CAMWARE

SHAPE CREATION
MODULE

SHAPE CREATION & EDITING

PRACTICE

Issue 1.0

Ó 1996 – 2003 Yamazaki Mazak Corporation

All rights reserved.
Publication No.:
01/04/03
 Contents
Introduction ....................................................................................................5
Rectangular Component ...............................................................................5
Drawing of model to create: ............................................................................................... 5
To create the main rectangular body: ................................................................................ 6
To create the inside (hollow) rectangular body: ................................................................. 6
To create the left hand side cylindrical body: ..................................................................... 7
To create the left hand side spherical body: ...................................................................... 8
To create the small square body in the bottom left hand corner of the main body: ........... 8
To create the small square body in the top left hand corner of the main body: ................. 9
To create the additionally required square, cylindrical and spherical bodies:.................. 10
To unite all bodies into one body:..................................................................................... 11
To add Chamfers to the top edges of the body:............................................................... 12
To add Blend Radii to the body: ....................................................................................... 13
How to select several linked edges (as opposed to selecting the edges individually):.... 13
Housing (Bobbin & Doughnut) ...................................................................17
To create the rectangular base body: .............................................................................. 18
Creating the Bobbin body in stages: ............................................................................... 19
To create the bobbin Line/Arc profile: .............................................................................. 19
To convert the bobbin Line/Arc profile to a Sheet Body:.................................................. 20
To create the bobbin solid body: ...................................................................................... 21
To create a Sheet Body in preparation for removing the unwanted portion of the bobbin
body:................................................................................................................................. 22
To remove the unwanted portion of the bobbin solid body: ............................................. 23
Creating the Doughnut body in stages:........................................................................... 25
To create the basic doughnut cylindrical body: ................................................................ 25
To create a line/arc profile in preparation for cutting the doughnut cylindrical body:....... 26
To convert the profile to a Sheet body in preparation for cutting the doughnut cylindrical
body:................................................................................................................................. 27
To cut and remove the unwanted central portion of the doughnut solid body: ................ 28
To add draft angles to the doughnut solid body: .............................................................. 30
To add blend radii to the doughnut solid body: ................................................................ 31
To add blend radii between the doughnut and bobbin solid bodies:................................ 32
Coffee Mug ...................................................................................................35
Drawing of model to create: ............................................................................................. 35
Creating the Mug body in stages: .................................................................................... 36
To create the basic mug shape body: .............................................................................. 36
To hollow out the mug body: ............................................................................................ 37
To add blend radii on the top edges of the mug body:..................................................... 37
Creating the Handle body in stages:................................................................................ 38
To define the Construction points for the spline curve: .................................................... 38
To create the handle profile – Method A – using Group and Fit Spline Curve: ............... 38
To create the handle profile – Method B - using Biarc Spline:......................................... 39
To create the handle cross section – using 2D Conics:................................................... 39
To convert the ellipse profile to a Sheet body in preparation for creating the Handle solid
body:................................................................................................................................. 41
To convert the biarc spline profile to a Wire body in preparation for creating the Handle
solid body: ........................................................................................................................ 41
Reverse Wire Body direction ?......................................................................................... 42
Create the Handle solid body: .......................................................................................... 42
Finalising the Coffee Mug model creation: ..................................................................... 43
To add blend radii between the mug and handle solid bodies:........................................ 43
Flanged Casing ............................................................................................47
Drawing of model to create: ............................................................................................. 47
Creating the Flanged Casing body in stages:................................................................. 48
To create the flange Line/Arc profile: ............................................................................... 48

2
 To create a Sheet body of the flange profile: ................................................................... 48
Check the Face Normal direction: .................................................................................... 48
To create the flange body:................................................................................................ 49
To create the casing Line/Arc profile:............................................................................... 50
To create the casing body: ............................................................................................... 51
To create the cavity Line/Arc profile: ................................................................................ 52
To create the cavity body: ................................................................................................ 53
Unite and Subtract bodies: ............................................................................................... 53
Creating a Simple Loft.................................................................................57
Shape of model being created: ........................................................................................ 57
st
To define 1 set of Construction Points: .......................................................................... 57
To Fit a Spline Curve through the points:......................................................................... 58
st
To create a mirrored spline curve from the 1 curve:....................................................... 58
nd
To define 2 set of Construction Points:.......................................................................... 58
nd
To Fit a Spline Curve through these 2 set of points: ..................................................... 58
To Fit a Loft Surface through the 3 Wire bodies: ............................................................. 59
Delete Faces And Heal Exercise.................................................................61
One final comment: .......................................................................................................... 64
Custom Component Design........................................................................67
Introduction....................................................................................................................... 67
Drawing of tool to create: ................................................................................................. 67
Create the profile of a Custom design End Mill:............................................................... 67
To register the profile as a Custom Component figure: ................................................... 68
To edit the profile of the End Mill:..................................................................................... 69
To re-register the modified profile as a Custom Component figure: ................................ 70

3
4
Introduction
The Solid Create and Solid Edit menus within the Solid CAMWARE Shape Creation module
offer a limited set of functions to aid basic model creation and editing.
These functions are no substitute for a full solid modelling CAD package. Users who required
utilising the full scope of 3D modelling should acquire a suitable package.
Many of the functions within the Solid CAMWARE Shape Creation module will probably never
be needed since they may be more suited to creating and editing models to be
programmed/machined using 3D surfacing applications.

Rectangular Component
Shape Creation and CAD features/functions used in creating this model include:
Solid Primitive Block, Cylinder and Sphere creation,
Subtract and Unite operations,
Mirror transformation,
Chamfer Blend, Constant Radius Blend, Variable Radius Blend,
Linked Edge selection.

Drawing of model to create:

5
To create the main rectangular body:
Select Solid Primitive from the Solid-Create menu:

Select the Block tab in the Create Solid dialog, enter the data as indicated below and select
the Create button:

To create the inside (hollow) rectangular body:

Select the Block tab in the Create Solid dialog, enter the data as indicated below and select
the Create button:

6
The inner rectangular body is initially created as a solid. This inner body must now be
subtracted from the outer rectangular body:

Select the Subtract button in the dialog, select the outer (Main) body first and then
select the inner body:
Note that a body is visually indicated as selected when the line style of the body’s wire frame
changes from a solid line to a broken line.

Finally select the End Command button:

To create the left hand side cylindrical body:

Select the Cylinder tab in the Create Solid dialog, enter the data as indicated below and
select the Create button:

7
To create the left hand side spherical body:
Select the Sphere tab in the Create Solid dialog, enter the data as indicated below and select
the Create button:

To create the small square body in the bottom left hand corner of the main body:
Select the Block tab in the Create Solid dialog, enter the data as indicated below and select
the Create button. Finally select the Done button to close the dialog:
Note that the Use Datum Corner option has been selected. In this situation, the X, Y & Z
Datum Corner co-ordinates can easily be digitised as an alternative to manually entering the
data.

8
The current model formed by the various body definitions is as displayed below:

The second instance of the cylindrical and spherical bodies and the 3 other instances of the
small square bodies could also be created using the Create Solid dialog. An alternative is to
use the CAD Mirror function.

To create the small square body in the top left hand corner of the main body:
Select Mirror About 2 Points from the Transformations menu:

Select the square body and End the select command:

In answer to the prompt: “First Point on Mirror Hinge Line”, select the Origin triad or enter
X0 Y0:
In answer to the prompt: “Second Point on Mirror Hinge Line…”, enter (for example) DX1:
Select the YES button in the “Leave un-mirrored items” message dialog:
(This mirrors the selected object about an imaginary line drawn parallel to the X axis at Y0).

9
Two small square bodies will now be displayed as below:

To create the additionally required square, cylindrical and spherical bodies:

Select Mirror About 2 Points from the Transformations menu as before:
Select the 2 square bodies, the cylindrical and spherical bodies and then End the select
command:

Note that it can occasionally prove difficult to select a spherical shape, and even when
selected, the selection may not be clearly indicated graphically. But information in the
message pane will indicate (for this example) that 4 items have been selected:

In answer to the prompt: “First Point on Mirror Hinge Line”, select the Origin triad or enter
X0 Y0:
In answer to the prompt: “Second Point on Mirror Hinge Line…”, enter (for example) DY1:
Select the YES button in the “Leave un-mirrored items” message dialog:
(This mirrors the selected objects about an imaginary line drawn parallel to the Y axis at X0)

10
All required bodies will now be displayed as below:

In the Solid Properties dialog (accessed from the Modify Menu), several independent bodies
will now be displayed. To enable any transformation operations to be easily executed on the
total number of bodies -as one, and also to facilitate the creation of chamfers and blend radii
at the join of 2 or more (currently) individual bodies, then these individual bodies must be
united into one body.
To unite all bodies into one body:
Select Unite from the Edit_Solid menu:

11
Select all the bodies (a window selection is easiest) and End the select command.
All bodies will now be united. See the before and after unite Solid Properties dialogs below:
Before Uniting Bodies After Uniting Bodies

To add Chamfers to the top edges of the body:

Select Chamfer from the Edit_Solid menu:
Enter a value of 2 in the Left Range edit box of the displayed Chamfer Blend dialog as
indicated below. Pick all the relevant Edges, Loops or Face at the top of the body and select
the OK button:

Note. To end the selection operation when picking Edges, the End Command button
must be selected to return to the Chamfer Blend dialog.

12
The images below indicates what edges will be selected for chamfering depending on which
of the Pick Edge, Pick Loop or Pick Face button is selected:
Pick Edge Pick Loop Pick Face

To add Blend Radii to the body:

Select Constant Blend, or alternatively, Variable Blend from the Edit_Solid menu:
Operation is similar to that of the Chamfer Blend dialog. That is, enter a required blend
radius value in the edit box of the displayed Constant/Variable Radius Blend dialog. Pick
the relevant Edges, Loops or Faces and select the OK button:
Note. With regard to the Variable Radius Blend dialog, different Start, Middle and End radii
can only be applied to one edge at a time.

How to select several linked edges (as opposed to selecting the edges individually):
The following procedure is typical for many functions (e.g. Chamfer Blend, Constant Radius
Blend, etc.), where linked selection may be required.

After selecting the Pick Edge button in the dialog, select the Linked Geometry button,
st
Select the 1 edge of the required linked geometry in response to the “Select First Item to
Link” prompt.
The selected edge will be marked and several arrows will be displayed indicating the various
direction choices for the next linked edge. The arrow displayed in Red is the default direction

that will be used by CAMWARE if the “Move this Way” button is selected.
To change a different direction arrow to Red (to set the next linked edge to be chosen), select

either of the CW or CCW direction scan buttons.

When the required direction arrow is set to Red, select the “Move this Way” button.

The Undo and Redo buttons are used in the normal way to undo previous steps
or redo the ‘undone’ steps.

After selecting the last of the required linked edges, select the End Command button to
end the linked geometry operation. The End Command button must be selected again to
return to the dialog.

13
First Linked Item selected Part way through selection Last Linked Item selected

Depending on the blend radii added to the model, the final model might look something like
the model below:

Any model data that has been created, can be saved in various solid model formats, e.g.
Parasolid (.x_t), 3D IGES (.igs), ACIS (.sat), StereoLithography (.stl), etc., depending on the
options purchased by users.
Parasolid and 3D IGES formats are standard for CAMWARE. – Parasolid is the preferred
model type to use with CAMWARE.
It is not possible to save model information using the VDM file format.

14
NOTES:

15
Housing (Bobbin & Doughnut)
Shape Creation & CAD features/functions used in creating this model include:
Create, Hide & Display Layers,
Construction Geometry, Line/Arc Draw & Blend (radii) commands,
Convert Line/Arc to Sheet Body, Convert Line/Arc to Wire Body, Convert Loop to Wire Body,
Convert Wire Body to Sheet Body,
Solid Primitive Block & Cylinder creation,
3D Rotate transformation,
Create Spun Body operation,
Section with Sheet Body operation,
Add Draft operation,
Unite operation,
Constant Radius Blend,
Linked Edge selection.

Drawing of model to create:

17
To create the rectangular base body:
In the Layer Maintenance dialog, create a New layer called Base. See below:
CAMWARE will make this the current layer on which the rectangular base will be defined.

Select Solid Primitive from the Solid-Create menu:

Select the Block tab in the Create Solid dialog, enter the data as indicated below and select
the Create button. Finally select the Done button to close the dialog:

18
 The model of the rectangular base body will be as displayed below:

Creating the Bobbin body in stages:

To create the bobbin Line/Arc profile:
In the Layer Maintenance dialog, select and Hide the layer: Base.
This will hide it from view to avoid any confusion while creating the bobbin body.

In the Layer Maintenance dialog, create a New layer called Bobbin.

CAMWARE will make this the current layer on which the bobbin body will be defined.

Using Construction geometry, Line/Arc draw and Blend (radii) commands, create the line/arc
profile of one side (e.g. the left-hand side) of the bobbin – also joining the top of the profile to
the bottom, as below:

19
To convert the bobbin Line/Arc profile to a Sheet Body:
Select Convert Entities from the Edit_Solid menu:

In the Convert Entities dialog, select the Input Type as Line/Arc and select the Output Type

as Sheet Body and then pick the Select button:

20
Select the Linked Geometry button, select the required line/arc profile and finally

select the End Command button.

After returning to the Convert Entities dialog, select the Done button to close the dialog.

The Sheet Body (of the Line/Arc profile) will be as displayed below:

To create the bobbin solid body:

Select Spin from the Solid-Create menu:
In the Create Spun Body dialog, select the Sheet Profile to be spun (i.e. rotated about an
axis), select the Start and End of Axis co-ordinates (i.e. the extremities of the rotation
centreline), enter a Spin Angle of 360º and OK the dialog.
Data similar to that indicated below will be displayed:

21
Note 1: The Spin Angle should actually be 180º but entering a value of 360º enables another
solid editing function to be illustrated later in this tutorial.
Note 2: The co-ordinates entered for the Start and End of Axis can be any 2 co-ordinates on
the axis of rotation.
Note 3: Depending on which of the 2 co-ordinates is given as the Start of Axis co-ordinate,
the direction of spin might be reversed. Normally, the most negative point is entered as the
Start of Axis co-ordinate.
Note 4: The original Wire or Sheet body (used to create a Sheet or Solid body) can be
deleted by selecting the Delete Profile option in the dialog.
Fewer problems could possibly occur later if this option is selected.
The model of the bobbin body will be as displayed below:

In the Layer Maintenance dialog, select and Display the layer: Base.
The portion of the bobbin that extends below the rectangular base must now be removed.

To create a Sheet Body in preparation for removing the unwanted portion of the bobbin body:
Select Convert Entities from the Edit_Solid menu:
In the Convert Entities dialog, select the Input Type as Loop and select the Output Type as
Wire Body and then pick the Select button:
Select the underside rectangular profile of the base as the ‘Loop’. See below:

22
After returning to the Convert Entities dialog, select the Input Type as Wire Body and select
the Output Type as Sheet Body and then pick the Select button:

Pick the previously created Wire Body, select the End Command button to return to
the Convert Entities dialog and finally select the Done button to close the dialog.
A Sheet Body (of the underside face of the rectangular base) has now been created.

To remove the unwanted portion of the bobbin solid body:

Select Section from the Edit_Solid menu:
st
In the 1 Section wizard dialog, select the options as indicated below, selecting the Bobbin as

the Parasolid body to section (select the End Command button to return to the wizard
dialog after selecting the body):

Bobbin (target) body selected

st nd
Select the Next button in the 1 Section wizard dialog - to display the 2 Section wizard
dialog.
nd
In the 2 Section wizard dialog, select the options as indicated below, selecting the
previously created Sheet body as the body with which to section the Bobbin:

23
 Sheet body selected

nd rd
Select the Next button in the 2 Section wizard dialog - to display the 3 Section wizard
dialog.
rd
In the 3 Section wizard dialog, select the options as indicated below, finally selecting the
Next button to complete the operation.

24
 The sheet body has now ‘cut’ the bobbin in two.

Select the Delete button, select the portion of the bobbin, to be deleted, on the

underside of the base (and also select the sheet body) and select the End Command
button:
The required bobbin shape has now been created. See below:

Select portion to delete Final bobbin and base body shape

Creating the Doughnut body in stages:

To create the basic doughnut cylindrical body:
Note: The Doughnut body could perhaps be created more easily using Line/Arc geometry
definition with final conversion to a solid using a Spun Sheet body – a method similar to that
used for the Bobbin body. The steps as indicated below, to create the doughnut body,
illustrate the use of alternative solid creation and editing procedures.

In the Layer Maintenance dialog, select and Hide the layers: Base and Bobbin.
This will hide them from view to avoid any confusion while creating the doughnut body.

In the Layer Maintenance dialog, create a New layer called Doughnut.

CAMWARE will make this the current layer on which the doughnut body will be defined.

Select Solid Primitive from the Solid-Create menu:

Select the Cylinder tab in the Create Solid dialog, enter the data as indicated below and
select the Create button. Finally select the Done button to close the dialog:

25
In the Layer Maintenance dialog, select and Hide the layer: Doughnut.
This will hide it from view to avoid any confusion while creating line/arc wire body geometry
with which to ‘cut’ the doughnut cylindrical body.

To create a line/arc profile in preparation for cutting the doughnut cylindrical body:
In the Layer Maintenance dialog, create a New layer called Dnut Wire.
CAMWARE will make this the current layer on which the doughnut wire line/arc geometry will
be defined.

Using Construction geometry and Line/Arc draw commands, in the XY plane, create the basic
internal line/arc profile of one side (e.g. the right-hand side) of the doughnut – as below:
Note 1: Keep the shape simple and ignore any blend radii.
Note 2: To avoid possible future problems, the taper line from 61.29, 30 to 97.82, 50 should
in fact extend beyond the 97.82, 50 co-ordinate.

The profile must now be rotated from the XY plane to the XZ plane about the drawing zero.
Select 3D Rotate from the Transformations menu:
In answer to the prompt: “Select items and click “End” or Press “[Enter]” when Done”,

select the Linked Geometry button, select the required line/arc profile and finally select

the End Command button.

In answer to the prompt: “Enter CENTRE POINT”, select the Origin triad or enter X0 Y0 Z0:
In answer to the prompt: “Specify another point lying on the axis of rotation…”, enter (for
example) DX1:
In answer to the prompt: “Angular rotation about the axis…”, enter 90:
(This rotates the selected profile through 90º about the X axis).
The profile will now be displayed as below:

26
To convert the profile to a Sheet body in preparation for cutting the doughnut cylindrical body:
Select Convert Entities from the Edit_Solid menu:
In the Convert Entities dialog, select the Input Type as Line Arc and select the Output Type
as Wire Body and then pick the Select button:

Select the Linked Geometry button, select the required line/arc profile and finally

select the End Command button.

After returning to the Convert Entities dialog, select the Done button to close the dialog.

Select Spin from the Solid-Create menu:

In the Create Spun Body dialog, select the Wire Body to be spun (i.e. to be rotated about
the Z axis), enter Start and End of Axis co-ordinates (i.e. 2 points lying on the rotation
centreline), enter a Spin Angle of 360º and OK the dialog.
Data similar to that indicated below will be displayed:

The resultant Sheet body created from the Wire body will be as displayed below:

27
To cut and remove the unwanted central portion of the doughnut solid body:
In the Layer Maintenance dialog, select and Display the layer: Doughnut.

Select Section from the Edit_Solid menu:

st
In the 1 Section wizard dialog, select the options as indicated below, selecting the Doughnut

as the Parasolid body to section (select the End Command button to return to the
wizard dialog after selecting the body):

Target body selected

st nd
Select the Next button in the 1 Section wizard dialog - to display the 2 Section wizard
dialog.
nd
In the 2 Section wizard dialog, select the options as indicated below, selecting the
previously created Sheet body as the body with which to section the Doughnut:

28
 Sheet body selected

nd rd
Select the Next button in the 2 Section wizard dialog - to display the 3 Section wizard
dialog.
rd
In the 3 Section wizard dialog, select the options as indicated below, finally selecting the
Next button to complete the operation.

29
The sheet body has now ‘cut’ the basic doughnut cylindrical body in two.

Select the Delete button, select the solid inner portion of the doughnut (and select the

sheet body), to be deleted, and select the End Command button.

Note: Less selection problems may occur if the sheet body is selected first.
The required doughnut body (but without the blend radii) has now been created. See below:
Select portion to delete Final doughnut body shape minus blend radii

To add draft angles to the doughnut solid body:

In the Layer Maintenance dialog, select and Hide the layer: Dnut Wire.
Change to the layer: Doughnut.
CAMWARE will make this the current layer on which the doughnut’s draft angles (and blend
radii) will be defined.

Select Add Draft from the Edit_Solid menu:

To apply a draft angle on the 160mm diameter surface, enter/set the data in the Add Draft
dialog, as indicated below. Pick the outside cylindrical face of the doughnut as the face
requiring the draft and select the OK button:

Note. To end the selection operation when picking Faces, the End Command button
must be selected to return to the Add Draft dialog.

30
To apply a draft angle on the 40mm diameter surface, repeat the Add Draft operation except
that the Draft Angle should be set to 3º in the Add Draft dialog and the inside cylindrical face
of the doughnut should be picked as the face requiring the draft.

To add blend radii to the doughnut solid body:

Select Constant Blend from the Edit_Solid menu:
Enter a value of 10 in the Blend Radius edit box of the displayed Constant Radius Blend
dialog as indicated below. Pick the tapered face between the two 10mm radii as the Face to
Blend and select the OK button:

Note. To end the selection operation when picking Edges, the End Command button
must be selected to return to the Constant Radius Blend dialog.

Repeat the Constant Radius Blend operation for the 2mm and 15mm blend radii – picking
either Edges or Loops, where appropriate, as the entities requiring the blend radii.

The model of the doughnut body will be as displayed below:

31
Finalising the Housing model creation:
To add blend radii between the doughnut and bobbin solid bodies:
In the Layer Maintenance dialog, select and Display the layers: Base and Bobbin.
(All 3 ‘body’ layers, Base, Bobbin and Doughnut should now be displayed).

Select Unite from the Edit_Solid menu:

Unite the Base, Bobbin and Doughnut bodies into one body.

Select Constant Blend from the Edit_Solid menu:

Apply a 3mm blend radius to the Loop where the Bobbin and Doughnut contact the Base. See
below:

Apply a 3mm blend radius at the join between the Bobbin and Doughnut. (Use Linked Edge
selection). See below:

32
The final model will look like the model below:

33
NOTES:

34
Coffee Mug
Shape Creation and CAD features/functions used in creating this model include:
Create, Hide & Display Layers,
Solid Primitive Cone creation,
2D and 3D Rotate transformation,
Hollow Face operation,
Group Definition,
Fit Spline Curve operation,
Create Bi-Arc Spline,
Draw 2D Conics - Ellipse,
Convert Line/Arc to Sheet Body, Convert Line/Arc to Wire Body,
Turn Wire Direction On/Off operation,
Reverse Wire Body Direction operation,
Create Swept Body operation,
Unite operation,
Constant Radius Blend.
Drawing of model to create:

35
Creating the Mug body in stages:
To create the basic mug shape body:
In the Layer Maintenance dialog, create a New layer called Mug.
CAMWARE will make this the current layer on which the basic mug body will be defined.

Select Solid Primitive from the Solid-Create menu:

Select the Cone tab in the Create Solid dialog, enter the data as indicated below and select
the Create button. Finally select the Done button to close the dialog:

When a Solid Primitive Cone is created, the circular section is created in the XY plane, and
the tapered side view is therefore displayed in the XZ (and YZ) plane.
In this example we require to rotate the body through 90º about the X axis so that the circular
section is subsequently displayed in the XZ plane with the tapered side view displayed in the
XY plane. –Hence the reason for entering -90º in the Rotation X edit box of the Create Solid
dialog.
The model of the basic mug body will be as displayed below:
Mug body before rotation Mug body after rotation

36
Rotation has been performed about the Centre of Base. The requirement here is that the top
centre of the mug is set at the drawing zero. Therefore a (Move) Translate operation is now
required.
Select Translate from the Transformations menu:
In answer to the prompt: “Select items and click “End” or Press “[Enter]” when Done”,

select the mug body and then select the End Command button:

In answer to the prompt: “Enter FROM position”, using the Centre of snap button,
select the centre of the circular top face of the mug:
In answer to the prompt: “Enter TO position”, select the Origin triad or enter X0 Y0 Z0:
Note: The 3D Rotate transformation menu could have been selected as an alternative to the
procedures used above to rotate and translate the mug body.

The mug body will now be correctly positioned as below:

To hollow out the mug body:

Select Hollow Face from the Edit_Solid menu:
In answer to the prompt: “Select solid body”, select the mug body:
In answer to the prompt: “Select faces (E - End)”, select the circular top face of the mug body

and then press E or select the End Command button:

In answer to the prompt: “Specify OFFSET distance”, enter a value of -5:
The inner part of the mug body will now be removed, with the top face ‘open’ – the mug will
be ‘hollow’.
Note: If no face had been selected in response to the “Select faces (E - End)” prompt, then
the inner part of the mug body would also have been removed but the ‘hollow’ would have
been totally enclosed, i.e. the top face would not have been removed.

To add blend radii on the top edges of the mug body:

Select Constant Blend from the Edit_Solid menu:
Apply a 2mm blend radius to the top Face. See below for selected face and final body shape:

37
 Selected face to apply 2mm radii Completed Mug body

Creating the Handle body in stages:

To define the Construction points for the spline curve:
In the Layer Maintenance dialog, select and Hide the layer: Mug.
This will hide it from view to avoid any confusion while creating the handle body.

In the Layer Maintenance dialog, create a New layer called Handle.

CAMWARE will make this the current layer on which the handle body will be defined.

Select Point, Explicit, Polar, Increm. from the Construction menu:

In answer to the successively repeated prompts: “Enter Point”, enter the Handle co-ordinate
points as listed in the drawing – finally escaping the command by selecting the End

Command button:
Note: If, for some reason, the co-ordinate points are not being drawn at Z0, then add Z0 to
the input data.

To create the handle profile – Method A – using Group and Fit Spline Curve:
Select Group Definition from the Solid-Create menu:
Accept (or optionally change) the Group Number in the Create a Group of Points dialog and
select the OK button:

Select the End of snap button and then select each of the previously defined points
starting at the top-most point, subsequently selecting the next adjacent point, finishing at the

lowest point. Complete the operation by selecting the End Command button:
The centre path from one point to the next will be displayed. If this feature is not enabled then

the Show Centre Path button can be selected to enable it.

38
(If the points have been randomly selected, the centre path optimisation function can be
accessed, to achieve the required a smooth centre path curve, by selecting the Change

Order of Group button).

Note: The colour of Construction points is dependent on the Construction colour set in the
Drawing Properties dialog whereas the colour of these points, when combined into a Group,
is changed to the Finite Geometry drawing colour.

Select Fit Spline Curve from the Solid-Create menu:

Select the group of points (i.e. simply select any one point), then select the End Command

button.
A spline curve Wire body, passing through the defined points, will be created.

To create the handle profile – Method B - using Biarc Spline:

(Suitable for 2D, XY plane spline creation only).
Select Biarc Spline from the Draw menu:

In answer to the prompt: “Digitise Point or Select Option”, pick the Select Items
button:
In answer to the prompt: “Select items and click “End” or Press “[Enter]” when Done”,
make a ‘windowed’ selection of all the previously entered point and then press [Enter] or

select the End Command button:

Select the Biarc Spline (Fit Curve) button and then Escape the command:
Using either method (A or B) ,a spline curve, passing through the defined points, will be
displayed as below:

To create the handle cross section – using 2D Conics:

Hide the Construction Point geometry:
Select 2D Conics from the Draw menu:

39
Enter/select the data in the 2D Standard Conics dialog as indicated below and select the OK
button:

In answer to the prompt: “Enter TO position”, select the End of snap button, select the

upper end of the spline curve and then select the End Command button:
Note: The ellipse is inserted as a Figure into the drawing.
Select the Cancel button in the 2D Standard Conics dialog to end the ellipse definition
operation.

The ellipse and spline curve will be displayed as below:

The ellipse must now be rotated through 90º, about the Y axis, to set it in the correct
orientation relative to the spline curve’s profile.
Select 3D Rotate from the Transformations menu:
In answer to the prompt: “Select items and click “End” or Press “[Enter]” when Done”,

select the ellipse profile and then select the End Command button.
In answer to the prompt: “Enter CENTRE POINT”, select the centre of the ellipse, i.e. the end
of the spline curve’s profile:

40
In answer to the prompt: “Specify another point lying on the axis of rotation…”, enter (for
example) DY1:
In answer to the prompt: “Angular rotation about the axis…”, enter either +90 or -90:
(This rotates the selected profile through 90º about the Y axis).
The profile will now be displayed as below:

To convert the ellipse profile to a Sheet body in preparation for creating the Handle solid
body:

Select the Explode button, select the ellipse figure and then select the End Command

button. – The ellipse figure has now been converted to line/arc entities.

Select Convert Entities from the Edit_Solid menu:

In the Convert Entities dialog, select the Input Type as Line Arc and select the Output Type

as Sheet Body and then pick the Select button:

In answer to the prompt: “Select items and click “End” or Press “[Enter]” when Done”,

select the Linked Geometry button, select the ellipse profile and finally select the End

Command button.

To convert the biarc spline profile to a Wire body in preparation for creating the Handle solid
body:
After returning to the Convert Entities dialog, select the Input Type as Line Arc and select

the Output Type as Wire Body and then pick the Select button:
In answer to the prompt: “Select items and click “End” or Press “[Enter]” when Done”,

select the Linked Geometry button, select the biarc spline profile and finally select the

End Command button:

After returning to the Convert Entities dialog, select the Done button to close the dialog.
Note: If the spline curve were created using the Group and Fit Spline Curve method, then the
spline curve is already a Wire body and does not need converting.

41
Reverse Wire Body direction ?
Move the cursor pointer to the wire body of the handle’s spline profile, right mouse click and
then select the context/shortcut menu “WIRE_001, Show Direction”:
If the direction arrow points from the bottom of the spline profile to the top, then this direction
must be reversed.
Select Reverse Wire Body from the Edit_Solid menu:
In answer to the prompt: “Select wire bodies (E - End)”, select the handle’s spline profile and

then select the End Command button:

(Alternatively, to reverse the wire direction, display and select the context/shortcut menu
“WIRE_001, Reverse”)
The Wire body direction should be indicated as below:

Create the Handle solid body:

Select Sweep from the Solid-Create menu:
Enter/select the data in the Create Swept Body dialog as indicated below and select the OK
button:
(Select the Sheet body of the ellipse as the ‘Sheet Profile To Sweep’ and select the Wire body
of the spline curve profile as the ‘Wire Path To Sweep Along’).

42
 The Handle solid body will be as displayed below:

Note: The thickness of section created depends on the angular relationship between the
ellipse profile and the handle profile in the XY plane.
The required angle can be achieved by rotation of the ellipse in the XY plane about the point
of contact of the ellipse and handle profiles using a Rotate transformation. See below:

Finalising the Coffee Mug model creation:

To add blend radii between the mug and handle solid bodies:
In the Layer Maintenance dialog, select and Display the layer: Mug.
(Both body layers, Mug and Handle, should now be displayed).

Select Unite from the Edit_Solid menu:

Unite the Mug and Handle bodies into one body.

Select Constant Blend from the Edit_Solid menu:

Apply 2mm blend radii to the Loops where the handle contacts the mug body.

43
The final model will look like the model below:

44
NOTES:

45
Flanged Casing
Shape Creation and CAD features/functions used in creating this model include:
Create, Hide & Display Layers,
Construction Geometry, Line/Arc Draw & Blend (radii) commands,
Convert Line/Arc to Sheet Body,
Face Normal On/Off checking,
Reverse Body Orientation,
Create Extruded Body operation,
Translate transformations,
Unite and Subtract operations,
Constant Radius Blend.

Drawing of model to create:

47
Creating the Flanged Casing body in stages:
To create the flange Line/Arc profile:
In the Layer Maintenance dialog, create a New layer called Flange.
CAMWARE will make this the current layer on which the flange body will be defined.

Using Construction geometry, Line/Arc draw and Blend (radii) commands, create the line/arc
profile of the flange, (at the default Z0 level), as below:

To create a Sheet body of the flange profile:

Select Convert Entities from the Edit_Solid menu:
In the Convert Entities dialog, select the Input Type as Line Arc and select the Output Type

as Sheet Body and then pick the Select button:

In answer to the prompt: “Select items and click “End” or Press “[Enter]” when Done”,

select the Linked Geometry button, select the flange profile and finally select the End

Command button.
After returning to the Convert Entities dialog, select the Done button to close the dialog.

Check the Face Normal direction:

Move the cursor pointer over the sheet body, right mouse click and then select the
context/shortcut menu “FACE_xxx, Show Normal”:
The direction arrow, that is displayed pointing away from the sheet body, indicates the
positive face normal direction. Any positive data entered in the subsequently displayed
Extruded Body dialog indicates a position in the direction of the arrow. Conversely, any
negative data entered indicates a position in the opposite direction to the arrow.

48
The Sheet body Face Normal direction will be indicated as below:

As to which direction the arrow points will depend on the order/direction of the original
geometry creation. Data must be entered in the subsequently displayed Extruded Body dialog
depending on the direction of the arrow and the required extrusion directions.
Note: It is possible to reverse the direction of the face normal of a Sheet or Solid body by
selecting the ‘Reverse Body Orientation’ menu from the Edit_Solid menu.

To create the flange body:

Select Extrude from the Solid-Create menu:
Enter/select the data in the Create Extruded Body dialog as indicated below and select the
OK button:

49
The model of the flange body will be as displayed below:

To create the casing Line/Arc profile:

In the Layer Maintenance dialog, select and Hide the layer: Flange.
This will hide it from view to avoid any confusion while creating the casing body.

In the Layer Maintenance dialog, create a New layer called Casing.

CAMWARE will make this the current layer on which the casing body will be defined.

Using Construction geometry, Line/Arc draw and Blend (radii) commands, create the line/arc
profile of the casing, (at the default Z0 level), as below:

In order to illustrate another extrusion feature, translate this profile from its current drawing
plane of Z0 to Z-130 (-to what will become the bottom face of the casing solid body):
Select Translate for the Translations menu:
In answer to the prompt: “Select items and click “End” or Press “[Enter]” when Done”,

select the Linked Geometry button, select the casing profile and finally select the End

Command button:
In answer to the prompt: “Enter FROM position”, enter Z0:
In answer to the prompt: “Enter TO position”, enter Z-130 or DZ-130:

50
Convert the Line/Arc profile to a Sheet body using the same procedure as explained for the
flange profile, i.e. use Convert Entities.

Check the Face Normal direction using the same procedure as explained for the flange
profile.

To create the casing body:

In the Layer Maintenance dialog, select and Display the layer: Flange.
(Both body layers, Flange and Casing, should now be displayed).

Select Extrude from the Solid-Create menu:

Enter/select the data in the Create Extruded Body dialog as indicated below and select the
OK button:
Note: Ensure that the Bounding Distance value in the End Condition section of the dialog
is set to 0 (and not to the previous value of -20), else the sheet body will be extruded down
from its current position by a further 20 mm.

Note 1: The Start Condition data of 0 sets one extremity of the casing solid body at the
casing sheet body’s current position.
Note 2: The End Condition Bounding Body is the flange sheet body. – It could also be the
flange solid body.

51
The model of the casing and flange bodies will be as displayed below:

To create the cavity Line/Arc profile:

In the Layer Maintenance dialog, select and Hide the layers: Flange and Casing.
This will hide them from view to avoid any confusion while creating the cavity body.

In the Layer Maintenance dialog, create a New layer called Cavity.

CAMWARE will make this the current layer on which the cavity body will be defined.

Using Construction geometry, Line/Arc draw and Blend (radii) commands, create the line/arc
profile of the cavity, (at the default Z0 level), as below:

Convert the Line/Arc profile to a Sheet body using the same procedure as explained for the
flange profile, i.e. use Convert Entities.

Check the Face Normal direction using the same procedure as explained for the flange
profile.

52
To create the cavity body:
Select Extrude from the Solid-Create menu:
Enter/select the data in the Create Extruded Body dialog as indicated below and select the
OK button:

The model of the cavity body will be as displayed below:

Unite and Subtract bodies:

In the Layer Maintenance dialog, select and Display the layers: Flange and Casing.
(All 3 ‘body’ layers, Flange, Casing and Cavity should now be displayed).

53
Delete the original line/arc geometry and any remaining sheet bodies, to ensure that there are
no Unite or Subtract operation problems encountered and to improve the appearance of the
model. Use the Mask function during the deletion operation to ensure correct entity selection.

Select Unite from the Edit_Solid menu:

Unite the Flange and Casing bodies into one body.

Select Subtract from the Edit_Solid menu:

Subtract the Cavity body from the main body.

Select Constant Blend from the Edit_Solid menu:

Add the various blend radii to the selected Loops on the body.

The final model will look like the model below:

54
NOTES:

55
Creating a Simple Loft
Shape Creation and CAD features/functions used in creating this model include:
Construction Point geometry,
Group Definition,
Fit Spline Curve operation,
Mirror transformation,
Fit Loft Surface operation,

Shape of model being created:

st
To define 1 set of Construction Points:
Select Point, Explicit, Polar, Increm. from the Construction menu:
In answer to the successively repeated prompts: “Enter Point”, enter the co-ordinate points

as listed below, – finally escaping the command by selecting the End Command
button:

X Y Z
0 0 0
10 20 -20
20 45 -10
10 65 0
0 80 -10

57
To Fit a Spline Curve through the points:
Select Group Definition from the Solid-Create menu:
Accept (or optionally change) the Group Number in the Create a Group of Points dialog and
select the OK button:

Select the End of snap button and then select each of the previously defined points
starting at the lower-most point (in the XY plane), subsequently selecting the next adjacent
point, finishing at the highest point. Complete the operation by selecting the End Command

button:

Select Fit Spline Curve from the Solid-Create menu:

Select the group of points (i.e. simply select any one point), then select the End Command

button.
A spline curve Wire body, passing through the defined points, will be created.

st
To create a mirrored spline curve from the 1 curve:
Select Mirror About 2 Points from the Transformations menu:
Select the Wire body and End the select command:
In answer to the prompt: “First Point on Mirror Hinge Line”, enter X50 Y0 Z0:
In answer to the prompt: “Second Point on Mirror Hinge Line…”, enter (for example) DY1:
Select the YES button in the “Leave un-mirrored items” message dialog:
(This mirrors the Wire body about an imaginary line drawn parallel to the Y axis at X50)
nd st nd
Note: In this exercise, the 2 spline curve is a mirror of the 1 . The 2 spline curve can, in
fact, be any ‘random’ curve.

nd
To define 2 set of Construction Points:
Select Point, Explicit, Polar, Increm. from the Construction menu:
In answer to the successively repeated prompts: “Enter Point”, enter the co-ordinate points

as listed below, – finally escaping the command by selecting the End Command
button:

X Y Z
20 10 10
40 40 40
90 90 -10

nd
To Fit a Spline Curve through these 2 set of points:
Select Group Definition from the Solid-Create menu:
Accept (or optionally change) the Group Number in the Create a Group of Points dialog and
select the OK button:

58
Select the End of snap button and then select each of the previously defined points
starting at the lower-most point, subsequently selecting the next adjacent point, finishing at

the highest point. Complete the operation by selecting the End Command button:

Select Fit Spline Curve from the Solid-Create menu:

Select the group of points (i.e. simply select any one point), then select the End Command

button.
A spline curve Wire body, passing through the defined points, will be created.

To Fit a Loft Surface through the 3 Wire bodies:

Select Fit Loft Surface from the Solid-Create menu:

Pick the Select button in the Loft Surface wizard and select the 3 Wire bodies in

the order of WIRE_001, WIRE_003 and WIRE_002 and then select the End Command
button:
(The order of Wire body selection will affect the final loft surface shape created).
Select the Next button on any subsequently displayed wizard dialogs:
The shape will now be displayed.

This surface could now be extruded to create a solid body. See the sample shape below:

59
NOTES:

60
Delete Faces And Heal Exercise.
The Delete Faces And Heal menu (to call the Delete Faces And Heal dialog) can be found in
the Edit_Solid menu. Select the menu and display the dialog.
The simple model below can be used to demonstrate some of the Delete Faces And Heal
functions:

(i) To remove the 10mm radius from between the top flat face and the partial
hemisphere and also the 3mm radius at the top of the partial hemisphere, select the
Treat As Blends option and then select the 2 radiused faces (10mm & 3mm) as
indicated below:

(Do not forget to select the End Command button after selecting the required faces to
return to the Delete Faces And Heal dialog. OK the dialog to complete the operation).

Note : Selecting the Normal Deletion option would also have caused the radii to be deleted.

(ii) To remove the blind chamfered hole, at the bottom left hand corner of the model,
select the Normal Deletion option and then select the 3 faces as indicated below:
Note 1: The 3 faces are the chamfer face, the side hole face and the bottom hole face.

61
Note 2: The through chamfered hole, at the top right hand corner of the model, could also
have been deleted at the same time as the blind chamfered hole.

(iii) To remove the through chamfered hole at the top right hand corner of the model,
select the options and then select the 2 faces as indicated below:
Note 1: This particular exercise illustrates that a separate solid of the removed feature (a
Child of the Parent) can also be created if required. Using the Translate option, the Child (the
model of the removed hole), can be translated, i.e. moved, out of the main body of the Parent
model – see the image of the Parent and Child models - bottom right (below):
Note 2: It is sometimes difficult to pick/select bodies that are embedded in other models. In
this instance, during the select procedure, press the right hand mouse button to display the
context menu and select the option: ‘Allow Hidden Face Picking’. If this menu option is not
displayed, then the option is already active.

62
(iv) To remove the rectangular recess at the bottom right hand corner of the model, select
the Normal Deletion option and then select the 3 faces as indicated below:

(v) To remove the large hole at the centre of the model, select the Normal Deletion
option and then select the 2 faces (large hole side wall and 3mm radiused face) as
indicated below:
Note: The method indicated here extends the partial hemisphere to a full hemisphere.

(vi) Alternatively, to cap the large hole at the centre of the model, leaving the partial
hemisphere unmodified, the 3mm radius at the top of the partial hemisphere must first
be removed as illustrated in section (i).
Subsequently, to cap the large hole, select the options and then select the
hemispherical face as indicated below:
Note: To cap and remove (fill) the large hole, then select the large hole side wall
instead of selecting the hemispherical face.

63
Using the exercises indicated above and depending on the method of deletion, the final model
will be as below:

One final comment:

Using the Delete Faces And Heal function is not always easy. Not all functions (and therefore
not all the relevant help documentation) have been implemented to date or some functions
may not be currently working as intended.
These exercises are purely a demonstration of the types of delete and heal operations that
can be performed and no further explanations, other than those in the Help file, are available.
To find out what can be achieved – this is a case of ‘trial & error’ – i.e. Experimentation.

64
NOTES:

65
Custom Component Design.
Introduction
The Custom Component Viewer dialog enables user-defined Tool, Toolholder, ATC Flange
and Spindle Nose shapes to be created or reloaded for editing.
The simulation graphics of this tooling will be generated from the user-defined ‘free-form’
figure stored in a CAMWARE VDM file - instead of using the parametric data.
The VDM file is created via the Custom Component Viewer dialog. The figure defined in the
VDM file is a 2D shape, representing the side of the tool or toolholder, which is rotated
through 360° about the Z-axis by CAMWARE during simulation, to generate the 3D graphic
shape of the tooling.
The VDM file must be allocated the same file name as the parametric tool or toolholder name
that it is to replace. Also, the VDM file must be stored in the same folder as the parametric
data file of the tooling that it is to replace during simulation.
The VDM file extension name allocation and the correct folder location will be automatically
handled by CAMWARE.
Drawing of tool to create:

Create the profile of a Custom design End Mill:

Create the outline profile of the custom tool, drawing from point A to B (or from B to A), using
standard Construction, Line/Arc and Blend Radius CAD definition geometry.
Note 1 : This exercise is to create a profile for:
(i) a metric unit Tool (not a Toolholder, ATC Flange or Spindle Nose);
(ii) a tool that is a Common usage tool (not a tool to be used for a specific machine);
(iii) a tool that will be used instead of the parametric tool: EML_1_20
Note 2: Any profile that is drawn in the colour green indicates the cutting edges on a tool. At
the drawing stage the colour of the part of the tool profile, that represents the cutting edges,
could be edited to green using the Edit Item Attributes dialog. But do not change the colour at
this time.

67
The created profile, (with any Construction geometry hidden), will look as below:

To register the profile as a Custom Component figure:

Select Custom Components from the Draw menu:

Select the Register Custom Component button on the displayed Custom Component
Viewer dialog, as indicated below:

68
Follow the instructions on the subsequently displayed Custom Component Wizard moving
from stage to stage after completing the instructions in each dialog.
The simple and self-explanatory wizard will guide you, step by step, through the following
procedures:
i) Optional display of the Instructions of how to create the initial 2D line/arc profile,
ii) Geometry selection (of the previously drawn geometry to comprise the figure),
iii) Selection of the tooling type, (select Tool for this exercise),
iv) Cutting edge identification for Tools, (select the cutting edge geometry),
v) Entry of the Component (figure) Name, (enter EML_1_20 for this exercise),
vi) Selection of the tool usage type, (select Common (Metric) for this exercise),
vii) File creation (Save).

The Custom Component Viewer dialog, as indicated below - left, will be automatically
redisplayed:
The figure shape created is shown below - right:

Close the dialog to finish the custom component registration operation.

To edit the profile of the End Mill:
To avoid complications or confusion, delete any geometry that is currently displayed on the
graphics background.
Then select Custom Components from the Draw menu:
Select the Common, Metric, Tools folder in the Custom Components Viewer window to
display any figures from that folder.
Select the previously created figure file, EML_1_20.vdm:
Select the Load File button, as indicated below, to load and display the selected file.

69
Select the Yes button in the subsequently displayed dialog, shown below, to load the selected
figure and commence geometry editing:

Close the Custom Components Viewer dialog.

Using the CAD functions, edit the drawing by changing the radiused end of the cutter to a
chamfer.
To do this, perform the following steps:
(i) Explode the figure into individual lines and arcs.
(ii) Then draw a line to represent the chamfer edge and delete the radius.
To re-register the modified profile as a Custom Component figure:
Select Custom Components from the Draw menu.
Repeat the steps as explained earlier to register a Custom Component figure.
Select the Yes button in the message dialog that is displayed part way through the Custom
Component Wizard, as shown below, to overwrite an existing figure:

70
Continue registering the modified Custom Component figure as explained earlier.
Finally, Close the dialog to finish the custom component registration operation.

The final profile (with the cutting edges coloured green), will look as below:

Note: The use of the Custom Component Viewer dialog is intended to simplify the creation,
edition and registration of a Figure that will be used for the custom tool display during
simulation.
It is also possible to create, edit and register this custom tool Figure by using the standard
CAD Figure Maintenance, Figure Edit and Figure End functions.

71
NOTES:

72