfaces, you need to have the FeatureMILL3D module. Snap Mode toolbar The Snap to Grid button displays a grid and enables snapping to the grid. Selecting Snapping Grids from the Options menu controls the spacing of the grid. Grid snaps to a point on a coordinate system that is laid out on the stock. The grid size can be modified from the Options menu. The Snap to Point button snaps to a point object. The Snap to End Point button snaps to the end points of finite lines and arcs; it also applies to the corners of the stock.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 47

The Snap to Midpoint button snaps to the middle points of finite lines and arcs. The Snap to Section button snaps equal intervals of a finite line. The number of sections is controlled by the Sections parameter of the Snapping Grids dialog. The Snap to Intersection button snaps to the intersection of lines, arcs, and circles. The Snap to Center button snaps to circle centers. This setting also controls the display of circle and arc center points. The Snap to Quadrant button snaps to the four points on a circle corresponding to 0, 90, 180, and 270. The Snap to Object button snaps to a point on another object. This includes lines of surfaces and is convenient for snapping points to locations on a surface. The Snap to Tangent button snaps the point so that the object you are creating will be tangent to the object you snapped to. The Snap to Toolpath button snaps to points on a centerline toolpath simulation. The Snapping Discrimination Dialog button opens the Snap Discrimination dialog if the point you select could snap to more than one location.

Display Mode toolbar The Shade Selected button shades objects selected on the screen. This is the only way to shade features. The Unshade Selected button removes shading from the selected objects, and returns them to line drawings. The Unshade All button returns all objects to line drawings. The Hidden Line button toggles the view of solids to hidden line mode. The Draft Hidden Line button toggles the view of solids to draft hidden line mode.

48 Using FeatureCAM

FeatureCAM 15.0 Getting Started

The Show Normals button shows the normals for selected surfaces in the model. The Unshow Normals button hides the normals for selected surfaces in the model. The 2D Turned Profiles button shows turning features as 2D profile.

Geometry toolbar The Point button creates a point at X Y Z coordinates. The Line menu lets you create different types of lines. The Circle menu lets you create different types of circles. The Fillet menu lets you create different types of fillets. The Arc menu lets you create different types of arcs. The Dimension menu lets you create dimensions, or special text labels with attached lines to indicate your part's size. The Edit menu lets you edit selected geometry. The Chain menu lets you construct feature curves from selected geometry.

Simulation toolbar The Eject button removes the Simulation toolbar from the screen, and erases the simulation from the Graphics window. The Show Centreline button selects a centerline simulation. When you click the Play button, the simulation is performed using the current view to draw the toolpaths. A line drawing representing the center of the tool tip is displayed.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 49

The 2D Simulation button selects 2D simulation. When you click the Play button, a two-dimensional color simulation is performed showing the regions cut by each operation. The view is changed to the top view automatically, and anything on the screen is temporarily erased until the simulation is complete. You can't change the view during the simulation. Once the simulation is complete you can change the view, but the toolpaths are erased. The 3D Simulation button selects 3D simulation. When you click the Play button, a 3D shaded simulation is performed in the current view with the tool animated through all of its moves. You can dynamically change the view of the simulation at any point during or after the simulation. The simulation does not have to be recalculated, so the view change is instantaneous. The 3D RapidCut button selects rapidcut simulation. When you click the Play button, a 3D simulation is performed without animating the tool. Only the final results are displayed. For most parts, the simulation takes only a few seconds to complete. This simulation can be viewed dynamically. This simulation type is available if you have the FeatureCAM3D module; it does not apply to turned parts. The Machine Simulation button selects machine simulation. When you click the Play button, a full machine simulation is performed showing you how the machine will cut the part. Odd motions and collisions can be detected so that the program can be adjusted long before code is sent to the CNC machine. This simulation type is available if you have the Machine Simulation module. The Stop button cancels a simulation. The Play button starts a simulation, or resumes a paused simulation. This button starts a simulation of the selected feature, or resumes a paused simulation.

50 Using FeatureCAM

FeatureCAM 15.0 Getting Started

The Pause button pauses the simulation. It appears on the toolbar when you press the Play button. Clicking the Pause button transforms it back into the Play button. The Fast Forward to End button speeds up the simulation, and fast forwards it to the end. This button speeds up the simulation of selected feature, and fast forwards it to the end. The Single Step button moves the simulation ahead by one tool move. The keyboard accelerator for this button is Alt+F3. This button moves the simulation of selected feature ahead by one tool move. The Simulation Next menu lets you specify how the simulation is played. The Simulation Next menu lets you select how the simulation of selected feature is played. The Clear Toolpath button erases any centerline toolpaths shown on the screen. The Region of Interest button lets you limit the portion of the part that is rendered during a 3D solid simulation or a rapidcut simulation. The Show Tool Load button displays the Tool Load dialog when the next 3D simulation is played. This dialog graphs the horsepower requirements of the part program, and displays the current simulation time and instantaneous horsepower. The Sim Speed slider is used to adjust the simulation speed. Moving the bar to the right speeds up the simulation; moving the bar to the left slows it down.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 51

Steps toolbar

The buttons on the Steps panel (see page 58) in the Toolbox window are also available as the Steps toolbar. Display this toolbar if you want to use the Part View panel (see page 72), but need an easy access to the buttons on the Steps panel. Solid toolbar The Solid from Curve menu lets you construct solids from curves. The Solid from Surfaces menu lets you construct solids from surfaces. The Modify Solid menu lets you edit solids. The Manufacturing Solids menu lets you select a

More Simulation toolbar This button toggles the display of the Simulation toolbar (see page 49), and lets you preview the toolpaths from start point. This button toggles the display of the Simulation toolbar, and lets you preview the toolpaths for selected Z level. This button toggles break points in the simulation at toolpath level. This button toggles break points in the simulation at Z level.

52 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Graphics window
The Graphics window is your main working area. It shows the graphical representation of the part, and the graphical toolpath simulations. You can control how much space the Graphics window uses compared to the Toolbox and the Results windows by moving the sliders from side to side. Alternatively, try expanding and collapsing the Toolbox and the Results windows by clicking the corresponding and icons. In most cases, right-clicking in the Graphics window displays a context menu with some options for the current situation. Mouse buttons The left, middle, and right mouse buttons have specific uses in FeatureCAM. Left mouse button selects objects, such as geometry, interface objects (buttons, tabs), and objects in the Part View panel. Middle mouse button is used to dynamically view objects in the Graphics window. By default, holding the middle mouse button as you drag the mouse zooms the view. Using the Ctrl key and the middle mouse button rotates the view. Using the Ctrl+Shift keys and the middle mouse button pans the view. You can customize the middle mouse behavior by selecting Options > Viewing from the menu. Right mouse button activates context-sensitive menus. For example, positioning the mouse cursor over the Steps panel, and right-clicking lets you customize the look of the buttons on the Steps panel. Mouse cursor The cursor shape may change to indicate the mode that is currently selected. In select mode, the cursor arrow indicates what you are selecting, or what the system expects you to select: - Part View panel. - Steps panel. - area that you can expand/collapse on the screen.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 53

- editable area on the Status bar. - stock. - feature. - geometry (point). - geometry (line). - geometry (circle, arc). - geometry (fillet). - geometry (dimension). - geometry (surface). In view mode, the cursor takes a shape of the chosen option, showing you what you can do with the part: - rotate along the X and Y axes. - trackball. - pan, that is move around without changing the magnification. The part is moved perpendicular to the viewing angle. - zoom, that is change the display magnification. Moving the mouse to the right enlarges the part, moving the mouse to the left shrinks the part. You can also zoom in and out using the mouse wheel. - zoom to a box (selected area). The selected portion of the drawing is enlarged to fill the Graphics window. - pan and zoom. The point where you click is centered on the screen, and then the part is zoomed with the mouse movement. - rotate along the X axis. - rotate along the Y axis. - rotate along the Z axis. In geometry mode, the cursor changes to crosshairs . A number next to the cursor indicates the progress of the shape construction, for example, a construction of an arc, requires creating three points.

54 Using FeatureCAM

FeatureCAM 15.0 Getting Started

When you use snap mode, a small snap icon shadows the cursor. When snapping to a circle center, endpoint, midpoint, quadrant or section, the snap icon is a small box:

When snapping tangent to a circle or arc, the icon is a small circle that can slide along the circle or arc while maintaining tangency:

Snapping to a grid point, the icon is a small plus sign:

When snapping to an object, the icon is a large dot:

When you chain geometry, your mouse cursor looks like a target point: . Smart dialogs To provide you with more space in the Graphics window, FeatureCAM automatically minimizes some dialogs by default. For example, the Select Stock Curve dialog minimizes into a small title bar when you click the Pick Curve button. When the dialog is minimized, the cursor shape changes to . This indicates you need to select an object in the Graphics window. When you select the object, the dialog is restored. If you want to restore the dialog without making a selection, click the button in the small title bar. To disable auto-minimization, deselect Options > Warp Dialogs in the menu. Selecting graphical objects Select mode is chosen by default. If you need to switch it on, click the button on the Standard toolbar. Select To select objects in the Graphics window you can:

FeatureCAM 15.0 Getting Started

Using FeatureCAM 55

Click the left mouse button on an object. This selects that object (by turning it red) and deselects any other object. Hold down the Shift key and click the left mouse button on an object. This adds that object to the selected set of objects. This method allows you to select more than one object. Click the left mouse button and drag the mouse before releasing the button. This method is called box select. As you drag the mouse, a box is displayed in the Graphics window. All objects that are completely enclosed in the box are selected. If you hold down the Shift key while selecting, the objects are added to the selected set of objects.

Viewing and shading your part Viewing Viewing is performed interactively in FeatureCAM with the mouse. You can choose a number of viewing options from the View menu on the Standard toolbar. By default, each viewing command executes only once. To stay in the selected viewing mode, press the Ctrl key on your keyboard as you click the viewing command. The selected viewing option is now active until you deselect it on the toolbar. Once you've selected a viewing option, you can activate it again, by holding the Shift key and pressing the right mouse button. Instead of zooming and panning to position your part, you can choose one of the pre-defined view from the Principal View menu on the Standard toolbar. You can also create up to four user views, and return to them to compare different aspects of your part. To create a user view, position the part in a view you will want to return to, and select View > User Views > Save View.

56 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Shading By default, everything that you create in FeatureCAM is displayed as a line drawing, for example:

Objects can also be viewed as: 3D shaded drawings

3D hidden line drawings

To control the current display mode, use the Display Mode toolbar. Deleting objects There are many ways to delete geometry, curves, surfaces and features: Right-click the object in the Graphics window and choose the Delete option from the menu. Select the object in the Graphics window, then press the Delete key on your keyboard. Select the object in the Graphics window, then choose Edit Delete from the Menu bar. From the View menu, choose Entities, select the object row in the Entities dialog, and click the Delete button.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 57

Steps panel
The Steps panel contains an ordered list of steps for creating part programs. Each step is a wizard that presents a series of dialogs for each process. They are listed in the order in which you should use them during the process of creating a part program. The flowchart below illustrates this process.

Step 1: Stock (see page 59). The Stock wizard steps you through entering the shape and dimensions of the stock, the stock material, part program zero and the coordinate system for modeling. Step 2: Geometry (see page 60). Points, arcs, lines and other shapes are used to describe the overall shape of parts. Many different geometry tools are available. Geometry can also be imported from CAD systems.

58 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Step 3: Curves (see page 61). Shapes that involve more than a single line or arc are described as curves. For FeatureMILL3D customers, there are also Surfaces and Solids steps for creating 3D surface and solid models. Step 4: Features (see page 62). Features are common shop terms like pocket, or thread. They are created from curves and dimensions. These objects describe your part in 3D and are used to generate toolpaths. Step 5: Toolpaths (see page 63). Toolpaths are generated from collections of features. You can simulate them in FeatureCAM using toolpath centerlines, 2D shaded or 3D solid shaded simulations. Step 6: NC Code (see page 66). Machine-specific G-codes are generated from the toolpaths. Translators are provided for many different NC controls and include a program for creating new translators. Customize Manufacturing (see page 66). FeatureCAM automates the entire part programming process, you can customize all of the system settings including feed/speed tables, tooling databases or feature settings. If you have 3D, Solid Modeling and FeatureRECOGNITION modules, the Steps panel may include extra steps (see page 71). Step 1: Stock The stock is the initial material from which you cut your part. It can be rectangular, circular, a more general extruded shape, or a solid model. The stock shape is used for 3D toolpath simulations and to control the extent of milling features like bosses. FeatureCAM has embedded feed/speed tables for many different stock materials, so that feeds and speeds can be automatically calculated based on the stock material. The Stock wizard provides step-by-step instructions for specifying or modifying the general stock shape, specific stock dimensions, fixture IDs, part program zero, and the origin of your modeling coordinate system.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 59

To navigate through the wizard, enter the desired information on each page and click the Next button to move to the next page.

After completing this step, if you want to create holes, rectangular pockets, slots, circular pockets or thread mill features, you can skip to Step 4: Features (see page 62). Step 2: Geometry Each part starts with an initial design. You may already have a part drawing, a part sketch or you may want to use FeatureCAM to draw your part design from scratch. The geometry step gives you methods of creating points, lines, arcs, and circles. You can also clip geometry. If you want to create multiple objects, select the Create more than one option at the bottom of the Geometry Constructors dialog before selecting the type of object you want to create.

60 Using FeatureCAM

FeatureCAM 15.0 Getting Started

After selecting the type of object you want to create, you see instructions in the yellow Assistance bar at the bottom of the screen. Enter any numeric arguments that are required. Use the Tab key to move to the next field. For point coordinates, either type the individual X, Y and Z coordinates, or use the mouse to graphically locate them in the Graphics window. As you move the mouse around the Graphics window, the cursor snaps to discrete locations like circle centers or line endpoints. You control this location using the Snap Mode toolbar (see page 47). Alternatively, you can select Options > Snapping Modes from the menu, and use the Snap Modes dialog. Step 3: Curves This step groups arcs and lines into curves by automatically tracing smooth paths. If you want to make a feature from more than a single line, arc or circle, you must connect the geometry into a curve. This option creates closed curves (curves that form a loop) by clicking on one piece of geometry. An attempt is made to create a closed loop by following smooth paths. If this method does not result in the correct pieces, click the Clear Pieces button in the Feature/Geometry Edit bar, select the Curves step again, and use the Pick Curve Pieces command. This option creates curves by manually clicking on segments of the curves. To create an open curve (curves that do not form a loop), click the beginning of the curve and then click the end. If the resulting curve is not correct, click a number of intermediate positions to guide the process of creating curves. Closed curves can also be created with this technique by clicking back to the initial piece of geometry. This option opens the Curve wizard that provides step-by-step instructions for creating curves using a variety of methods.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 61

This option lets you create curves using the projection of straight walled vertical surfaces. This method is only available if you have a licensed FeatureRECOGNITION module.

Step 4: Features

Toolpaths are generated from features. For example, if you want a hole in your part, choose the Hole feature. If your part has a pocket, choose the Pocket feature. The New Feature wizard walks you through the process of creating features.

One category of features is those that can be created solely from dimensions. These features include holes, rectangular-shaped pockets, threads, and round pockets (called step bores).

62 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Other features require curves to describe their shape. They are listed under the From Curve category. These features include pockets, bosses, grooves, chamfers, rounds, sides, and faces. If you want to create a pattern of features, select the Make a pattern from this feature check box. Click Next to step through the wizard. This wizard steps you through: Selecting the feature type. Optionally entering pattern dimensions. Positioning the feature. Specifying the manufacturing strategy. Reviewing the automatically selected tools. Reviewing the automatically calculated feeds and speeds. Overriding the tooling and feed/speed values. Changing manufacturing attributes. To modify a feature either double-click on it or select it and click the Properties button to open the Properties dialog. The dialog presents the pages of the New Feature wizard in a single dialog. The individual pages are separated into different tabs of the dialog. Step 5: Toolpaths This step displays the Simulation toolbar. This toolbar has two sections, simulation types and simulation controls.

To run a simulation: 1. Select the mode of simulation you would like to run from:

FeatureCAM 15.0 Getting Started

Using FeatureCAM 63

Centerline simulation displays lines that represent the center of the tool:

2D shows a color simulation from the top view. Each operation is displayed in a different color:

3D shows a 3-dimensional solid shaded simulation:

64 Using FeatureCAM

FeatureCAM 15.0 Getting Started

RapidCut displays the final result without animating the tool. This option only applies to FeatureMILL3D module. Machine simulation displays the entire machine. This option is only available if you have the Machine Simulation module.

2. Use the simulation controls to control the simulation: Click the Play button to run the simulation. After clicking the Play button, this button turns into the Pause button. Click this button again to pause the simulation. The Single Step button will display one toolpath move. The Fast Forward to End button, displays all the toolpaths for the part without animating the results. You can then view the toolpaths for each individual operation by clicking the Clear button and then clicking on an operation in the Operation List window. The Play to Next Operation button will display one complete operation such as a spot drill or a pocket roughing operation. This button is actually a menu. By clicking on the triangle to the right of the button the following additional options are revealed:

The Next Rapid button simulates up to the next rapid move. The Next Tool Change button simulates up to the next tool change.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 65

Play to Next Z Level displays the next Z level of a Z level rough or finish operation. Use the Erase button to erase the centerline toolpaths on the screen. The Region of Interest is used to limit the portion of the part that is simulated for 3D or Rapid Cut simulations. The Show tool load button indicates whether to display a graph of the tool load when the next 3D simulation is performed. The Eject button removes the toolbar and the simulation from the screen. The speed control slider controls how fast simulations run. Move the slider to the right to speed up, or to the left to slow down. 3. If you see something in the simulation you want to change, you can override any of the tool choices, operation order, or the feeds and speeds if you wish. Continue to simulate and fine-tune the part until you have the settings exactly right. Step 6: NC Code You generate NC code in FeatureCAM using this step. The NC Code dialog opens. The Feed Optimization button evens out the load on the tool by adjusting the feedrate of each NC block. The View the NC Code button displays the code in the Results window. You can also display the tooling lists and operations sheets by clicking the tabs located at the bottom of the Results window. The Save NC button opens the Save NC dialog and lets you save the NC code to disk. You can also save additional documentation like tool lists, operations lists and part databases. The Tool Mapping button lets you change the locations of the selected tools in the tool changer.

Customize manufacturing This step lets you customize the tools and materials databases, post options, and the default system parameters. The Customize Manufacturing dialog opens. The Set default feature attributes button lets you configure machining preferences (see page 67).

66 Using FeatureCAM

FeatureCAM 15.0 Getting Started

The Create tools and manage tool crib contents button lets you configure the tools database (see page 69). The Feeds/Speeds and Cutting Data Tables button lets you configure the materials database (see page 70). The Post Process Options button lets you customize post options (see page 71).

Machining preferences Machining preferences, or attributes, control the way a feature is manufactured. FeatureCAM has two types of attributes: Default - specify the defaults for values such as stepovers, ramping, canned cycle use, or operation ordering. These settings are used for all features that you create. To modify the default attributes, select the Customize Mfg. step on the Steps panel, and click the Set default feature attributes button in the Customize Manufacturing dialog. This opens the Machining Attributes dialog.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 67

The configurable attributes are divided into three categories: Milling, Turning, and Wire. Select a option, and then modify the settings as desired. The settings are saved with the FeatureCAM file. Feature - apply to specific features, and override the default settings. For example you may set a default setting for climb milling, but override it for bi-directional roughing for a particular feature. To set feature attributes, select the feature in the Graphics window, and click the Properties button located below the Assistance bar.

This opens the Properties dialog. Click on an operation in the tree view, to display tabs that are specific to the operation. Use this dialog to adjust the settings for the selected feature.

68 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Tools database FeatureCAM supports all the tool types in your shop including drills, taps, reamers, end mills, boring bars, and face mills. Each tool type is described by a series of dimensions. Tools are grouped into tool cribs. FeatureCAM provides a comprehensive tools database and creates a basic tool crib for inch, or millimeter tools, or both. FeatureCAM selects tools from the active tool crib to manufacture the part. You can pick the tool crib you want to use for each part or machine. You can also create custom tool cribs with the Tool Manager to reflect the tools owned by your shop or to exactly represent the tools preloaded in your tool changer.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 69

Materials database FeatureCAM comes standard with an integrated materials database. Feeds and speeds are stored in tables for each material. Each table contains the settings for different cutting operations. These tables can be customized to change the values or you can add tables for new materials.

70 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Post options FeatureCAM has many post processors built-in. To tell FeatureCAM, which one you want, use the Post Options dialog. It lets you customize various settings for milling, turn/mill, or Wire EDM posts.

Optional steps - Surfaces. This step is available in FeatureMILL3D. This step launches the 3D Surface wizard which steps you through creating surfaces from curves, primitive surfaces, surfaces from one surface, and surfaces from multiple surfaces. - Solids. This step is available in the Solid Modeling option. The Solids step initiates the Solids wizard which helps you create solids using numerous techniques. - AFR. This step is available in the FeatureRECOGNITION option. AFR stands for Automatic Feature Recognition. This step automatically recognizes features from solid models.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 71

Part View panel

The Part View panel provides a hierarchical view of the part.

Each setup is listed with each of the feature of the setup listed underneath. From this view you can select, show, hide, or modify features. All objects are represented in the part view with the exception of geometry. When you click on an object in the Part View panel, its icon is highlighted in red, for example . Part icon represents the entire part. The part filename is also displayed in the tree view. Stock icon represents the part stock. Setup icon represents a setup. The features of a setup are listed underneath a setup. If you click a setup, it changes the current setup and current UCS. Feature icon represents features. It can be a 2.5D, 3D or turn feature. The check box next to the feature can be used to exclude it from toolpath generation. The feature is not deleted; it is just ignored for toolpath generation. Pattern icon represents patterns. It can be linear, radial, rectangular, or points pattern. Patterns lets you quickly create the same feature at multiple locations. The check box next to the pattern can be used to exclude associated features from toolpath generation. The feature is not deleted; it is just ignored for toolpath generation. Curve icon represents a curve in the part model. Surface icon represents surfaces. Surface milling features are classified as features, not surfaces.

72 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Solid icon represents a solid. Individual design features are listed underneath. Turret icon represents a turret on a lathe. Selecting a specific turret displays the NC code for that turret. To navigate the Part View tree: If an object has a + in its left margin, click it to expand the view to reveal objects that are subordinate. Click the - to collapse the view and hide the subordinate objects. Double-clicking on the object also performs the same function. Clicking on an object in the tree view will select the object in the Graphics window. This selection method is good for distinguishing between overlapping objects in the Graphics window. Make sure you click the name and not the check box. Clicking on an object also reveals the button for that feature. Clicking this button brings up a menu of actions you can perform on the object. The actions available are dependent on the object type. Right-clicking on the object in the tree view also reveals this menu. Features have check boxes. Deselecting the check box excludes the corresponding object from the next toolpath generation. You can reorder these items by dragging a feature or setup. Double-clicking on a feature displays its Properties dialog for editing.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 73

Results window
The Results window contains the automatically generated documentation including tooling lists, setup sheets, and the NC part programs. Selecting one of the tabs at the bottom of the window changes the content of this window. Op List tab The Operation List tab contains a table with manufacturing operations for your part.

Each row displays the operation, feature that the operation came from, and the tool that will be used to cut the feature. As the toolpaths are simulated, the current operation is indicated with a yellow arrow in the left-hand margin. To edit a feature, double-click the corresponding row. If a manufacturing error is detected, a warning sign is displayed in the left-hand side of the row. Double-clicking on the icon takes you to the description of the problem on the Details tab. Details tab The Manufacturing Details tab contains two sheets: Operations List lists the cut type, cut depth, center point, tool details, speed/override, feed/override and estimated manufacturing time for each manufacturing step.

74 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Tool List provides in-depth information for the tools used to manufacture the part, including tool name, tool slot or tool pocket number, tool offset number and so on. To view a sheet, select the corresponding radio button. NC Code tab This tab contains the generated NC code for your part. The tab appears when you select the NC Code step from the Steps panel. If you select the NC Code step before you have generated toolpaths, FeatureCAM prompts you to create the toolpaths, and then opens the NC Code tab.

Assistance bar
The yellow Assistance bar displays step-by-step instructions for the current command.

Feature/Geometry Edit bar

The Feature/Geometry Edit bar is located below the Assistance bar. It is context-sensitive, and lets you select and edit a feature, or enter the point locations and parameters for geometry creation.

Status bar
The Status bar appears at the bottom of the FeatureCAM screen. It shows your current drawing units, toolcrib, and post processor settings, as well as your keyboard status and information about the simulation when you run one. This is not a toolbar; you can't move it around, but you can turn it on and off by selecting View > Toolbars from the menu and using the check box in the Misc tab. You can also customize the simulation information by going to Options > Simulation, and selecting the check boxes in the Status frame for all items that you want to be displayed. The Status bar contains: Cursor coordinates - the current X Y Z location of the cursor in the Graphics window. Grid coordinates - the grid point X Y location of the cursor in the Graphics window. Drawing units

FeatureCAM 15.0 Getting Started

Using FeatureCAM 75

Layers - the currently active layer. You can change the layer by doubleclicking it here. User Coordinate System (UCS) - the currently active UCS. UCS is an origin and three vectors (X, Y, and Z) that determine a position and orientation in 3-dimensional space. You can use an unlimited number of these to conveniently model your part. To change the currently active UCS, double-click its name. Setup - the currently active setup for your part. A setup is an orientation and part program zero for a physical setup on the machine tool. You change the setup by double-clicking its name. CNC file - the currently selected CNC file. Double-clicking it opens the Post Options dialog, and enables you to change the settings. Toolcrib - currently active toolcrib (set of tools in the tooling database). You can change the toolcrib by double-clicking its name. Keyboard status Simulation information, such as tools, feeds/speeds, elapsed time.

Saving your work

To save a FeatureCAM part file the first time: 1. Select File > Save from the menu. 2. In the Save As dialog, choose the folder to store your file. 3. Enter the name in the File name field. By default, the file is called FM[N].fm, where N is an incremental number. FeatureCAM automatically appends an fm suffix to your part file name - this identifies file as a FeatureCAM file. 4. Click Save. In FeatureCAM, you have the option of saving a number of previous versions of your part as you work. To create a backup copy: 1. Select Save Options from the File menu. 2. In the Save Options dialog, select the Create Backup Copies check box. 3. Enter the Number of copies to keep, for example 1. 4. Choose the backup location.

76 Using FeatureCAM

FeatureCAM 15.0 Getting Started

5. Click OK. Now when you save your file, the last saved version is saved as Backup of <Filename>.fm in the same location as the original.

Printing
You can print the Manufacturing Operations and Manufacturing Tool Detail sheets, NC programs, and drawing for a part. The files are all ASCII text files that print like a text document. 1. Select File > Print from the menu. 2. In the Print dialog, use the Print Range frame to choose what you want to print.

Some options may not be available. For example, if you haven't yet generated the NC code, you can't print it. 3. If you are printing a drawing: To print the toolpaths displayed in the Graphics window, select the Print Toolpath check box. To print the drawing at actual size, select the Print to Scale check box. This means, that a 1 inch line segment, for example, will measure 1 inch on the paper. To make the drawing fit the paper, leave the Print to Scale check box deselected. 4. Choose the print quality from the drop-down list. The specific options depend on your printer. 5. Set the number of copies to print. 6. Click OK.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 77

Keyboard shortcuts
Key sequence Delete Esc F1 Alt + F1 Alt + F2 Alt + F3 Alt + 1 (2,3,4) Alt + Enter Alt + L Alt + R Alt + Shift + V Ctrl + A Ctrl + C Ctrl + E Ctrl + F Ctrl + H Ctrl + L Ctrl + N Ctrl + O Ctrl + R Ctrl + S Ctrl + P Ctrl + V Ctrl + Z Ctrl + Y Action Delete the selected object Stop current simulation Context-sensitive help Centerline simulation Play or pause simulation Single-step simulation User View 1-4 Properties Last view Refresh Save view Select all Copy Center selected Find (text in a text window). The cursor must be in a text window. Replace (text in a text window). The cursor must be in a text window. Center all New file Open file New feature Save file Print Paste Undo Redo

78 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Key sequence Ctrl + X Ctrl + Shift + A Ctrl + Shift + C Ctrl + Shift + N Ctrl + Shift + P

Action Cut Shade selected Unshade all Unshade selected Toggles perspective

Getting help
FeatureCAM provides a variety of ways for you to get help as you work. Context-sensitive help gives you quick access to the information relevant to the tasks you are attempting to carry out. You can also refer to the numerous examples in the Examples folder, located in the FeatureCAM root directory. Finally, if you cannot find an answer to your question, you can visit our website or contact our technical support. User manuals User manuals are provided in Adobe's Portable Document Format (PDF), and can be accessed from the Help menu. Online help The online help documentation is your primary source for in-depth technical information about FeatureCAM. It covers all FeatureCAM modules, and can be accessed from the Help menu, or by clicking on the toolbar. Three different tabs are available: Contents tab provides an outline view of the help system. Double-click a book or a page to open it. Index tab allows you to access the help file using index topics. Type the topic name in the top box and click the Display button. Search tab provides search capabilities for all pages of the help file. Type the word you would like to find in the top box and then pick a topic in the bottom box. Click Display to view the page.

FeatureCAM 15.0 Getting Started

Using FeatureCAM 79

Context-sensitive help You can use one of the following methods to get help relevant to the task you are carrying out: For some commands, FeatureCAM automatically displays the stepby-step instructions in the Assistance bar. When you hover the mouse over a toolbar icon for a few moments, a description of the icon is displayed.

Pressing F1 displays the relevant help page. Most FeatureCAM dialogs have the Help button. Clicking it displays the relevant help page. Click the Context Help button on the toolbar. When the cursor has changed to a question mark (?), click a menu item, button or dialog for more information. Links You can find FeatureCAM information online via the Help menu: Select: Help > FeatureCAM Training to book a training session. Help > FeatureCAM on the Web for product news, online support, discussion forum, and mailing list. Help > Check for New Version for product updates. Technical Support If you have any questions related to FeatureCAM, which you cannot find an answer to in the documentation, you can contact the Delcam technical support service. Email [email protected], describing your problem as precisely as possible. This support is free for the first 60 days after your initial purchase and 30 days after the purchase of an upgrade.

80 Using FeatureCAM

FeatureCAM 15.0 Getting Started

Customizing FeatureCAM
You can change the default behavior of FeatureCAM by using the commands on the Options menu. This chapter shows you how to configure the dynamic viewing options, the snap/grid options, adjust colors, and customize the toolbars.

Managing your settings

You can customize the toolbars, view options, colors, and so on, but your changes will last only for the duration of the current session, unless you instruct FeatureCAM to save them. You can choose to save your changes automatically. To do this, select the Save on Exit option from the Options menu. If you don't want to save your changes every time you exit the program, deselect the Save on Exit option. Now you can choose Options > Save Settings Now to save the modified configuration yourself. The changes are written into the ezfm.ini file located in the same directory that Windows is installed in. If you are not happy with the changes made for your current session, choose Options > Reload Settings. Your current settings will be replaced with the previously saved settings.

FeatureCAM 15.0 Getting Started

Customizing FeatureCAM 81

You can make a backup copy of the ezfm.ini file before you save any changes; this way you can revert to the default settings if something goes wrong. Alternatively, you can delete the ezfm.ini file; when you restart FeatureCAM, this file will be recreated automatically with the default settings.

Controlling wizards
Some wizards in FeatureCAM can be switched on and off. New Part Document wizard To turn the New Part Document wizard off, restart FeatureCAM, and deselect the Show this dialog on program start check box. To turn the New Part Document wizard back on, restart FeatureCAM, choose File > Part Wizard from the menu, and select the Show this dialog on program start check box. Stock wizard To turn the Stock wizard on/off: 1. Select File > New from the menu. 2. In the New Part Document dialog, specify how you would like to setup your stock. Wizard - the Stock wizard is shown next. This is a default option. Properties - the stock Properties dialog is shown next. This dialog presents the pages of the Stock wizard in a more concise form. None - FeatureCAM does not ask you to set up the stock. You will need to select the Stock 3. Click OK. step from the Steps panel.

82 Customizing FeatureCAM

FeatureCAM 15.0 Getting Started

Setting up dynamic viewing options

To customize the dynamic viewing options: 1. Select Options > Viewing from the menu. 2. In the Viewing Options dialog, click the Dynamic Viewing Options tab.

3. Customize the viewing mode used on startup. All standard viewing modes are available as options, plus an option called Mode from Last Session. This option keeps track of the viewing mode last set before FeatureCAM was closed, and uses that viewing mode the next time FeatureCAM starts up. 4. Customize the default behavior for the middle mouse button. You can set the behavior to be specific viewing modes such as Trackball, Rotate, Pan, Zoom, Pan and Zoom, or choose the Current Viewing Choice option that allows the middle mouse button (along with key combinations) to perform the viewing mode that is currently set in the toolbar. If you want to reverse the association of direction of the scroll wheel with the zoom direction, select the Reverse Scroll Wheel Zoom check box. 5. Click OK. To revert to default FeatureCAM settings: 1. Select Options > Viewing from the menu.

FeatureCAM 15.0 Getting Started

Customizing FeatureCAM 83

2. In the Viewing Options dialog, click the Dynamic Viewing Options tab. 3. Click the Reset Settings to FeatureCAM button. To revert to default PowerMILL settings: 1. Select Options > Viewing from the menu. 2. In the Viewing Options dialog, click the Dynamic Viewing Options tab. 3. Click the Reset Settings to PowerMILL button.

Adjusting colors
You can customize the default color used for the following objects: Feature - manufacturing features like holes, threads or surface milling objects. Geometry - 2D objects like circles, lines, or arcs. Curve - 2D or 3D curves. Surface - 3D surfaces Solid - 3D solids. All faces of the solid use this color. Dimension - dimension objects like linear, radial and annotation dimension objects. Stock - the stock that the part is cut from. Selection - this color is used whenever an object is selected in the Graphics window. Highlight - this color is used to emphasize the objects that are currently active in a dialog. Lower Background - this is the color of the lower portion of the Graphics window. If it is a different color than the Upper Background color, then the two are blended horizontally. Upper Background - this is the color of the upper portion of the Graphics window. If it is a different color than the Lower Background color, then the two are blended horizontally. Construction - the color is used for rubber-banding objects during geometry construction. Preview - this is the color for temporary objects that are displayed when the Preview button is pressed.

84 Customizing FeatureCAM

FeatureCAM 15.0 Getting Started

Hyperlink - this is the color for text labels in warping dialogs (that is dialogs that allow the use of interrogation to obtain the value). Rapid - the color of a rapid tool path move. Toolpath - the color of a feed toolpath move. Index - the color of a toolpath move that represents a rotation of a indexer. Part Line Program - the color of a toolpath that has part line programming activated. Ramps and Leads - the color of ramps and leads. 3dSimholder - the color of the tool holder. To customize the default colors: 1. Select Options > Coloring > Default Colors from the menu. 2. In the Default Colors dialog, select an object type, for example, Feature.

3. Click the More Colors button, and choose a new color from the palette. 4. Click Apply. This color is now used for any new objects of this type that you create in FeatureCAM. If you want to change the color for the objects that already exist in FeatureCAM, select the corresponding check box, and then click Apply. 5. Click Done.

FeatureCAM 15.0 Getting Started

Customizing FeatureCAM 85

To quickly override the default color for a group of objects: 1. Press the Shift key and select several screen objects. 2. Select Options > Coloring > Default Colors from the menu. 3. In the Selected Object Color Overrides dialog, click on the More Colors button, and choose a new color from the palette.

4. Click Apply. 5. Click Done to close the dialog.

Setting up snap and grid options

When you create geometry, you can enter point coordinates directly from the Feature/Geometry Edit bar.

This method is exact but not always convenient or feasible. You can also pick points directly on the screen with the mouse, although this method may be less precise. To increase the drawing precision, FeatureCAM uses the snap and grid functionality. Grid is a set of evenly spaced dots that serve as a visual distance reference. Snap is a set of evenly spaced invisible hot spots that restrict the points that you can pick with your mouse, and therefore helps you position lines, points or shapes more precise. To control how the cursor snaps, use the Snap Mode (see page 47) toolbar. Snapping to grid is the most common mode, and enables you to snap to a point on a coordinate system that is laid out on the stock. The grid plane rotates with the viewing plane: in a front or back view, the grid is in the X plane; in a right or left view, the grid is in the Y plane; and in the top or bottom view, the grid is in the Z plane. The procedure below allows you to adjust the grid size.

86 Customizing FeatureCAM

FeatureCAM 15.0 Getting Started

To adjust the grid: 1. Select Options > Snapping Grids from the menu. 2. In the Snapping Grids dialog, enter the grid coordinates.

Setting grid spacing too fine can slow the display down. 3. In the Section field enter the number of segments to divide the open geometry into when snapping to sections. 4. To have the grid redrawn during view shifts, select the Grid resizes to match block in standard views check box. 5. Choose the Grid Display option: Always show displays the grid, even if you have turned off snapping to grid. Always unshow hides the grid even if you have turned on snapping to grid. Automatic displays the grid only when you are snapping to grid. 6. Click OK.

Customizing toolbars
To customize an existing toolbar: 1. Select View > Toolbars from the menu. 2. In the Customize Toolbars dialog (Toolbars tab), select the check box next to the toolbar that you want to modify.

FeatureCAM 15.0 Getting Started

Customizing FeatureCAM 87

3. Click the Commands tab.

a. Select the command category. b. Drag the button from the Buttons frame to a location on your toolbar. 4. Repeat Step 3 until you have added all necessary commands. 5. Click OK. If you make a mistake, and want to revert to default settings, open the Customize Toolbars dialog again, select the toolbar, and click the Reset Selected button. To create your own toolbar: 1. Select View > Toolbars from the Menu bar. 2. In the Customize Toolbars dialog, click the New button on the Toolbars tab. 3. In the New Toolbar dialog, enter the name for your toolbar, and click OK.

A new empty toolbar is created. 4. Follow Steps 3 - 5 in the procedure above to add commands to your toolbar.

88 Customizing FeatureCAM

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling

You must have FeatureMILL2.5D to perform this tutorial. This tutorial uses a simple example to introduce you to: Creating features 3D viewing Generating toolpaths 3D toolpath simulation Automatic tool selection, feed/speed calculation Dynamically generated setup documentation The measurements in this tutorial are in inches; the values in millimeters are shown in brackets.

Creating a part file

1. Start FeatureCAM by double-clicking the FeatureCAM icon on the desktop. 2. If the New Part Document wizard is displayed, select the New file option, and click Next. Select Milling Setup, click Inch or Millimeter, depending on your preference, and click Finish. If the New Part Document wizard is not displayed, select File > New from the menu. Select Milling Setup, click Inch or Millimeter, depending on your preference, and click OK.

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling 89

3. In the Stock wizard (Dimensions page), enter 1 (25mm) for Thickness, 4 (100mm) for Width, 5 (120mm) for Length, and click Finish. Next time you use FeatureMILL, it will remember the stock dimensions that you entered last. In this tutorial, we assume that the stock has already been prepared. 4. Click OK to close the Properties dialog. For reference, here is a dimensioned drawing of the sample part: English Units

Metric Units

5. Create a hole feature. a. Select the Features step from the Steps panel.

b. In the New Feature wizard, select Hole in the From Dimensions frame, and click Next. c. Enter 0.5 (12mm) for the Diameter, and click Next. d. Enter 1.0 (25mm) for the X location of the hole center and 1.0 (25mm) for the Y location. e. Click Next.

90 Introduction to 2.5D milling

FeatureCAM 15.0 Getting Started

The Strategies page is presented. This page provides control over the types of operations that will be used to cut the feature. The default operations for a hole are to spot drill and drill the hole. If the hole has a chamfer, the default is to cut the chamfer with the spot drill operation. f. Accept the default strategy settings by clicking Next. The Operations page shows a summary of the operations that will be created to cut the feature. The names of the tools that have been automatically selected and the feeds and speeds are also displayed.

g. Click the triangle next to the Finish button, and select the Finish option. 6. Create a pocket feature. a. Select the Features step from the Steps panel.

b. In the New Feature wizard, select Rectangular Pocket in the From Dimensions frame, and click Next. c. Accept the default dimensions by clicking Next. d. Enter 0.75 (15mm) for X, 2.5 (60mm) for Y and 0 for Z. Click Next.

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling 91

The Strategies page indicates that rough and finish operations will be created.

e. Click the Finish button. step to create a second 0.5 (12mm) 7. Use the Features diameter hole at X=4 (95mm) and Y=3 (75mm). 8. Use the Features step to create another pocket just like the first, except positioned at X=2.5 (55mm), Y=0.5 (15mm). Your part in the Graphics window should look something like this:

9. Select Save from the File menu, and save the part as milling.fm.

92 Introduction to 2.5D milling

FeatureCAM 15.0 Getting Started

Viewing
1. So far you have been viewing the part from the top view. Click the button on the Standard toolbar to get a 3Isometric View dimensional view.

2. The Isometric View button is part of the Principle View menu. Click the triangle next to the button to access the menu, and select Front to display the front view of the part.

3. Click Isometric to return to the isometric view. See Interface tour (see page 42) for more information about pull-down menus. The sample part is complete. Now we will use the simulation features to see how the part will be manufactured.

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling 93

Toolpaths
1. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. button, and then click the Play button to start 2. Click the 3D the simulation. If the Automatic Ordering Options dialog appears, click OK to close it. The ordering options will be covered later. A solid 3D rendering of the cutting process is displayed.

FeatureMILL runs simulations best in 256 color mode or higher. Depending on your video settings, you might see a warning about this. You may ignore this warning for this tutorial.

94 Introduction to 2.5D milling

FeatureCAM 15.0 Getting Started

3. Click the Play to Next Operation operation is displayed.

button. The spot drill

4. Click this button to view each operation until the entire part is cut. 5. Click Eject screen. . The Simulation toolbar is removed from the

Order of manufacturing operations

The Op List tab in the Results window shows all of the operations that the features are translated into. A yellow warning sign next to an operation indicates a potential problem with that operation. If you see any warnings, ignore them. To use the automatic ordering options: 1. Ensure that the Automatic Ordering radio button is selected on the Op List tab. This means that automatic rules are being applied to order the operations. 2. Change automatic ordering to group together the operations which use the same tool. a. Click the Ordering Options button.

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling 95

b. In the Automatic Ordering Options dialog, ensure that only the Minimize tool changes check box is selected, and click OK.

3. Simulate the part. a. Select the Toolpaths b. Click the 3D Simulation button. step from the Steps panel. button, and then click the Play

The Simulation toolbar is displayed.

If the Automatic Ordering Options dialog appears, click OK to close it. Notice that the simulation first performs all the spot-drills, then the drills, and then the rough and finish milling for the pockets. c. Click the Stop button when simulation is complete to exit simulation mode. 4. Change automatic ordering to move the finish operations to the end of the list. a. Click the Ordering Options button. b. In the Automatic Ordering Options dialog, select Do Finish Cuts Last, deselect everything else, and click OK.

The order of operations has changed in the Operation List.

96 Introduction to 2.5D milling

FeatureCAM 15.0 Getting Started

5. Simulate the part. a. In the Simulation toolbar, click the Play b. Click the Stop button. The finish cuts for the two pockets are now cut last. button when simulation is complete. 6. Change automatic ordering to match the order of the features in the Part View panel. a. Click the Ordering Options c. Open the Part View panel. The tree view contains all the setups and features you have created. See Part View panel (see page 72) for more details. d. Click the rect_pock2 item in the Setup1 node, and drag it up above hole2. button. b. Deselect everything, and click OK.

7. Simulate the part. a. In the Simulation toolbar, click the Play b. Click the Stop button. The second pocket is now cut as the third feature. button when simulation is complete. So far the order of the operations was determined automatically by a set of rules. You can also specify an exact ordering of operations manually. To use the manual ordering options: 1. Select the Manual Ordering radio button on the Op. list tab.

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling 97

2. In the Fixed Operation Ordering dialog, select Do Not Show This Warning Again, and click OK.

3. Select the spotdrill operation for hole2 from the list, and drag it up ahead of the drill operation for hole1.

4. Simulate the part. a. In the Simulation toolbar, click the Play button. The simulation now performs the operations in the order that you had specified. b. Click the Stop button when simulation is complete. 5. Return to automatic ordering by selecting the Automatic Ordering radio button. 6. Click OK to close the Automatic Ordering Options dialog. If you want to erase the simulation and remove the button. Simulation toolbar, click the Eject

Part documentation
Not only did the simulation model the manufacturing of the part, it also generated complete tool and operations lists. The tools selected are based on the tool cribs you design so you're always sure to simulate what you can produce with the tools at hand. The information is already computerized and can be printed for use as an operator's checklist.

98 Introduction to 2.5D milling

FeatureCAM 15.0 Getting Started

1. Click the Details tab in the Results window. By default, the Manufacturing Operations sheet is shown.

You can review this sheet using the scroll bars, or print it by selecting Print from the File menu. 2. Select the Tool List option at the top of the Details tab to show the Manufacturing Tool Detail sheet.

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling 99

It contains all of the tools used to create the part based on the crib you have selected. You can print this documentation by selecting Print from the File menu.

Controlling the automation

1. Open the Part View panel, right-click hole1 under the Setup1 node, and select the Properties option.

2. In the Properties dialog, click the Strategy tab, deselect the Spot Drill check box, and click OK.

3. Select the Toolpaths

step from the Steps panel.

100 Introduction to 2.5D milling

FeatureCAM 15.0 Getting Started

4. In the Simulation toolbar, click the 3D button, and then click button to start the simulation. the Play There is no spot drilling for that hole this time. If you look through the operations list, notice there is now only one spotdrill operation listed. FeatureMILL can optimize the part manufacturing process for you, but you control the level of automatic optimization you want. 5. Click Eject screen. . The Simulation toolbar is removed from the

NC code
The purpose of FeatureMILL is to generate NC code to manufacture parts with CNC machines. After you have simulated the part, you can generate NC code. Before you can generate NC code for a part, you have to run a simulation to calculate toolpaths. If you are starting this part of the tutorial without having just run the simulation described above, simulate your part now (see page 94). To generate NC code: 1. Select the NC Code step from the Steps panel. button in the NC Code

2. Click the View the NC Code dialog to generate the NC code.

If you are running an evaluation copy of FeatureMILL, a dongle, a device that attaches to the computer printer port, is necessary to generate NC code, or save or export files and is not available in the demonstration version. When you purchase FeatureMILL, a dongle is provided to you.

Tool mapping
1. Select the NC Code step from the Steps panel. button in the NC Code dialog. 2. Click the Remap the Tools

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling 101

3. The Tool Mapping dialog is displayed showing the current tool order. You can use it to modify the location of the tools in the tool changer. For example, let's move the center drill to the 5th position in the tool changer.

a. Click Center_5 in the table. b. Change the Tool Number to 5 in the Slots frame. c. Click Set. You can't change the number directly in the table. 4. To save the changes, and close the Tool Mapping dialog, click OK.

Changing post processors

1. Select Manufacturing > Post Process from the menu. 2. In the Post Options dialog, click the Browse button to view available post processors. The default folder is C:\Program Files\FeatureCAM\Mlbry\Inch for English units. If you need a metric post, browse up one folder level to M-lbry. Then browse the Metric folder.

102 Introduction to 2.5D milling

FeatureCAM 15.0 Getting Started

3. Select your processor and click Open. The new processor is shown in the CNC File field. 4. Click OK to exit the Post Options dialog and use the new post processor; click Close to exit the dialog and keep the original post processor. 5. Select the Toolpaths step from the Steps panel.

6. Run a simulation of the part to regenerate the NC code.

Saving NC code
1. Select the NC Code 2. Click the Save NC step from the Steps panel. button in the NC Code dialog.

3. In the Save NC dialog, accept the default filename and folder, and click OK. You are now ready to machine the part.

You have completed this tutorial.

FeatureCAM 15.0 Getting Started

Introduction to 2.5D milling 103

Features from curves

You must have FeatureMILL to perform this tutorial. We recommend that you complete the Introduction to 2.5D milling (see page 89) tutorial before starting this one. This tutorial builds on the one you just completed and introduces you to: Creating geometry (lines, arcs, fillets, and so on) Creating irregularly-shaped features Contouring around a part and adjusting where the tool plunges

104 Features from curves

FeatureCAM 15.0 Getting Started

Getting started
In the next sections we will build a curve around the features. The curve is created with the layout tools and drawing tools. 1. Select File > Open from the menu. 2. In the Open dialog, browse to the part file you created in the Introduction to 2.5 D milling (see page 89) tutorial.

If you skipped the earlier tutorial, browse to the sample2.fm file (in inches), or the mtrc_gsg.fm file (in metric units). If you installed FeatureCAM in the default folder, these files are in C:\Program Files\FeatureCAM\Examples\Tutorials\Features from Curves. 3. Click Open.

FeatureCAM 15.0 Getting Started

Features from curves 105

Setting the snaps

1. Select Options > Snapping Modes from the menu. 2. In the Snap Modes dialog, click the following buttons: Grid points, End points, Intersections, Circle centers, Tangent to objects, Display snap mode dialog.

Selected buttons have pale grey borders around them. 3. Ensure the rest of the geometry creation buttons are not selected. If you want to have the Snap Mode toolbar displayed on the screen, select the Show Snap Mode toolbar check box. 4. Click OK to close the dialog.

Building circles
1. Click the triangle next to the button in the Principal View menu in the Standard toolbar, and select the Top option. It is usually easier to draw geometry in this view. For more information about the toolbar options, refer to the Interface tour (see page 42). 2. Select the Geometry step from the Steps panel.

3. In the Geometry Constructors dialog, select the Create more than one check box at the bottom of the dialog, and click the button. Circle from Rad, Center

106 Features from curves

FeatureCAM 15.0 Getting Started

4. In the Feature/Geometry Edit bar, enter R = 0.75 inch (20mm). 5. In the Graphics window, click near the center of one hole. The snap jumps to the grid at the hole's center. If you miss the hole on the Standard toolbar and try again. center, click Undo

Repeat this action for the other hole. Your part now looks similar to the figure below:

Drawing lines
1. Select the Geometry step from the Steps panel. 2. In the Geometry Constructors dialog, ensure the Create more than one check box is selected, and click the Line from 2 button. Pts 3. Use the diagram below to draw lines in the Graphics window:

FeatureCAM 15.0 Getting Started

Features from curves 107

a. To create the first point x1, click the top of the right circle. If more than one snap possibility exists for the point you are creating, the Snap Discrimination dialog opens. Select the Tangent to circle option, and click OK. b. For the second point x2 click the upper left grid point. c. Continue building lines from point x2 to point x3, from point x4 to point x5, and from point x5 to point x6. 4. Create corner fillets. a. Select the Geometry step from the Steps panel.

b. In the Geometry Constructors dialog, ensure the Create more than one check box is selected, and click the Corner button. Fillet c. In the Feature/Geometry Edit bar, enter R = 0.75 inch (20mm). d. Position the mouse in the upper left corner, and click. A corner fillet appears automatically trimming the lines to fit.

e. Position the mouse in the lower right corner. A corner fillet appears automatically trimming the lines to fit.

108 Features from curves

FeatureCAM 15.0 Getting Started

The drawing should look something like this:

Chaining a curve
1. Click the Curves step from the Steps panel. 2. In the Curves Creation dialog, select the Closed Curve button. 3. In the Graphics window, click the bottom line.

FeatureMILL automatically chains a closed curve, and chooses a smooth path so you dont have to chain all curves manually.

FeatureCAM 15.0 Getting Started

Features from curves 109

Creating a feature from a curve

1. With the curve still highlighted in the Graphics window, select the Features step from the Steps panel.

2. In the New Feature wizard, select Boss in the From Curve frame, and click Next.

The curve you selected is already selected in the wizard. 3. Keep clicking Next until you get to the Dimensions page. 4. Set the Height to 0.75 (20mm). 5. Click Finish.

110 Features from curves

FeatureCAM 15.0 Getting Started

Simulating the part

You are now ready to simulate your part. 1. Click the Isometric View to get a 3-dimensional view. 2. Select the Toolpaths button on the Standard toolbar

step from the Steps panel.

button, and then click 3. In the Simulation toolbar, click the 3D button to start the simulation. If the Automatic the Play Ordering Options dialog appears, click OK to close it. The 3D simulation is displayed in the Graphics window.

4. Click Eject screen.

. The Simulation toolbar is removed from the

Modifying the boss feature to contour around the part

If you watched the simulation carefully, you saw that the boss feature performed both a roughing and finishing operation. To simply contour around the outer boundary of the part, you need to eliminate the roughing operation. The operations that are initially created for a feature are specified on the Strategies page of the New Feature wizard, but you can easily modify the strategy for any existing feature. To modify the feature's strategy: 1. In the Graphics window, select the boss1 feature.

FeatureCAM 15.0 Getting Started

Features from curves 111

2. Click the Properties button in the Feature/Geometry Edit bar. The Properties dialog opens. It contains the pages of the New Feature wizard as separate tabs. 3. Click the Strategy tab. Notice that the Rough and Finish check boxes are selected. Deselect the Rough check box, and click OK.

4. Select the Toolpaths

step, and simulate the part.

Changing the plunge point

During the simulation, you saw that the tool ramped on and off the part at the location where you chained the curve. At the moment, the tool is plunging on the stock. Let's modify the plunge point for this operation. To change the plunge point: 1. Click the triangle next to the button in the Principal View menu in the Standard toolbar, and select the Top option. 2. In the Graphics window, select the boss1 feature, and click the Properties button in the Feature/Geometry Edit bar.

112 Features from curves

FeatureCAM 15.0 Getting Started

The Properties dialog opens. The left-hand side of the dialog contains the tree view. It shows the feature with its operations listed underneath. By clicking on an operation in the tree view, you can modify an operation.

3. Click the finish operation in the tree view. The tabs of the dialog change to represent information specific to the operation. 4. Click the Milling tab. This tab contains the various attributes for changing the toolpaths that are generated for the operation. 5. Select the Plunge points attribute, and click the Pick Location button. The Properties dialog warps away, and the cursor point changes its shape. 6. Click at a location below the part.

7. Click OK to close the dialog. 8. Simulate the part.

FeatureCAM 15.0 Getting Started

Features from curves 113

a. Select the Toolpaths

step from the Steps panel.

b. In the Simulation toolbar, click the Show Centerline button, and then click the Play button to view the changes in the toolpath. If you pick a location that is too close to the part, the plunge point is ignored, and the toolpaths will remain unchanged. You have completed this tutorial.

114 Features from curves

FeatureCAM 15.0 Getting Started

Introduction to turning

You must have FeatureTURN or FeatureTURN/MILL to perform this tutorial. The example in this tutorial is a simple turned part designed to introduce you to several of the drawing and machining tools available in FeatureTURN. The tutorial walks you through creating the part and introduces you to FeatureTURN's automation and ease of use. The measurements in this tutorial are in inches; the values in millimeters are shown in brackets.

Getting started
In the next sections we will be using FeatureTURN. If you don't have a license for this module, but would like to evaluate it: 1. Start FeatureCAM by double-clicking the FeatureCAM icon on the desktop. 2. From the File menu, choose Evaluation Options, and make sure Turning is selected. 3. Click OK.

Create a part file

1. If the New Part Document wizard is displayed, select the New File radio button, and click Next. Select Turn/Mill, click Inch or Millimeter, depending on your preference, and click Finish.

FeatureCAM 15.0 Getting Started

Introduction to turning 115

If the New Part Document wizard is not displayed, select File > New from the menu. Select Turn/Mill, click Inch or Millimeter, depending on your preference, and click OK. 2. Create the stock. a. In the Stock wizard (Dimensions page), set the OD to 4 (100mm), Length to 5 (125mm), and ID to 0, and click Next. A turning setup defaults to a round stock. b. Click the triangle next to the Finish button, and select the Finish and Edit Properties option.

c. In the Properties dialog, set Z to 0.0625 (1.5mm), and click OK. 3. Select Options > Turning Input Modes > 3D (XYZ) from the menu. 4. Select Manufacturing > Set Tool Crib from the menu, choose the Tools option in the Select Active Tool Crib dialog, and click OK. 5. Click the triangle of the View menu on the Standard toolbar, and choose the Center All option to bring your entire drawing into view. Your part should look something like this:

6. Draw two lines. a. Select the Geometry step from the Steps panel.

b. In the Geometry Constructors dialog, ensure the Create more than one check box is selected, and click the Line button. from 2 pts

116 Introduction to turning

FeatureCAM 15.0 Getting Started

c. In the Feature/Geometry Edit bar, enter the following values to create two lines that define the OD profile: point 1: X=2 (50mm); Y=0, Z= -3.5 (-88mm) point 2: X=1 (25mm), Y=0, Z= -3.5 (-88mm) Press Enter. A line is drawn in the Graphics window. d. Create a second line with the values: point 1: X=1 (25mm), Y=0, Z= -3.5 (-88mm) point 2: X=1 (25mm), Y=0, Z=0 Press Enter. Your part now looks something like this:

7. Create a chamfer to trim your lines. a. Select the Geometry step from the Steps panel.

b. In the Geometry Constructors dialog, click the Chamfer button in the list of Fillet commands. c. In the Feature/Geometry Edit bar, enter width=0.25 (6mm) and height=0.25 (6mm). d. Position your mouse close to the chamfer location as shown in the figure below. The chamfer snaps into place.

e. Click once to place the chamfer on your drawing. The chamfer automatically trims your lines. 8. Create third line. It will be used to create a bore feature later. a. Select the Geometry step from the Steps panel.

b. In the Geometry Constructors dialog, click the Line from button. 2 pts

FeatureCAM 15.0 Getting Started

Introduction to turning 117

c. In the Feature/Geometry Edit bar, enter the following values: point 1: X=0.625 (16mm), Y=0, Z=0 point 2: X=0.625 (16mm), Y=0, Z= -3.75 (-94mm) d. Press Enter. 9. Chain the trimmed lines into curves. a. Select the Curves step from the Steps panel.

b. In the Curves Creation dialog, select the Pick Curve Pieces button.

c. In the Graphics window, click locations 1, 2, 3 as shown in the figure below. Each line segment changes color when it is selected.

d. In the Feature/Geometry Edit bar, name the curve turn, and press Enter. 10.Chain the Bore ID curve. a. Select the Curves step from the Steps panel.

b. In the Curves Creation dialog, click the Pick Curve Pieces button. c. In the Graphics window, click locations 4 and 5, as shown above. d. In the Feature/Geometry Edit bar, name the curve bore, and press Enter.

118 Introduction to turning

FeatureCAM 15.0 Getting Started

Making features
1. Use the 2D Turned Profiles button, on the Display Mode toolbar, to switch to a simplified 2D representation of your part. 2. Create a turn feature. a. Select the Features step from the Steps panel.

b. If you have the Turn/Mill module, the New Feature wizard asks you which type of feature you want to create. Select the Turning radio button, and click Next.

c. Select Turn in the From Curve frame, and click Next. d. Select the curve graphically: In the Curve field select turn from the drop-down list. Click the Pick Curve button. The dialog minimizes to reveal the Graphics window beneath. Click the curve you named turn earlier.

FeatureCAM 15.0 Getting Started

Introduction to turning 119

In this particular case, two objects are available for selection: a line and a curve. Whenever your selection needs to be clarified, FeatureCAM opens the Select dialog. In the Select dialog, choose turn, and click OK. e. Click Next. Your drawing should look something like this:

f. Click the triangle next to the Finish button, and select the Finish and Create More option to continue creating features. 3. Create a face feature. a. If the New Feature wizard asks you which type of feature you want to create, select the Turning radio button, and click Next. b. Select Face in the From Dimensions frame, and click Next. c. Set Outer Diameter to 4 (100mm), Inner Diameter to 0, Thickness to 0.0625 (1.5mm). A face feature automatically knows the OD and ID values from the stock properties. d. Click Finish. 4. Create a hole feature. a. If the New Feature wizard asks you which type of feature you want to create, select the Turning radio button, and click Next. b. Select Hole in the From Dimensions frame, and click Next. c. On the Dimensions page, set the Diameter to 1.0 (24mm), Depth to 3.75 (94mm). d. Click Next, and set Z to 0.

120 Introduction to turning

FeatureCAM 15.0 Getting Started

Your drawing should look something like this:

e. Click Finish. 5. Create a bore feature by using the same process you used to create the turn feature. Use the curve you named Bore.

6. Create a groove feature. a. If the New Feature wizard asks you which type of feature you want to create, select the Turning radio button, and click Next. b. Select Groove in the From Dimensions frame, and click Next. c. On the Dimensions page, set Location to ID, Orientation to X-axis, Diameter to 1.25 (31mm), Depth to 0.125 (3mm), Width to 0.250 (6mm). Leave the other settings at 0. d. Click Next, and set Z to -3 (-75mm).

FeatureCAM 15.0 Getting Started

Introduction to turning 121

Your drawing should look something like this:

e. Click Finish. 7. Create a thread feature. a. If the New Feature wizard asks you which type of feature you want to create, select the Turning radio button, and click Next. b. Select Thread in the From Dimensions frame, and click Next. c. On the Dimension page, select Get the thread dimensions from a standard thread, click OD, and select the 2.00004.5 UNC (M50-15 for metric) in the Designation field. d. Click Next. e. On the Dimensions page, set Thread to Right hand, Thread Length to1.0 (24mm), and click Next. Your drawing should look something like this:

f. Click Finish. 8. Create a cutoff feature. a. If the New Feature wizard asks you which type of feature you want to create, select the Turning radio button, and click Next. b. Select Cutoff in the From Dimensions frame, and click Next.

122 Introduction to turning

FeatureCAM 15.0 Getting Started

c. On the Dimensions page, set Diameter to 4 (100mm), Inner Diameter to 0, Width to 0.122 (3mm). d. Click Next and set Z to 4.5 (112mm). Your drawing looks something like this:

e. Click Finish.

Viewing
1. Click the 2D Turned Profiles button, on the Display Mode toolbar, to return to a 3-dimensional view of the model. 2. Click the Isometric View button on the Standard toolbar.

3. Shade the part. a. Open the Part View panel, and select bore1 under the Setup1 node. b. Click the Shade Selected toolbar. button on the Display Mode

FeatureCAM 15.0 Getting Started

Introduction to turning 123

c. Select thread1, and click the button again.

button on the Display Mode toolbar 4. Click the Unshade All to return to the line drawing view. The sample part is complete. Now the simulation features will be used to see how the part will be manufactured.

Toolpaths
1. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. button, and then click the Play button to start 2. Click the 3D the simulation. If the Automatic Ordering Options dialog appears, click OK to close it. The ordering options will be covered later.

124 Introduction to turning

FeatureCAM 15.0 Getting Started

A solid 3D rendering of the cutting process is displayed. By default, the 3/4 view is shown when cutting or drilling the ID of the part. You can control this setting by selecting Options > Simulation from the menu.

FeatureCAM runs simulations best in 256 color mode or higher. Depending on your video settings, you might see a warning about this. You may ignore this warning for this tutorial. 3. Click the Play to Next Operation operation is displayed. 5. Click Eject screen. button. The face

4. Click this button to view each operation until the entire part is cut. . The Simulation toolbar is removed from the

Ordering of operations
The Op List tab in the Results window shows all of the operations that the features are translated into. A yellow warning sign next to an operation indicates a potential problem with that operation. If you see any warnings, ignore them. The ordering can be automatic or manual. Automatic ordering You can control the automatic ordering of operations by using either rules or operation templates. Using rules is similar to the way you used automatic ordering in the 2.5D Milling tutorial (see page 95).

FeatureCAM 15.0 Getting Started

Introduction to turning 125

In this section we will change the automatic ordering by modifying the Turn Operation template. This template lists the manufacturing order of the various turning features. To modify the template: 1. Click the Ordering options Results window. button on the Op List tab in the

The Automatic Ordering Options dialog opens. 2. Select the Use template radio button, and click Edit template. 3. In the Feature Order dialog, click Rough OD Turn.

4. Click the down arrow until the item is located under the Finish ID Turn operation. 5. Click Finish OD Turn, and click the down arrow until the item is located under Finish ID Turn. 6. Click OK to close the Feature Order dialog. 7. Click OK to close the Automatic Ordering Options dialog. 8. Simulate the part. a. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. b. Click the 3D button, and then click the Play button. Notice that the OD roughing and finishing now happen after the hole is drilled. c. Click the Stop button when simulation is complete to exit simulation mode.

126 Introduction to turning

FeatureCAM 15.0 Getting Started

Manual ordering You can specify an exact ordering of operations manually, the same way as you did in the 2.5D Milling tutorial (see page 95).

Part documentation
FeatureTURN automatically generates the part documentation, which you can view by clicking the Details tab in the Results window. The Manufacturing Operation List is shown by default. It contains information such as machining time, selected tools, feeds and speeds, and horsepower requirements for the various operations. Each operation of the process plan is listed in order. The Tool List is displayed by selecting the Tool List radio button at the top of the Details tab. It contains a summary of all the tools needed for the job as well as details of each tool. You can print this documentation by selecting Print from the File menu.

NC code
After you have simulated the part, you can generate NC code. FeatureTURN comes with many post processors and the ability to create custom post processors as well. Before you can generate NC code for a part, you have to run a simulation to calculate toolpaths. If you are starting this part of the tutorial without having just run the simulation described above, simulate your part now (see page 124). To generate NC code: 1. Select the NC Code step from the Steps panel. button in the NC Code

2. Click the View the NC code dialog to generate the NC code.

If you are running an evaluation copy of FeatureTURN, a dongle (a device that attaches to the computer printer port) is necessary to generate NC code, or save or export files and is not available in the demonstration version. When you purchase FeatureTURN, you will receive a dongle.

FeatureCAM 15.0 Getting Started

Introduction to turning 127

Changing post processors

If you are running FeatureTURN, the default post processor is for a Bridgeport machine. Follow the steps to change your post processor and generate the NC code. 1. From the Manufacturing menu, select the Post Process option. 2. In the Post Options dialog, click the Browse button to view available post processors. The default folder is C:\Program Files\FeatureCAM\Tlbry\Inch for English units. If you need a metric post, browse up one folder level to T-lbry. Then browse the Metric folder. 3. Select your processor and click Open. The new processor is shown in the CNC File field. 4. Click OK to exit the Post Options dialog and use the new post processor; click Close to exit the dialog, and keep the original post processor. 5. Select the Toolpaths regenerate the NC code. step, and run a simulation of the part to

Saving NC code
1. Select the NC Code 2. Click the Save NC step from the Steps panel. button in the NC Code dialog.

128 Introduction to turning

FeatureCAM 15.0 Getting Started

3. In the Save NC dialog, accept the default filename and folder, and click OK. You are now ready to machine the part.

You have completed this tutorial.

FeatureCAM 15.0 Getting Started

Introduction to turning 129

Advanced turning and machine simulation

You must have FeatureTURN, Multi-turret Turning, and Machine Simulation to perform this tutorial. You also need the Solid plugin installed. This tutorial introduces you to: Creating subspindles. Using machine simulation. Setting up a second turret. Synchronizing operations.

130 Advanced turning and machine simulation

FeatureCAM 15.0 Getting Started

Getting started
1. Select File > Open from the menu. 2. In the Open dialog, browse to the tutorial file twinturret_tutorial.fm. If you installed FeatureCAM in the default folder, it is in C:\Program Files\FeatureCAM\Examples\Tutorials\Multi-turret Turning.

3. Click Open.

Setting up machine simulation

1. Select the machine simulation design file for your setups. a. Click the Setups button on the Advanced toolbar. If the toolbar is not displayed, select View > Toolbars from the menu, select the Advanced check box in the Customize Toolbars dialog, and click OK.

FeatureCAM 15.0 Getting Started

Advanced turning and machine simulation 131

b. In the Setups dialog, select Setup1 from the drop-down list, and click Edit.

c. In the Setup wizard, keep clicking Next until you get to the Setup > Simulation information page. d. Select the Always use this one radio button. e. Click the Browse button and open the TURNING_INDEX_G200.md. If you installed FeatureCAM in the default folder, the file is in C:\Program Files\FeatureCAM\Examples\Tutorials\Multi-turret Turning. f. Click Finish to close the wizard and return to the Setups dialog. g. Repeat the previous steps to select the simulation design file for Setup2. h. In the Setups dialog, change the Current Setup back to Setup1 and click Close. 2. Select the post processor. a. From the Manufacturing menu, select Post Process.

132 Advanced turning and machine simulation

FeatureCAM 15.0 Getting Started

b. In the Post Options dialog (Turn/Mill page), click Browse, select the Moriseiki with Mitsubishi Mill-turn upper and lower example.CNC file, and click Open.

If you installed FeatureCAM in the default folder, the file is in C:\Program Files\FeatureCAM\Examples\Tutorials\Multi-turret Turning. c. In the Tool Change Location field, enter X = 18 and Z =0. d. Click OK. 3. Simulate the part. a. Select the Toolpaths step from the Steps panel.

b. In the Simulation toolbar, click the Machine Simulation button, and then select the Single Step button. If the Automatic Ordering Options dialog appears, click OK to close it. You should now see the machine displayed on your screen. (You may need to zoom out to see the machine.)

FeatureCAM 15.0 Getting Started

Advanced turning and machine simulation 133

c. Click the Play button. You should now see the machine parts moving and cutting the part.

You can right-click the part in the Graphics window during simulation, and use the options in the View menu to get a better view of the machine and the part without having to pause the simulation. 4. Click Eject screen. . The Simulation toolbar is removed from the

Adding a subspindle feature

So far only a single spindle was used in the part simulation. Let's introduce a second spindle, to the part setup. 1. Open the Part View panel, and select the Setup1 node. A number of spindle and subspindle features are already there.

2. Add a new subspindle feature to Setup1.

134 Advanced turning and machine simulation

FeatureCAM 15.0 Getting Started

a. Select the Features

step from the Steps panel.

b. If the New Feature wizard asks you which type of feature you want to create, select the Turning radio button, and click Next. c. Select Subspindle, and click Next. d. On the Dimensions page, select Sub Spindle and Position the Spindle radio buttons, and click Next. e. On the Location page, select the Send subspindle home check box. f. Click the triangle next to the Finish button, and select the Finish option. 3. Open the Part View panel. The new subspindle feature ss1 is added to the Setup1 node. 4. Right-click ss1, and select Rename.

5. In the Rename Object dialog, enter sub_home as the new name, and click OK. Now Setup1 contains all necessary spindle and subspindle moves.

FeatureCAM 15.0 Getting Started

Advanced turning and machine simulation 135

Adding a bar feed feature

1. Open the Part View panel, and select the Setup1 node. 2. Select the Features step from the Steps panel.

3. If the New Feature wizard asks you which type of feature you want to create, select the Turning radio button, and click Next. 4. Select Bar Feed in the From Dimensions frame, and click Next. 5. On the Dimensions page, enter 3.0 for Diameter and 4.2 for Feed Amount. 6. Click the down arrow next to the Finish button, and select the Finish and Edit Properties option. 7. In the Properties dialog, enter 4.2 for the Z location, and click OK.

Running a subspindle simulation

1. Open the Part View panel, and select all check boxes. 2. Right-click the Operation column header on the Op List tab in the Results window, and select the Show Setup option.

This displays a new column in the Operation List called Setup Name. This column indicates which spindle is used to run an operation. All the features listed under Setup1 in the Part View have the setup name of Main spindle in the Operation List. These features are cut on the main spindle of the machine. Features listed under Setup2 are cut on the subspindle. 3. Press the CTRL key and select the last two operations in the Operation List.

136 Advanced turning and machine simulation

FeatureCAM 15.0 Getting Started

4. Drag the lines up and place them right below the cutoff operation for the cutoff1 feature. 5. Select the Toolpaths step from the Steps panel.

6. In the Simulation toolbar, click the Machine Simulation button. button. You should now see the machine parts 7. Click the Play moving and cutting the part on both the main spindle and the subspindle. The operations are simulated twice. This is done to show how production turning works. This feature will become more apparent at the end of this tutorial. 8. Click Eject screen. . The Simulation toolbar is removed from the

Setting up the second turret

1. Right-click the Operations column header on the Op List tab in the Results window, and select the Show Turret option.

The Tool Name column now contains the turret number (P1) to the left of the tool name. 2. Let's set all subspindle operations to lower turret. a. Select the first subspindle operation in the list, hold down the Shift key and select the last operation. b. Right-click, and select the Set opers to Lower turret option. The turret number for these operations changes from P1 to P2, showing that the operations now run on the machine's second, or lower, turret.

FeatureCAM 15.0 Getting Started

Advanced turning and machine simulation 137

Synchronizing operations
1. Click the Turrets tab in the Results window and select Time view. The Time view contains the Spindle list on the left, and the Timeline for operations performed on each turret on the right. The operations are represented as boxes; the box length indicates the machining time in minutes. You can view the operation's details by placing the mouse over a box. 2. Roll the mouse wheel to scale the view. If you need more screen space, collapse the Toolbox, and resize the Results window. 3. Select the last drill operation block in the Sub Spindle section, then press and hold the Ctrl key and select the off Main spindle operation block in the Main Spindle section. 4. Right-click and select the option Set sync for radial_pattern1.hole2.drill before main_off. Main spindle off.

The operations order has changed, and a new synchronization point is set. The off Main spindle operation after the hole2 drill operation . is now performed

138 Advanced turning and machine simulation

FeatureCAM 15.0 Getting Started

5. Press the Ctrl key and select the bore2 finish operation block in the Main Spindle section, and the bore1 rough pass 1 operation block in the Sub Spindle section. 6. Click the right mouse button and select the option Set sync for bore2.finish before bore1.rough pass 1. You should now have two synchronization points set.

Running synchronized multi-turret simulation

1. If necessary, expand the Toolbox, and adjust the Results window so that the Graphics window is shown. 2. Select the Toolpaths step from the Steps panel.

3. In the Simulation toolbar, click the Machine Simulation button. 4. Click the Play button. Now both turrets are running in a synchronized fashion, based on the synchronization points that we set earlier. 5. Click Eject screen. . The Simulation toolbar is removed from the

You have completed this tutorial.

FeatureCAM 15.0 Getting Started

Advanced turning and machine simulation 139

Introduction to turn/mill

You must have licensed the Turn/Mill option to run this tutorial. This tutorial is only available in inch units. This tutorial introduces you to: Creating parts for lathes with milling capabilities. Mixing turning and milling features. Creating milling features on the OD and face of the part. Simulating a turn/mill part.

Getting started
1. Start FeatureCAM by double-clicking the FeatureCAM icon on the desktop. 2. If the New Part Document wizard is displayed, select the New file option, and click Next. Select Turn/Mill, click Inch, and click Finish. If the New Part Document wizard is not displayed, select File > New from the menu. Select Turn/Mill, click Inch, and click OK. 3. In the Stock wizard (Dimensions page), enter 3 for the OD, 2 for the Length, and 0 for the ID. If the wizard does not open automatically, select the Stock step from the Steps panel.

140 Introduction to turn/mill

FeatureCAM 15.0 Getting Started

A turn/mill setup defaults to a round stock. 4. Click the triangle next to the Finish button, and select the Finish option. 5. Click the triangle of the View menu on the Standard toolbar, and choose the Center All option to bring your entire drawing into view. Your part should look something like this:

6. Select Options > Turning Input Modes > Diameter from the menu.

Creating a turn feature

1. Draw three lines. a. Select the Geometry step from the Steps panel.

b. In the Geometry Constructors dialog, ensure the Create More Than One check box is selected, and click the Connected Lines button. c. In the Feature/Geometry Edit bar, enter the following values to create lines that define the OD profile: point 1: D1=2.5, Z1= 0 point 2: D2=2.5, Z= 1.5 Press Enter. A line is drawn in the Graphics window. Create a second line with the values: point 2: D2=2.75, Z= 1.5

FeatureCAM 15.0 Getting Started

Introduction to turn/mill 141

Press Enter. Create a third line: point 2: D2=2.75, Z= 2.0 Press Enter. Your part now looks something like this:

2. Create a corner fillet. a. Select the Geometry step from the Steps panel.

b. In the Geometry Constructors dialog, click the Corner button. Fillet c. In the Feature/Geometry Edit bar, enter R = 0.125. d. Position the mouse in corner between the first and the second lines, and click. A corner fillet appears automatically trimming the lines to fit.

3. Chain the lines into curves.

142 Introduction to turn/mill

FeatureCAM 15.0 Getting Started

a. Select the Curves

step from the Steps panel.

b. In the Curves Creation dialog, select the Pick Curve Pieces button.

c. In the Graphics window, click the first and third lines.

d. In the Feature/Geometry Edit bar, name the curve Turn, and press Enter. 4. Create a turn feature. a. Select the Features step from the Steps panel.

b. When the New Feature wizard asks you which type of feature you want to create, select the Turning radio button, and click Next. c. Select Turn in the From Curve frame, and click Next. The Turn curve is already selected in the Curve field. d. Click the triangle next to the Finish button, and select the Finish option.

FeatureCAM 15.0 Getting Started

Introduction to turn/mill 143

Your drawing should look something like this:

Viewing
1. Click the Isometric View button on the Standard toolbar.

2. Open the Part View panel, and select turn1 under the Setup1 node. 3. Click the Shade Selected toolbar to shade the feature. button on the Display Mode

144 Introduction to turn/mill

FeatureCAM 15.0 Getting Started

If the toolbar is not displayed, select View > Toolbars from the Menu bar, and select the Display Mode check box in the Customize Toolbars dialog.

button on the Display Mode toolbar 4. Click the Unshade All to return to the line drawing view. 5. Click the triangle next to the button in the Principal View menu in the Standard toolbar, and select the Top option.

Creating a radial hole pattern on the face

1. Use the 2D Turned Profiles button, on the Display Mode toolbar, to switch to a simplified 2D representation of your part.

2. Create a hole. a. Select the Features step from the Steps panel.

FeatureCAM 15.0 Getting Started

Introduction to turn/mill 145

b. When the New Feature wizard asks you which type of feature you want to create, select the Turn/Mill radio button, and click Next. c. Select Hole in the From Dimensions field and click Next. d. Set Chamfer to 0.0, Depth to 1.0, and Diameter to 0.25. e. Click the triangle next to the Finish button, and select the Finish option. 3. Create a pattern from feature: a. Select the Features step from the Steps panel.

b. When the New Feature wizard asks you which type of feature you want to create, select the Turn/Mill radio button, and click Next. c. Select Pattern in the From Feature field and click Next. d. Select the hole you just created to create the pattern from and click Next. e. Select the Radial in the setup XY plane radio button, and click Next. f. On the Pattern - Dimensions page, set Number to 3.0, Diameter to 2.0, Spacing Angle to 120, and Angle to 60. g. Click the triangle next to the Finish button, and select the Finish option. 4. View the results. a. Click the 2D Turned Profiles button, on the Display Mode toolbar, to return to 3D line drawing view. b. Click the Isometric View toolbar. button on the Standard

Your drawing should look something like this:

146 Introduction to turn/mill

FeatureCAM 15.0 Getting Started

Engraving on the face

1. Create a curve. a. Select the Curves step from the Steps panel.

b. In the Curves Creation dialog, select the Curve Wizard button. c. In the Curve wizard, select Other methods as the construction method, Text as the constructor, and click Next.

d. On the Engraving Text page, configure the text properties.

Enter TURNMILL as Text, select Linear as Path type. Enter 0.0, -0.045, 0.0 as the X, Y and Z locations. Enter -90 into the Angle field.

FeatureCAM 15.0 Getting Started

Introduction to turn/mill 147

Select Center in the Justification field. Enter 0.4 for both the X and Y Scaling. Click the Font button, select Machine Tool Gothic for the font type, and 72 for the font size in the Font dialog, and click OK. e. Click Finish to close the wizard. 2. Create a groove feature. a. Select the text string (curve1) in the Graphics window, and select the Features step from the Steps panel.

b. When the New Feature wizard asks you which type of feature you want to create, select the Turn/Mill radio button, and click Next. c. Select Groove in the From Curve field, and click Next until you get to the Dimensions page. d. On the Dimensions page, set Width to 0.0625, Depth to 0.02, and ensure that the Simple check box and the Face radio button are selected. e. Click the triangle next to the Finish button, and select the Finish option. Your part should look something like this:

148 Introduction to turn/mill

FeatureCAM 15.0 Getting Started

Creating a pattern of wrapped slots

1. Select the Features step from the Steps panel. 2. Select Turn/Mill as the feature type, and click Next. 3. Select Slot in the From Dimensions frame, select the Make a pattern from this feature check box, and click Next. 4. Set Length to 1.0, Width to 0.5, Depth to 0.25, and click Next. 5. Select the Radial around index axis radio button, and click Next. 6. Set B Angle to 90, Radius to 1.25, Z to 0.25 and click Next. 7. Set Number to 3 and Spacing Angle to 120. 8. Click the triangle next to the Finish button, and select the Finish option. Your part should look something like this:

Simulating a turn/mill part

1. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. button, and then click the Play 2. Click the 3D Simulation button to start the simulation. If the Automatic Ordering Options dialog appears, click OK to close it.

FeatureCAM 15.0 Getting Started

Introduction to turn/mill 149

A solid 3D rendering of the cutting process is displayed. Notice how the toolpaths are accurately simulated including the part rotations.

FeatureCAM runs simulations best in 256 color mode or higher. Depending on your video settings, you might see a warning about this. You may ignore this warning for this tutorial. 3. Click Eject screen. . The Simulation toolbar is removed from the

You have completed this tutorial. If you want to see more examples of turn/mill parts, look in the Examples/Turnmill folder.

150 Introduction to turn/mill

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models

You must have FeatureMILL with the FeatureRECOGNITION option or FeatureMILL3D to perform this tutorial. You also need the Solid plugin installed. This tutorial is only available in metric units. In this tutorial you will learn how to: Import 3D models. Dynamically shade 3D models. Create features directly from 3D solid models using both automatic feature recognition and more interactive methods.

Getting started
You must have metric tools loaded into the tool database to perform this tutorial. To add metric tools to your database: 1. Select Exit from the File menu to close FeatureCAM. 2. From the Start menu, select All Programs > FeatureCAM > INITDB. You can also run Initdb.exe from the folder where FeatureCAM is installed.

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models 151

3. In the Tool and Material Setup dialog, select the On my local computer radio button, and click Next. 4. Select Both as the tools to load, and click Next. 5. Select Inch or Metric to indicate which tool type you use more often, and click Next. 6. Click Finish.

Importing the CAD model

1. Start FeatureCAM by double-clicking the FeatureCAM icon on the desktop. 2. If the New Part Document wizard is displayed, select the New file option, and click Next. Select Milling Setup, click Millimeter, and click Finish. If the New Part Document wizard is not displayed, select File > New from the menu. Select Milling Setup, click Millimeter, and click OK. 3. In the Stock wizard (Dimensions page), click the triangle next to the Finish button, and select the Finish option. 4. Select File > Import/Export Options from the menu. 5. In the Import/Export Options dialog, select the Center stock automatically check box on the General tab.

152 Creating features from 3D CAD models

FeatureCAM 15.0 Getting Started

6. Click the Solid Import tab, ensure the Import file as solids check box is selected, and click OK.

7. Select File > Import from the menu. 8. In the Import dialog, select Acis as Files of type, and open the file Tutor9.sat. If you installed FeatureCAM in the default folder, the file should be in C:\Program Files\FeatureCAM\Examples\Tutorials\3D models. 9. In the Import Results wizard, select the Use the wizard... radio button, and keep clicking Next until you get to the Stock Dimensions page. 10.Select Use the wizard option in the Import Results dialog and keep clicking Next until you get to the Stock Dimensions page. 11.Select Compute stock size from the size of the part, ensure all of the Extra stock size fields are set to 0 and click Finish.

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models 153

12.The imported part should look something like this:

Aligning the model

1. Open the Part View panel, and select solid1 under the Solids node.

This is the solid model you have just imported. button on the Standard toolbar. 2. Click the Isometric View The stock has been resized, but the setup is located at the center of the stock.

3. Click the Setups

button on the Advanced toolbar.

154 Creating features from 3D CAD models

FeatureCAM 15.0 Getting Started

If the Advanced toolbar is not displayed, select View > Toolbars from the menu, select the Advanced check box in the Customize Toolbars dialog, and click OK. 4. In the Setups dialog, select Setup1 from the drop-down list, and click Edit.

5. In the Setup wizard, click Next to get to the Setup - Part Program Zero page, select Align to Stock Face, and click Next. 6. Click the LL button in the XYZ Location frame.

7. Click Finish to close the wizard, and click Close to exit the Setups dialog. The stock has now been aligned to the stock face. 8. Select Manufacturing > Set Tool Crib from the menu. 9. In the Select Active Tool Crib dialog, select the tools crib, and click OK.

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models 155

Shading the part

1. Click the Shade part. button on the Standard toolbar to shade the This shaded view makes it easier to see the cavities in the model. Remember, at this point the part model contains only surfaces.

2. Click the Shade

button again to turn off the shading.

156 Creating features from 3D CAD models

FeatureCAM 15.0 Getting Started

Automatic feature recognition

This entire part can be automatically recognized using the automatic feature recognition (AFR) wizard. 1. Select the AFR step from the Steps panel.

2. In the Automatic Feature Recognition wizard, click the Next button twice.

The features that were recognized are listed. 3. Click the Finish button. 4. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. button, and then click the Play button to start 5. Click the 3D the simulation. If the Automatic Ordering Options dialog appears, click OK to close it. 6. Click Eject .

All features of the model were automatically recognized and the part is ready to cut. With many parts automatic feature recognition is all you need to program your part, but with others, you may need to use some of the other feature recognition (FR) techniques. 7. Click the Undo button to remove the features you created so far. You are now ready to try additional recognition methods.

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models 157

Recognizing holes
1. Select the Features step from the Steps panel. 2. In the New Feature wizard, select Hole in the From Dimensions frame, select the Extract with FeatureRECOGNITION check box, and click Next twice.

3. Select Recognize and construct multiple holes, and click Next. The holes that are automatically recognized are shown on the screen. Three holes were recognized along with the circular pocket in the middle.

158 Creating features from 3D CAD models

FeatureCAM 15.0 Getting Started

4. In the Graphics window, ignore the central pocket, and use the mouse to select the holes. (You may need to move the wizard out of the way by dragging its title bar.)

5. Click the triangle next to the Finish button, and select the Finish option. The three holes have now been recognized. 6. Click the Ordering Options button on the Op List tab. 7. In the Automatic Ordering Options dialog, select Minimize tool changes, Cut higher operations first and Minimize rapid distance, and click OK.

step from the Steps panel. The 8. Select the Toolpaths Simulation toolbar is displayed.

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models 159

9. Click the 3D Simulation button, and then click the Play button to start the simulation.

10.Click Eject

Recognizing pockets
1. Select the Features step from the Steps panel. 2. In the New Feature wizard, select Pocket in the From Curve frame, select the Extract with FeatureRECOGNITION check box, and click Next.

3. Select Automatic recognition, and click Next.

160 Creating features from 3D CAD models

FeatureCAM 15.0 Getting Started

The pockets that are automatically recognized are shown on the screen. 4. Click the Select All button, and click Finish. Both pockets have now been recognized.

step from the Steps panel. The 5. Select the Toolpaths Simulation toolbar is displayed. 6. Click the 3D Simulation button. button, and then click the Play

7. Click Eject

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models 161

Creating a slot feature

1. Select the Features step from the Steps panel. 2. In the New Feature wizard, select Slot in the From Dimensions frame, select the Extract with FeatureRECOGNITION check box, and click Next.

3. Click the Pick surface shown below.

button, and select the first location as

If the Select dialog opens, select the name that corresponds to the surface at this location, and click OK. The surfaces are highlighted in the graphics window as you select the names.

162 Creating features from 3D CAD models

FeatureCAM 15.0 Getting Started

4. Click the Pick surface location as shown below.

button again, and select the second

5. Click Next, review the extracted slot dimensions, and click Finish.

Creating a side feature

1. Click the triangle next to the button in the Principal View menu in the Standard toolbar, and select the Top option. 2. Box-select the region shown below. To do this, click the left mouse button and drag the mouse before releasing the button.

3. Select Isometric from the Principal View

menu.

button, on the Standard toolbar, to shade the 4. Click the Shade part. The shaded view makes it easier to select faces on the surface.

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models 163

5. Hold down the Shift key and click the side of the hole pattern that is selected as shown in the image.

This removes the hole pattern from the selected group. 6. Select the Features step from the Steps panel.

7. In the New Feature wizard, select Side in the From Curve frame, select the Extract with FeatureRECOGNITION check box, and click Next.

8. On the Feature Extraction page, choose the Select Side Surfaces method, and click Next twice to get to the Machining Side page.

164 Creating features from 3D CAD models

FeatureCAM 15.0 Getting Started

9. The blue arrow in the Graphics window should point to the outside of the part (to the side you wish to cut).

If it points to the inside of the part, click the Switch Machining Side button to reverse the machining side. 10.Click Finish.

Simulating the entire part

1. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. 2. Click the 3D Simulation button. button, and then click the Play

FeatureCAM 15.0 Getting Started

Creating features from 3D CAD models 165

3. Click Eject

at the completion of the simulation.

You have completed this tutorial. The features for the entire part have been created directly from the surfaces of the solid model. Using FeatureCAMs feature-based manufacturing automation, this part can be created quickly and easily.

166 Creating features from 3D CAD models

FeatureCAM 15.0 Getting Started

Introduction to 3D milling

You must have FeatureMILL3D to perform the examples in this chapter. These examples are only specified in inch units. You must have the basic tool crib installed. This tutorial introduces you to: Modeling 3D surfaces. Manufacturing surfaces using surface milling features. Manufacturing operations. Tool selection. 3D manufacturing attributes.

Getting started
1. Start FeatureCAM by double-clicking the FeatureCAM icon on the desktop. 2. If the New Part Document wizard is displayed, select the New file option, and click Next. Select Milling Setup, click Inch, and click Finish. 3. If the New Part Document wizard is not displayed, select File > New from the menu. Select Milling Setup, click Inch, and click Finish. 4. In the Stock wizard (Dimensions page), enter 3 for Width, 6.25 for Length, and 2.0 for Thickness.

FeatureCAM 15.0 Getting Started

Introduction to 3D milling 167

A milling setup defaults to a block stock. 5. Click the triangle next to the Finish button, and select the Finish option. 6. Select View > Toolbars from the Menu bar, ensure that the Advanced and Geometry check boxes are selected in the Customize Toolbars dialog, and click OK. 7. Create three vertical lines. a. Select Vertical from the Line toolbar. menu on the Geometry

b. In the Feature/Geometry Edit bar, enter 1.0 for X, 0.0 for Z, and press Enter. c. Create two more lines at X= 5.25 and X = 6.0. Your part should look something like this:

8. Create three horizontal lines. a. Select Horizontal from the Line toolbar. menu on the Geometry

b. Create horizontal lines at Y= 0.5, 1.125, and 1.5, and Z = 0.

9. Create a through line. a. Select Pt, Angle from the Line toolbar. menu on the Geometry

b. In the Feature/Geometry Edit bar, enter 30 as the angle.

168 Introduction to 3D milling

FeatureCAM 15.0 Getting Started

c. In the Graphics window, click at the intersection between the second horizontal and second vertical lines to create a through line.

10.Create arcs. a. Select 2 Pts, Radius from the Arc Geometry toolbar. menu on the

b. In the Feature/Geometry Edit bar, enter R = 0.5, and click immediately below the intersection between the first vertical line and the second horizontal line to create the first arc point. Click to the right of the intersection between the first vertical and the third horizontal line to create the first arc.

c. In the Feature/Geometry Edit bar, enter R = 1.0, and click the third horizontal line just to the left of the intersection with the through line to create the first arc point. Click the through line just above and to the right of the intersection to create the second arc.

FeatureCAM 15.0 Getting Started

Introduction to 3D milling 169

d. Click the through line just to the left of the intersection with the second vertical line to create the first arc point. Click on the second horizontal line just to the right of the intersection with the through line to create the third arc.

11.Chain geometry into curves. a. Select the Curves step from the Steps panel.

b. In the Curves Creation dialog, select the Pick Curve Pieces button.

c. Click the intersection between the third vertical line and the second horizontal line. d. Click the intersection between the first vertical and the first horizontal lines. Your part should look something like this:

Creating the bottle surface

1. Click the Surfaces step from the Steps panel. 2. In the Surface wizard, click Surface of Revolution, and click Next. 3. On the Surface of Revolution page, enter 0.0 for Start Angle, and 180 for End Angle.

170 Introduction to 3D milling

FeatureCAM 15.0 Getting Started

The curve you chained is automatically selected in the Curve field. button in the Axis field, and select the first 4. Click the Pick line horizontal line (the one at Y=1.5).

5. Click Finish. Your part now looks something like this:

Viewing
1. Click the Isometric View button on the Standard toolbar.

2. Use the Viewing Options dialog to control how the part is displayed. a. Select Options > Viewing from the menu to open the Viewing Options dialog.

FeatureCAM 15.0 Getting Started

Introduction to 3D milling 171

b. Select the Show surface boundaries only check box, and click Apply. With this option enabled, surfaces are displayed as only their outer boundaries and trimmed loops. No additional lines will be drawn in the interior of the surface. This option makes the display of larger models much faster. c. Now deselect the Show surface boundaries only check box, and click Apply. You should now see your part drawn with lines in the interior of the surface. For large models, this option makes the display of the part slower. d. Enter 20 for Wireframe, and click Apply. The surface is now drawn with more lines. Decreasing the value of Surface Fineness improves the display quality but can slow down the graphics. 3. Select the Hide All Geometry option from the Hide on the Advanced toolbar. 4. Click the Shade part. menu

button, on the Standard toolbar, to shade the

172 Introduction to 3D milling

FeatureCAM 15.0 Getting Started

Creating a surface milling feature

To mill 3D surfaces you must create a surface milling feature. A surface milling feature lets you generate toolpaths for multiple surfaces using a number of 3D toolpath strategies (see page 184). 1. Click the Select the surface (srf1). button, on the Standard toolbar, and select

2. Select the Features

step from the Steps panel.

3. In the New Feature wizard, select the Surface Milling radio button in the From Surface frame. 4. Click Next twice to get to the New Strategy page, select the Choose Rough, Semi Finish, and Finish radio button, and click Next.

FeatureCAM 15.0 Getting Started

Introduction to 3D milling 173

5. On the Rough page, select the Z Level Rough radio button, select Classify slices as 3D Pocket, and click Next.

6. On the Semi-Finish page, select None, and click Next.

174 Introduction to 3D milling

FeatureCAM 15.0 Getting Started

7. On the Finish page, select Isoline.

8. Click the triangle next to the Finish button, and select the Finish option.

Simulating the entire part

1. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. button, and then click the Play button to start 2. Click the 3D the simulation. FeatureCAM prepares the model, and processes the toolpaths.

3. Click the 3D simulation 4. Click Eject screen.

button and click Play

. The Simulation toolbar is removed from the

You have completed this tutorial, and can move to the next tutorial (see page 176) for more advanced 3D manufacturing techniques.

FeatureCAM 15.0 Getting Started

Introduction to 3D milling 175

Advanced 3D milling

You must have FeatureMILL3D to perform this tutorial. We recommend that you complete the Introduction to 3D milling (see page 167) tutorial before starting this one. In this tutorial, you will import a 3D IGES surface model and create four different types of toolpaths for manufacturing the part.

Importing the part

1. Click the New Part Document button. 2. In the New Part Document dialog, select Milling Setup, Inch, and click OK. If the New Part Document dialog is not shown, choose Options > File Options from the menu, and select the Always Ask When a New Document is Created check box. 3. In the Stock wizard (Dimensions page), click the triangle next to the Finish button, and select the Finish option. 4. Select Import/Export Options from the File menu.

176 Advanced 3D milling

FeatureCAM 15.0 Getting Started

5. In the Import/Export Options dialog, select the Center stock automatically check box, and click OK.

6. Select Import from the File menu. 7. In the Import dialog, select IGES as Files of Type, and open the file phone.igs. If you installed FeatureCAM in the default folder, the file should be in C:\Program Files\FeatureCAM\Examples\3D. 8. Select No when you are asked to review the IGES log. 9. In the Import Results wizard, select the Use the wizard radio button, and keep clicking Next until you get to the Stock Dimensions page. 10.Select Compute stock size from the size of the part, and click Finish. The imported part should look something like this:

FeatureCAM 15.0 Getting Started

Advanced 3D milling 177

Selecting toolpath strategies

To mill 3D surfaces you must create a surface milling feature. A surface milling feature lets you generate toolpaths for multiple surfaces using a number of 3D toolpath strategies (see page 184). 1. Click the Isometric View button on the Standard toolbar, and choose Select All from the Edit menu. The part in the Graphics window should look something like this:

2. Select the Features

step from the Steps panel.

3. In the New Feature wizard, select the Surface Milling radio button in the From Surface frame, and click Next twice. 4. On the New Strategy page, select the Choose Rough, Semi Finish, and Finish option, and click Next. 5. On the Rough page: a. Select the Z Level Rough option. b. Select Classify Slices as 3D Boss. c. Select the Flat surface support check box. d. Click Next. 6. On the Semi-Finish page, select Z Semi, and click Next. 7. On the Finish page, select Z Level, click the triangle next to the Finish button, and select the Finish and Edit Properties option.

178 Advanced 3D milling

FeatureCAM 15.0 Getting Started

8. In the Properties dialog, click the second z level operation in the tree view, select the Interleave spiral paths check box, and click OK.

9. Select Manufacturing > Post Process from the menu. 10.In the Post Options dialog, change the Tool Change Location Z to be 2.0, and click OK.

FeatureCAM 15.0 Getting Started

Advanced 3D milling 179

Simulating the toolpaths

1. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. 2. Click the Shade part. button on the Standard toolbar to shade the

button, and then click the Play 3. Click the Show Centerline button to start the simulation. 4. When the simulations stops, click the Clear toolpath button. 5. On the Op List tab in the Results window, double-click the first operation (rough2-zlevel). 6. In the Properties dialog, click the Preview button. The Simulation toolbar now has extra options. 7. Click the Play Selected button to view the toolpath for the rough2-zlevel operation only.

180 Advanced 3D milling

FeatureCAM 15.0 Getting Started

8. Select the second operation (rough3-zlevel) in the Operations button. List, and click the Play Selected

9. Select the third operation (finish4-zlevel) in the Operations button. List, and click the Play Selected

FeatureCAM 15.0 Getting Started

Advanced 3D milling 181

Cleaning up the fillets

1. Open the Part View panel, right-click the srf_mill1 option, and select the Properties option.

2. In the Properties dialog, click the Process tab, and click the button. Add New Operation 3. In the New Strategy wizard, select the Pencil radio button in the Specialized Strategies frame, and click Finish.

182 Advanced 3D milling

FeatureCAM 15.0 Getting Started

4. In the Properties dialog, select the finish process for the pencil operation in the tree view, select a 0.25 diameter Ball endmill on the Tools tab, and click OK.

5. Select the finish5-pencil operation on the Op List tab in the Results window, and click the Preview Toolpaths button.

button on the Simulation toolbar. A 6. Click the Play Selected single toolpath is created along the fillet. This operation may take some time to calculate.

7. Click the Stop

button.

You have completed this tutorial. The next section discusses the 3D toolpath strategies you can use in FeatureCAM.

FeatureCAM 15.0 Getting Started

Advanced 3D milling 183

3D toolpath strategies
In FeatureCAM, you have a number of options for milling a 3D feature. When you use the New Strategy wizard, select a method that is efficient for your feature's shape and that also gives an acceptable finish. Finishing Parallel - creates a raster pattern within a boundary and projects it onto the model. The part is machined in a series of parallel passes at a specified angle and stepover. A second perpendicular pass can be applied to improve surface finish in steep areas. Toolpaths are parallel to the X or Y axes.

Z Level - creates a toolpath by slicing the model at specific Z heights. Toolpaths are parallel to the XY plane. This technique works well for steep sloped walls.

Isoline - uses the isoline curves of a surface to mill the surface. Toolpaths follow the rows or columns of individual surfaces. This gives a great level of control over the surface finish and tool loading.

184 Advanced 3D milling

FeatureCAM 15.0 Getting Started

2D Spiral - creates a toolpath from offsets of a pattern and projecting it onto the model. Toolpaths move in a spiral toward or away from the center of the part. Stepover is constant from the top view.

3D Spiral - creates a toolpath by offsetting the model and block. Toolpaths move in a spiral toward or away from the center of the part. Stepover is constant in 3D. This technique is best suited to machining areas which require a constant stepover and works well on near vertical surfaces.

Radial - creates a radial pattern within a boundary and projects it onto the model. Toolpaths move out radially from the center of the feature.

FeatureCAM 15.0 Getting Started

Advanced 3D milling 185

Flowline - a control surface is used to guide the direction of machining. Toolpaths follow the rows or columns of a flowline surface, which are then projected onto the part. This enables the production of toolpaths with an exceptional level of control over surface finish. With suitable cutters, it is possible to use the flowline strategy to machine undercuts without the use of a 5-axis machine tool.

Between 2 Curves - limits machining to between two curves. The toolpath direction can be set to along or across.

Roughing Z Level Rough - slices the feature at various depths and mills the corresponding 2.5D contours as a pocket or boss shape at each depth. Toolpaths are parallel to the XY plane.

186 Advanced 3D milling

FeatureCAM 15.0 Getting Started

Plunge - a specialized cutting tool is used to remove large amounts of material through a series of vertical plunging movements. The advantage of this technique is parts can be roughed quickly since the force of the operation is directly up the spindle.

Specialized Strategies Horizontal + Vertical - this strategy combines two different toolpath operations, one for finishing shallow portions of the part and a Z-level for finishing the steep regions.

Corner Remachining - a remachining technique used to clean up corners that occur between non-tangential surfaces.

Pencil - a single clean-up pass for corners.

FeatureCAM 15.0 Getting Started

Advanced 3D milling 187

Swarf - toolpaths are cut using the side of the tool. This technique only works on developable surfaces as the tool needs to be in contact with the surface for the whole cutting depth.

Four Axis Rotary - a part is mounted in a rotary chuck which rotates to allow access to areas of the part not normally reachable by 3 axis machining.

5-Axis Trim - creates toolpaths that are along the edges of surfaces. You have an option to cut on the inside or outside edge of the surface. This technique only works on surface models.

You can find more information about the 3D toolpath strategies in online help. You can also download the 3D tutorials from the website.

188 Advanced 3D milling

FeatureCAM 15.0 Getting Started

Introduction to 5-axis simultaneous

You must have 5-Axis Simultaneous and FeatureMILL3D to perform this tutorial. We recommend that you complete the Introduction to 3D milling (see page 167), Advanced 3D milling (see page 176) and Creating features from 3D CAD models (see page 151) tutorials before starting this one. This tutorial is only available in metric units. In this tutorial you will learn to: Tilt the tool axis while cutting a 3D surface milling feature. Recognize and drill 5-axis holes in a single setup.

Getting started
1. Start FeatureCAM by double-clicking the FeatureCAM icon on the desktop. 2. If the New Part Document wizard is displayed, select the New file option, and click Next. Select Milling Setup, Millimeter, and click Finish. Close the Stock wizard (Dimensions page) by clicking the Cancel button. 3. If the New Part Document wizard is not displayed, select File > New from the menu. Select Milling Setup, Millimeter, None, and click OK. 4. From the Manufacturing menu, select Set Tool Crib.

FeatureCAM 15.0 Getting Started

Introduction to 5-axis simultaneous 189

5. In the Select Active Tool Crib dialog, select the tools crib, and click OK.

Creating a surface milling feature

A 5-axis simultaneous surface milling feature requires your machine to have 5 degrees of freedom. For FeatureCAM, the 5 degrees of freedom are restricted to moving in X, Y and Z, and rotating in two single revolute rotational joints. A single part of your machine can only rotate about one axis. Unlike the human wrist, for example, machine joints can only rotate about one mechanical axis. That is, you can define 5-axis features in a Turn/Mill document with a Baxis enabled post (*.cnc file) so that your 5 degrees of freedom are X, Y, Z, B and C. This can be used, for instance, on a Mazak Integrex lathe that has a B-axis swiveling head. You can also use 5-axis features in a 5-axis indexed milling environment in a Milling document. To create a surface milling feature: 1. Select File > Import from the menu. 2. In the Import dialog, select ParaSolids as Files of type, and open the file myjayfilledholes_untrimmed.x_t. If you installed FeatureCAM in the default folder, the file should be in C:\Program Files\FeatureCAM\Examples\5axis simul. 3. In the Import Results wizard, select the Use the wizard option, and keep clicking Next until you get to the Stock Dimensions page.

190 Introduction to 5-axis simultaneous

FeatureCAM 15.0 Getting Started

4. Select Compute stock size from the size of the part, allow 3 extra millimeters in +Z, and then click Finish.

5. Cancel the Automatic Feature Recognition wizard, if it opens. 6. Select Edit > Select All from the menu. 7. Select the Features step from the Steps panel.

8. In the New Feature wizard, select the Surface Milling radio button in the From Surface frame. 9. Click Next twice to get to the New Strategy page, select the Choose a single operation radio button, and click Next.

FeatureCAM 15.0 Getting Started

Introduction to 5-axis simultaneous 191

10.Select the Z Level radio button in the Roughing Strategies frame, and click Next until you reach the Default Tool page.

11.Select the I want to search for another tool or make a new one radio button, and click Next.

192 Introduction to 5-axis simultaneous

FeatureCAM 15.0 Getting Started

12.On the Tool Search page, click the Diam. column header to order the tools, choose the flat endmill tool with the largest diameter, and click Finish.

Importing geometry
1. Select File > Import from the menu. 2. In the Import dialog, select IGES as Files of type, and open the file myjayfilledholes_gsg.igs. If you installed FeatureCAM in the default folder, the file should be in C:\Program Files\FeatureCAM\Examples\5axis simul. 3. Select No when you are asked to review the IGES log. 4. In the Import Results wizard, select the Accept the imported data as is and exit the wizard radio button, and click Finish. The part with imported geometry should look something like this:

FeatureCAM 15.0 Getting Started

Introduction to 5-axis simultaneous 193

Adding flowline operation

1. Open the Part View panel, select stock1, and click the Properties button on the Feature/Geometry Edit bar. 2. In the Properties dialog for stock1, click the Indexing tab, select the 5th Axis Positioning radio button, and click OK. 3. Select srf_mill1 under the Setup1 node on the Part View panel, and click the Properties Edit bar. button on the Feature/Geometry

4. In the Properties dialog for srf_mill1, click the Process tab, button. and click the Add new operation 5. In the New Strategy wizard, select Flowline in the Finishing Strategies frame, and click Finish.

6. In the Properties dialog, select the finish2 process for the flowline operation in the tree view.

194 Introduction to 5-axis simultaneous

FeatureCAM 15.0 Getting Started

7. Click the Milling tab, select the Stepover attribute, enter 3 as the New Value, and click Set.

8. Add a new tool. a. Click the Tools tab, and select Bullnose Endmill in the Tool Group field. b. Select the tool with the biggest diameter, and click the New button. Tool This opens the Tool Properties dialog with the currently selected tool used for the initial values for the new tool. c. Enter bullnose40 as the Name, and 40 as the Diameter.

FeatureCAM 15.0 Getting Started

Introduction to 5-axis simultaneous 195

d. Deselect the Ball-end check box, enter 4 as the End Radius, and click OK.

e. Click Yes, when the system asks Set the new tool as override? The new tool is now selected. 9. In the Properties dialog for srf_mill1, select the flowline operation in the tree view. 10.Click the 5-Axis tab, select Use Lead and Lean, and click Apply. This ensures the tool is at a fixed angle relative to the direction of the toolpath.

196 Introduction to 5-axis simultaneous

FeatureCAM 15.0 Getting Started

Using a lead/lean strategy keeps the tool normal to the cutting surfaces and enables you to take large stepovers while leaving a good quality finish. 11.Ensure the Retract to cylinder check box is not selected. Retracting to Cylinder will retract in X and Y, and in this example, we need to retract along the Z vector. 12.Click the Surface control tab, and select the surface <ig_srf3> as the flowline guide surface (the surface name may have a different number in your file). 13.Click the Set Isoline Row/Col button until the value in the Start Curve column is set to First Col, and then click OK.

14.Select the Toolpaths 15.Click the 3D Simulation button.

step from the Steps panel. button, and then click the Play

The 3D simulation of 5-axis simultaneous parts can be slow. To speed up 3D simulation, select Options - Simulation from the Menu bar, and use the fields on the 2D/3D Shaded tab in the Simulation Options dialog. We recommend setting a larger wrapping tolerance, and a larger tool cutting tolerance. Adjusting turn/mill angular interpolation and tool visual tolerance can also improve the simulation speed.

FeatureCAM 15.0 Getting Started

Introduction to 5-axis simultaneous 197

To accelerate the graphics, choose Options - Surface Shading from the Menu bar, and select the Use Graphics Hardware check box.

Recognizing holes
1. Select Import from the File menu. 2. In the Import dialog, select ParaSolids as Files of type, and open the finished ParaSolids part myjayfilledholes_gsg.x_t. If you installed FeatureCAM in the default folder, the file should be in C:\Program Files\FeatureCAM\Examples\5axis simul. 3. In the Import Results wizard, select the Use the same alignment as last import check box, and click Finish. 4. Open the Part View panel, expand the Solids node, and select the solid part that contains holes (this should be the second solid in the list).

5. From the Hide Unselected.

menu on the Advanced toolbar, select Hide

The part in the Graphics window looks like this:

6. Select the Features

step from the Steps panel.

198 Introduction to 5-axis simultaneous

FeatureCAM 15.0 Getting Started

7. In the New Feature wizard, select Hole in the From Dimensions frame, select the Extract with FeatureRECOGNITION check box, and click Next. 8. Select the Along a specific Vector radio button, select the Recognize all holes check box, and keep clicking Next until you get to the Hole Recognition Options page. 9. Click the Select All button, click the triangle next to the Finish button, and select the Finish and Create More option. The part in the Graphics window should look something like this:

Recognizing side features

1. Return to the New Feature wizard, select Side in the From Curve frame, select the Extract with FeatureRECOGNITION check box, and click Next.

2. Hide everything except the part you selected. Select View > Hide > Hide Unselected.

FeatureCAM 15.0 Getting Started

Introduction to 5-axis simultaneous 199

3. Select the Automatic Recognition option, and click Next. 4. Click the Select All button, click the triangle next to the Finish button, and select the Finish option. The part in the Graphics wizard looks something like this: 5. Open the Part View panel, and right-click the first side feature (side1) under the Setup1 node.

6. In the Properties dialog for side1, click the Strategy tab, deselect the Rough check box, and click OK. This is the outer side feature, and, therefore, it does not need to be roughed. 7. Select the Toolpaths step from the Steps panel.

200 Introduction to 5-axis simultaneous

FeatureCAM 15.0 Getting Started

8. Click the 3D Simulation button.

button, and then click the Play

You have completed this tutorial.

FeatureCAM 15.0 Getting Started

Introduction to 5-axis simultaneous 201

Solid modeling basics

You must have the Solid Modeling option to perform this tutorial. This tutorial introduces you to the solid modeling capabilities of FeatureCAM by creating a model of the simple computer speaker shown below.

The tutorial is available only in metric units and introduces you to: Extrude design features. Hidden line graphics. Loft design features. Filleting solid models. Core/cavity separation of a solid model. Creating manufacturing features from solids.

202 Solid modeling basics

FeatureCAM 15.0 Getting Started

Getting started
1. Start FeatureCAM by double-clicking the FeatureCAM icon on the desktop. 2. If the New Part Document wizard is displayed, select the New file option, and click Next. Select Milling Setup, Millimeter, None, and click Finish. 3. If the New Part Document wizard is not displayed, select File > New from the menu. Select Milling Setup, Millimeter, None, and click OK. 4. Select Toolbars from the View menu. 5. In the Customize Toolbars dialog, select the Steps, Display Mode and Solid check boxes on the Toolbars tab, and click OK. This opens the toolbars you need for this tutorial.

Creating the initial solid

1. Select the Curves step from the Steps panel. 2. In the Curves Creation dialog, select the Curve Wizard button. 3. In the Curve wizard, select Other methods as the construction method, Rectangle as the constructor, and click Next.

FeatureCAM 15.0 Getting Started

Solid modeling basics 203

4. On the Rectangle page, select the Use corner, width and height radio button, and enter 0.0 and 0.0 for the X and Y Corner coordinates. 5. Set Width to 100 and Height to 65, select the Create as arcs and lines check box, and click Finish.

6. In the Graphics window, right-click the right vertical line, and select the Delete option.

7. Select Snapping Modes from the Options menu.

204 Solid modeling basics

FeatureCAM 15.0 Getting Started

8. In the Snap Modes dialog, ensure the End points option is selected (selected buttons have pale grey borders around them), and click OK.

9. Create an arc. a. Select 2Pts, Radius from the Arc Geometry toolbar. menu on the

b. In the Feature/Geometry Edit bar, enter R = 105. c. Click the two open points in the Graphics window where the vertical line was.

10.Chain geometry into curves. a. Select the Curves step from the Steps panel.

b. In the Curves Creation dialog, select the Closed Curve button, and click the arc you just created. c. Click the Create button on the Feature/Geometry Edit bar. 11.Click the Solid Wizard button on the Advanced toolbar.

FeatureCAM 15.0 Getting Started

Solid modeling basics 205

12.In the Solid wizard, select Define a custom shape..., and click Next. 13.Select From Curves as the construction method, Extrude as the constructor, and click Next. Select From Curves as the method and Extrude as the constructor and click Next.

14.On the Extruded Solid page, enter -50 as the Vector Z coordinate and -5 as the Draft Angle, and click Finish.

206 Solid modeling basics

FeatureCAM 15.0 Getting Started

Your part in the Graphics window looks something like this:

15.Open the Part View panel, and expand the Solids node to reveal solid4. This is the name of the solid we are creating. The number following the solid name may be different for you. 16.Expand solid4 to reveals the features that make it up. There is only one feature called extbase1. A base feature is the initial feature for a solid.

Hidden line graphics

With solids there are additional graphics options available. By default, you are in line-drawing mode. With solids, hidden line graphics are available. 1. Click the Isometric View button on the Standard toolbar. menu on the

2. Select the Hide Stock option from the Hide Advanced toolbar.

FeatureCAM 15.0 Getting Started

Solid modeling basics 207

The default view of your solid model is shown below. On this stage, it is impossible to tell if there is a top on the solid.

3. Click the Hidden Line

button on the Display Mode toolbar.

The view of your solid model changes, making it clear that there is a top on the solid.

While hidden-line mode provides nice quality graphics, it is considerably slower than simple line drawings, and sometimes hides portions of the model you need to pick. 4. To return back to line drawing mode, click the Hidden Line button again.

208 Solid modeling basics

FeatureCAM 15.0 Getting Started

Hidden line graphics are only available for solids.

Creating the curved lower surface

1. From the Show Show Stock. menu on the Advanced toolbar, select 2. In the Graphics window, double-click the stock to open the Properties dialog, and click the Resize button on the Dimensions tab.

3. In the Stock wizard (Stock Dimensions page), select Compute stock size from the size of the part, and click Next. 4. On the Resize page, select Move Stock, and click Finish. The view automatically changes to top view.

FeatureCAM 15.0 Getting Started

Solid modeling basics 209

5. Select the Front option from the Principal View the Standard toolbar.

menu on

6. Create two arcs. a. Select 2Pts, Radius from the Arc Geometry toolbar. menu on the

b. In the Feature/Geometry Edit bar, enter R = 400. c. Set X1 to 120, Y1 to 0 and Z1 to -20; set X2 to -10, Y2 to 0 and Z2 to -40, and click the Create button. The part in the Graphics window looks something like this:

d. Entering R = 160 for the second arc.

210 Solid modeling basics

FeatureCAM 15.0 Getting Started

e. Click the right endpoint of the first arc, and then click the left endpoint of the arc. The new arc should curve down.

If your arc curves up instead of down, select the arc, and click the Options button on the Feature/Geometry Edit bar. If the cursor is still in the arc create mode, click the Select button on the Standard toolbar. Now you are able to click and select the arc. 7. Select the first (top) arc, and click the Transform the Standard toolbar. button on

8. In the Transform dialog, select the Translate and Copy radio buttons, enter 70 in the Y coordinate of XYZ Distance, and click OK.

9. Select the second (bottom) arc, and click the Transform button.

FeatureCAM 15.0 Getting Started

Solid modeling basics 211

10.In the Transform dialog, select the Translate and the Move radio buttons, and enter 35 in the Y coordinate of XYZ Distance, and click OK.

11.Select the Isometric option from the Principal View on the Standard toolbar. 12.Click the Solid Wizard

menu

button on the Advanced toolbar.

13.In the Solid wizard, select From Curves as the construction method and Lofted as the constructor, and click Next.

212 Solid modeling basics

FeatureCAM 15.0 Getting Started

14.Since we want to use this design feature to remove material, on the Lofting page select the As Cut radio button, and click the Pick Curve button, and select the arcs in the order shown in the figure.

15.If the selected arcs appear out of order in the curve list, use the arrows to move the arcs up or down. 16.Click Finish.

The curves are used to create a lofted surface and then the surface is used to cut the solid. An additional design feature, called loftcut1 is now listed in the Part View panel.

FeatureCAM 15.0 Getting Started

Solid modeling basics 213

Creating constant and variable radius fillets

1. Click the Solid Wizard button on the Advanced toolbar. 2. In the Solid wizard, select Shape Modifiers as the construction method and Fillet Edges as the constructor, and click Next.

3. On the Edge Fillet page, enter 5 as the Radius, click the Pick button, and select the bottom edges 1-4 as shown in the Curve figure.

4. Return to the wizard, click the Variable radio button, and enter 5 as the Begin radius and 10 as the End radius.

214 Solid modeling basics

FeatureCAM 15.0 Getting Started

5. Return to the Graphics window, and select the vertical edges 5-8 as shown in the figure.

This creates a variable radius fillet on these edges. As you click each edge an arrow is displayed to show the edge direction. The first radius is applied to the tail of the arrow and the second to the head of the arrow. 6. Click Finish.

FeatureCAM 15.0 Getting Started

Solid modeling basics 215

The solid part looks something like this:

The selected edges are filleted and the surrounding surfaces have been trimmed. The corners where the fillets meet are automatically filleted. An additional design feature, called fillet1 is now listed in the Part View panel.

Adding thickness
1. Click the Solid Wizard button on the Advanced toolbar. 2. In the Solid wizard, select Shape Modifiers as the construction method and Shell as the constructor, and click Next.

216 Solid modeling basics

FeatureCAM 15.0 Getting Started

3. On the Shell page, enter an Offset distance of -2, and click the button. Pick Surface 4. Click the top surface as shown in the figure.

This surface will not be offset. If the Select dialog opens, select the name that corresponds to the top surface. The surfaces are highlighted in the Graphics window as you select the names. 5. Click Finish.

All faces of the solid except the top surface are now offset by 2mm to provide thickness to the part. An additional design feature, called shell1 is now listed in the Part View panel. 6. Select the Hide All Geometry option from the Hide on the Advanced toolbar. menu

FeatureCAM 15.0 Getting Started

Solid modeling basics 217

7. Click the Hidden Line button on the Display Mode toolbar to have a better view of the solid.

At this point, the solid model of the speaker is complete.

Creating a mold cavity

Now the challenge is to create a mold from the solid model. For parts that can be created with two mold halves, FeatureCAM's core/cavity feature is a useful tool. 1. Click the Solid Wizard button on the Advanced toolbar.

218 Solid modeling basics

FeatureCAM 15.0 Getting Started

2. In the Solid wizard, select Manufacturing as the construction method and Select Core/Cavity as the constructor, and click Next.

3. On the Select Core/Cavity page, select the Bottom radio button. 4. Select the Make solid from result check box. This creates a new solid that contains the cavity faces. 5. Click Finish.

A new solid, called sheet1, is added to the Solids node on the Part View panel. 6. Right-click the solid4 on the Part View panel, and select the Hide Selected option. You can now see the cavity. You have completed this tutorial.

FeatureCAM 15.0 Getting Started

Solid modeling basics 219

Introduction to FeatureWIRE

You must have FeatureWIRE to perform this tutorial. In this tutorial, you will learn the basics of creating wire EDM toolpaths using FeatureWIRE. This tutorial is only available in inch units. Specifically, you will learn how to: Set up your material and wire thickness. Create wire EDM features. Specify a wire EDM cutting strategy. Simulate wire EDM toolpaths.

Getting started
1. Start FeatureCAM by double-clicking the FeatureCAM icon on the desktop. 2. If the New Part Document wizard is displayed, select the New file option, and click Next. Select Wire EDM Setup, Inch, Wizard, and click Finish. 3. If the New Part Document wizard is not displayed, select File > New from the menu. Select Wire EDM Setup, Inch, Wizard, and click OK. 4. In the Stock wizard (Dimensions page), set the stock Width and Length to 4.0 and the thickness to 0.5.

220 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

5. Click the triangle next to the Finish button, and select the Finish option.

Creating the profile

1. Select the Curves step from the Steps panel. 2. In the Curves Creation dialog, select the Curve Wizard button. 3. In the Curve wizard, select Other methods as the construction method and Rectangle as the constructor, and click Next.

4. On the Rectangle page, select Use corner, width, and height. 5. Set the corner point to 1, 1, 0. 6. Set the corner radius to 0.5 and set the Width and Height to 2.0.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 221

7. Click Finish.

Your part in the Graphics window should look something like this:

222 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

Creating a wire EDM feature

1. Select the Features step from the Steps panel. 2. In the New Feature wizard, select the Die radio button in the 2 Axis frame, and click Next.

3. On the Curves page, click the Pick Curve the curve you just created.

button, and select

4. Click Next until you get to the Dimensions page. 5. Enter 0.5 as the Thickness and click Next twice to get to the Strategies page.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 223

6. Select Retract in the Operations field, and select the Cutoff and Contour check boxes.

7. Click the triangle next to the Finish button, and select the Finish option.

Simulating a wire EDM toolpath

1. Select the Toolpaths step from the Steps panel. The Simulation toolbar is displayed. 2. Click the 2D Simulation button on the Simulation toolbar. 3. Move the Sim Speed slider to the middle so that the simulation is slowed down. 4. Select the Play to Next Operation option from the Simulation Next menu.

224 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

Youll notice that the Retract operation makes two passes. If you need to slow down the simulation, drag the Sim Speed slider to the left.

button again. The Cutoff 5. Click the Play to Next Operation operation now takes two passes. Slow down the simulation if you need to.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 225

6. Click the Play to Next Operation button once more. The final Contour operation is now simulated.

7. Click Eject

Generating NC code
1. Select the NC Code step from the Steps panel. button in the NC Code 2. Click the Display the NC Code dialog to generate the NC code.

Adding a taper angle

1. Open the Part View panel, select the die1 feature from the Setup1 node, and click the Properties Feature/Geometry Edit toolbar. button on the

226 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

2. In the Properties dialog for die1, select the Constant radio button, choose Left as the taper type, enter 10 as the taper angle in the Deg. field, and click Apply.

menu on the 3. Select the Hide Stock option from the Hide Advanced toolbar, and click the Isometric View button on the Standard toolbar to get a 3-dimensional view of the part.

4. Return back to the Properties dialog, set the taper type to Right, and click Apply. View the new shape in Isometric view.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 227

5. Change the taper type back to Left, and click OK to close the Properties dialog. 6. Select the Toolpaths 7. Click the 3D Simulation button. step from the Steps panel. button, and then click the Play

Since this is a die feature, it is assumed that the region inside of the curve will be discarded.

8. Click the Select

button on the Standard toolbar.

9. Click the stock in the region inside of the curve. FeatureCAM deletes that part of the stock.

10.Click Eject

. menu on the Advanced toolbar, select

11.From the Show Show Stock.

228 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

12.Open the Part View panel, right-click the die1 feature, and select the Hide Selected option. Now the feature will not be displayed on the screen.

Creating the second profile

1. Select the Top option from the Principal View Standard toolbar. 2. Select the Curves step from the Steps panel. menu on the

3. In the Curves Creation dialog, select the Curve Wizard button. 4. In the Curve wizard, select Other Methods as the construction method and Rectangle as the constructor, and click Next.

5. On the Rectangle page, select Use corner, width and height. 6. Set the corner point to 0.5, 0.5, 0.0.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 229

7. Set the Width and Height to 3.0, and click Finish.

Your part in the Graphics window should look something like this:

230 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

Creating a 4-axis wire EDM feature

1. Select the Features step from the Steps panel. 2. In the New Feature wizard, select the Die radio button in the 4 Axis frame, and click Next.

3. On the Upper Curve page, click the Pick Curve select the curve that you just created.

button and

4. Click Next.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 231

5. On the Lower Curve page, click the Pick curve select the smaller curve that you created first.

button and

6. Keep clicking Next until you get to the Dimensions page. 7. Enter 0.50 as the Thickness, click the triangle next to the Finish button, and select the Finish option.

232 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

The feature is twisted because the start points were not set.

Modifying the start point

1. Open the Part View panel, select the die4x1 feature from the Setup1 node, and click the Properties Feature/Geometry Edit bar. 3. Click the Pick Location Start/End Point. button on the

2. In the Properties dialog for die4x1, click the Start tab. button for the Upper Curve

4. In the Graphics window, click a point in the center of the stock, and then click on the bottom horizontal line of the outer curve. You should notice a green line between the point and the edge of the curve.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 233

5. Click the Pick location Curve Start/End Point.

button this time for the Lower

6. Click in the center of the stock and click the bottom horizontal line of the inner curve.

7. Click OK. The feature now should no longer be twisted.

Matching the curves

1. Open the Part View panel, select the die4x1 feature from the Setup1 node, and click the Properties Feature/Geometry Edit bar. button on the

234 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

2. In the Properties dialog for die4x1, click the Dimensions tab and click the Match Curves button.

3. In the Match Curves dialog, click the Pick Lower Curve button. Point 4. In the Graphics window, select the top right point on the lower curve, and then select the right corner point on the upper curve. You should see a green line between the two points.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 235

5. Hold down the Shift key and select the upper-right point on the lower curve, and then select again the right corner point at location.

Now you have matched both points on the lower curve to the single point on the upper curve. 6. Click Apply, and then click OK to close the Match Curves dialog. 7. Click OK in the Properties dialog. The part in the Graphics window looks something like this:

Simulating the part

1. Open the Part View panel and deselect the check box next to the die1 feature to exclude it from the simulation. 2. Click the Isometric option from the Principal View on the Standard toolbar. menu

236 Introduction to FeatureWIRE

FeatureCAM 15.0 Getting Started

3. Select the Toolpaths 4. Click the 3D Simulation button.

step from the Steps panel. button, and then click the Play

5. Click the Select

button on the Standard toolbar.

6. Click the stock in the region inside of the curve. FeatureCAM deletes that part of the stock.

7. Click Eject

You have completed this tutorial.

FeatureCAM 15.0 Getting Started

Introduction to FeatureWIRE 237

Index
Z-level finishing 184 Z-level roughing 184

2
2.5D Milling 89 2D Simulation button 49 2D spiral finishing 184 2D turned profiles 48

4
4-axis Rotary 184

3
3D milling 167 3D rapidcut simulation 49 3D simulation 49 3D spiral finishing 184 3D toolpath strategies 184 2D spiral finishing 184 3D spiral finishing 184 4-axis Rotary 184 5-axis Trim 184 Between Two Curves finishing 184 Corner Remachining 184 Flowline finishing 184 Horizontal and Vertical strategy 184 Isoline finishing 184 Parallel finishing 184 Pencil 184 Plunging 184 Radial finishing 184 Swarf 184

5
5-axis Trim 184

A
Advanced toolbar 46 Arc menu 49 Assistance bar 42, 75 Automatic Feature Recognition 157

B
Bar feed 136 Between Two Curves finishing 184

C
Chain menu 49 Circle menu 49 Colors 81, 84 Context-sensitive help 45, 78, 79 Corner Remachining 184 Curves

FeatureCAM 15.0 Getting Started

Index 239

Curve from Curve menu 47 Curve from Surface menu 47 Curve menu 47 Curve wizard 46 Curves and Surfaces toolbar 47 Curves step 61 Features from curves (tutorial) 104 Customising FeatureCAM 87 Customize Manufacturing step 66

D
Databases Materials database 70 Tools database 69 Delete 45, 57, 78 Details tab 74 Dimension menu 49 Display Mode toolbar 48 2D turned profiles 48 Draft hidden line mode 48 Hidden line mode 48, 207 Shade Selected button 48 Show normals 48 Unshade all 48 Unshade selected 48 Unshow normals 48 Dongle 9, 10 Draft hidden line mode 48

Feature/Geometry Edit bar 42, 75 Features from curves (tutorial) 104 Features step 62 FeatureTURN 115, 130 FeatureTURN/MILL 140 FeatureWIRE 3, 220 Fillet menu 49 Finishing 184 2D spiral finishing 184 3D spiral finishing 184 Between Two Curves finishing 184 Flowline finishing 184 Isoline finishing 184 Parallel finishing 184 Radial finishing 184 Z-level finishing 184 Flex licensing 12 Flowline finishing 184

G
Geometry Feature/Geometry Edit bar 42, 75 Geometry step 60 Geometry toolbar 46, 49 Arc menu 49 Chain menu 49 Circle menu 49 Edit menu 49 Fillet menu 49 Line menu 49 Point 49 Importing geometry 193 Graphics window 42, 53 Grids 86

E
Edit menu 49 Eject button 49 Engraving 147 Evaluation 10, 11

F
Fast forward to end of simulation 49 Feature/Geometry Edit bar 42, 75 FeatureMILL3D 167 Features 46

H
Help 45, 79 Context-sensitive help 45, 78, 79 Hidden line mode 48, 207

240 Index

FeatureCAM 15.0 Getting Started

Hide menu 46 Horizontal and Vertical strategy 184

I
Importing geometry 193 INITDB 34, 151 Installing FeatureCAM 5 PAF (Product Authorization File) 7 Product Authorization File (PAF) 7 Interface 42 Graphics window 42, 53 Title bar 42, 43 Toolbars 42, 44, 87 Part View panel 42, 72 Steps panel 42, 58 Isoline finishing 184

View menu 45 Metric 151 Modules 3, 11 More Simulation toolbar 52 Mouse Mouse buttons 53 Mouse cursor 53 Mouse cursor 53

N
NC code 66, 75 NC Code step 66 NC Code tab 75 New Feature 46 New file 37, 45

O
Opening files 37, 45 Operation list 74 Options 45

K
keyboard shortcuts 43, 78

L
Licensing 12 Line menu 49

P
PAF (Product Authorization File) 7 Parallel finishing 184 Part View panel 42, 72 Pause simulation 49 Pencil 184 Play button 49 Plunging 184 Point 49 Post options 71 Principle View menu 45 Printing 77, 78 Product Authorization File (PAF) 7

M
Machine simulation 49, 130, 131 Machining preferences 66, 67 Maintenance releases 10 Materials database 70 Menus 42, 43 Circle menu 49 Dimension menu 49 Fillet menu 49 Hide menu 46 Line menu 49 Menu bar 42, 43 Principle View menu 45 Show menu 46

R
Radial finishing 184 Region of interest simulation 49 Results window 42, 74 Roughing 184

FeatureCAM 15.0 Getting Started

Index 241

Plunging 184 Z-level roughing 184

S
Saving files 45, 76, 78 Selecting 45, 55, 78 Shading 45, 48, 56 Draft hidden line mode 48 Shade Selected button 48 Unshade all 48 Unshade selected 48 Show menu 46 Show normals 48 Simulation More Simulation toolbar 52 Region of interest simulation 49 Simulation toolbar 49 2D Simulation button 49 3D rapidcut simulation 49 3D simulation 49 Eject button 49 Fast forward to end of simulation 49 Machine simulation 49, 130, 131 Pause simulation 49 Play button 49 Region of interest simulation 49 Simulation speed 49 Single step simulation 49 Stop simulation 49, 78 Single step simulation 49 Snap modes Snap Mode toolbar 47 Snap Modes dialog 46 Snapping options 86, 106 Solids Solid toolbar 52 Solid wizard 46 Standard toolbar 45 Status bar 42, 75

Steps 58 Curves step 61 Customize Manufacturing step 66 Features step 62 Geometry step 60 NC Code step 66 Steps panel 42, 58 Steps toolbar 52 Stock step 59 Toolpaths step 63 Stock 39, 84 Stock step 59 Stop simulation 49, 78 Subspindle 134, 136 Surfaces Curves and Surfaces toolbar 47 Surface from Curve menu 46 Surface from Surface menu 47 Surface from Surfaces menu 47 Surface Primitives menu 47 Surface wizard 46 Swarf 184

T
Text See Engraving Title bar 42, 43 Tool load 49 Toolbars 42, 44, 87 Curves and Surfaces toolbar 47 Curve from Curve menu 47 Curve from Surface menu 47 Curve menu 47 Surface from Curve menu 46 Surface from Surface menu 47 Surface from Surfaces menu 47 Surface Primitives menu 47 Display Mode toolbar 48 Geometry toolbar 46, 49 Arc menu 49 Chain menu 49 Circle menu 49 Dimension menu 49

242 Index

FeatureCAM 15.0 Getting Started

Edit menu 49 Fillet menu 49 Line menu 49 Point 49 More Simulation toolbar 52 Simulation toolbar 49 3D rapidcut simulation 49 3D simulation 49 Eject button 49 Fast forward to end of simulation 49 Machine simulation 49, 130, 131 Pause simulation 49 Play button 49 Region of interest simulation 49 Simulation speed 49 Single step simulation 49 Stop simulation 49, 78 Snap Mode toolbar 47 Solid toolbar 52 Standard toolbar 45 Steps toolbar 52 Toolbox 42, 53 Part View panel 42, 72 Steps panel 42, 58 Toolpath strategies 184 2D spiral finishing 184 3D spiral finishing 184 4-axis Rotary 184 5-axis Trim 184 Between Two Curves finishing 184 Corner Remachining 184 Flowline finishing 184 Horizontal and Vertical strategy 184 Isoline finishing 184 Parallel finishing 184 Pencil 184 Plunging 184 Radial finishing 184

Z-level finishing 184 Z-level roughing 184 Toolpaths step 63 Tools database 69 Transform 45, 209 Troubleshooting 8, 10, 22 Turn/mill 140 Turning 115, 130

U
UCS 46 Undo 45, 78 Units 151 Unshading 48 Unshade all 48 Unshade selected 48 Unshow normals 48

V
View menu 45 Viewing 56 Display Mode toolbar 48 Hidden line mode 48, 207 Shade Selected button 48 Show normals 48 Unshade all 48 Unshade selected 48 Unshow normals 48 Graphics window 42, 53 View menu 45

W
Wizards 82 Curve wizard 46 Solid wizard 46 Surface wizard 46

Z
Z-level finishing 184 Z-level roughing 184

FeatureCAM 15.0 Getting Started

Index 243

244 Index

FeatureCAM 15.0 Getting Started