COVER PAGE

CAMWorks 2017
Wire EDM
Tutorial
Disclaimer
Geometric Limited makes no warranties, either expressed or implied with respect to this manual.
Geometric Limited reserves the right to revise and improve products as it sees fit, and to revise
the specifications and information contained herein without prior notice. Due to continuing
product development, specifications and capabilities described in this manual are subject to
change without notice.

Trademarks
The following and other product names and corporate references herein are registered or
proprietary trademarks of their respective owners.
CAMWorks® is a registered trademark of Geometric Ltd.
SOLIDWORKS® is a registered trademark of Dassault Systèmes SOLIDWORKS Corp.
FeatureManager™ is a trademark owned jointly by DS SOLIDWORKS and Bentley Systems,
Inc.
All other brands and names are the property of their respective owners.

Copyright ©1998-2016 Geometric Americas, Inc. All Rights Reserved.

 Wire EDM Tutorial

TABLE OF CONTENTS

NOTE ............................................................................................................. iii

1. Learning Wire EDM Basics .............................................................. 6
Wire EDM 1...................................................................................................................... 7
Steps to Generate EDM Toolpaths and NC Code ............................................................. 7
Step 1: Model Part in SOLIDWORKS/CAMWorks Solids or Import Part .......................... 8
Viewing the FeatureManager Design Trees .............................................................................. 8
Step 2: Change to CAMWorks Feature Tree ................................................................... 9
CAMWorks Machining Trees ..................................................................................................... 9
CAMWorks Menu and CAMWorks NC Manager ..................................................................... 10
CAMWorks Command Manager .............................................................................................. 11
CAMWorks Workflow Toolbar .................................................................................................. 11
CAMWorks Options .................................................................................................................. 11
Step 3: Define the Machine ........................................................................................... 12
Step 4: Define the Stock ................................................................................................ 15
Step 5: Define Machinable Features .............................................................................. 16
Using Automatic Feature Recognition (AFR) ........................................................................... 16
Step 6: Generate Operation Plan and Adjust Machining Parameters ............................. 18
Adjusting Operation Parameters .............................................................................................. 19
Step 7: Generate Toolpaths ........................................................................................... 21
Step 8: Simulate Toolpath ............................................................................................. 22
Step Through Toolpath............................................................................................................. 23
Step 9: Post Process Toolpaths..................................................................................... 26

2. Learning 2 Axis Contour Cutting ................................................... 28

2 Axis Contour 1 ........................................................................................................... 29
Open the Part and Defining the Machine and Stock ....................................................... 29
Extracting Machinable Features and Customizing AFR .................................................. 30
Generating a 2 Axis Contour Operation and Toolpaths ................................................... 33
Simulating and Post Processing Toolpaths ..................................................................... 33
Simulation Toolpath.................................................................................................................. 33
Post Process Toolpath ............................................................................................................. 34
2 Axis Contour 2 ........................................................................................................... 36
Open the Part and Defining the Machine and Stock ....................................................... 36
Extract Machinable Features .......................................................................................... 37
Inserting 2.5 Axis EDM Features Interactively ................................................................ 37
Generating Operations Plan and Toolpaths .................................................................... 39
Changing the Machining Order and Post Processing...................................................... 40
2 Axis Contour 3 ........................................................................................................... 42
Open the Part and Defining the Machine and Stock ....................................................... 42
Extract Machinable Features and Interactively Inserting a Part Setup ............................ 43
Inserting Vertical and Tapered Open Profile Features .................................................... 43
Generate Operations Plan and Toolpaths....................................................................... 46
Simulation and Post process Toolpath............................................................................ 46
2 Axis Contour 4 ........................................................................................................... 48

Table of Contents i
Wire EDM Tutorial
Open the Part and Defining the Machine and Stock ....................................................... 48
Extract Machinable Features .......................................................................................... 49
Generate Operation Plan and Toolpath .......................................................................... 49
Post Process the Die Features ....................................................................................... 50

3. Learning 4 Axis Contour Cutting ................................................... 53

4 Axis Contour 1 ........................................................................................................... 54
Open the Part and Defining the Machine and Stock ....................................................... 54
Extract Machinable Features and Interactively Inserting Part Setup ............................... 55
Defining a 4 Axis Die Feature Interactively ..................................................................... 55
Generating a 4 Axis Contour Operation and Toolpaths ................................................... 56
Simulation and Post Process Toolpath ........................................................................... 56
4 Axis Contour 2 ........................................................................................................... 58
Open the Part and Defining the Machine and Stock ....................................................... 58
Extract Machinable Features and Interactively Inserting Part Setup ............................... 59
Inserting and Automatically Extracting Sync Curves to Define a 4 Axis EDM Feature .... 59
Generating the 4 Axis Contour Operation and Toolpaths ................................................ 60
4 Axis Contour 3 ........................................................................................................... 61
Open the Part and Defining the Machine and Stock ....................................................... 61
Extract Machinable Features and Using Sketches to Define a 4 Axis EDM Feature ....... 61
Interactively Inserting the 4 Axis EDM Feature ............................................................... 62
Generate Operation Plan and Toolpath .......................................................................... 63
Changing the Leadin Point ............................................................................................. 63
Toolpath Simulation ........................................................................................................ 64
4 Axis Contour 4 ........................................................................................................... 65
Open the Part and Defining the Machine and Stock ....................................................... 65
Extract Machinable Features and Inserting Part Setup ................................................ 65
Interactively Inserting and Picking Sync Curves to Define a 4 Axis EDM Feature ........... 66
Generate Operation Plan and Toolpath .......................................................................... 67
Simulate Toolpath .......................................................................................................... 67

Appendix A: Linking EDM Post Files & Adding EDM Machines/Models . 68

EDM Post Files............................................................................................................... 68
Folder Location of EDM Post Files ........................................................................................... 68
EDM Updating from a Previous CAMWorks Release...................................................... 69
Restoring customized EDM Post Files after installing a Service Pack .................................... 69
Linking customized EDM Post Files after installing Service Pack ........................................... 69
Restoring customized EDM Post Files after installing a new CAMWorks Release .......... 70
Procedure to Add Machines and Models ........................................................................ 70
Verifying the successful addition/edit of a Machine Make/Model..................................... 73

ii Table of Contents
 Wire EDM Tutorial

NOTE

Customizing Wire EDM module to suit your facility’s requirements

The Wire EDM module of CAMWorks is used for the purpose of Wire EDM machining.
Before you can machine parts using this module, you need to customize the Wire EDM
Machines, Models and Post files to suit your facility’s requirements.
Please refer the Appendix A: Linking EDM Post files & Adding EDM
Machines/Models section of this manual to understand how to link EDM Post files
and add/edit EDM Machine/Models.
Wire EDM Tutorial

1. LEARNING WIRE EDM BASICS

This chapter provides an opportunity to learn CAMWorks Wire EDM through a step-by-step tour of
the features and functions.
The exercises in this chapter are intended to show you how to use CAMWorks and may not
correspond to actual machining practices.
The exercise parts are installed when you install CAMWorks and are in the
\Examples\Tutorial_Parts\EDM folder. This folder is inside the CAMWorks data folder.
(Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM)

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

operations to features. The Technology Database contains the data for the machining
process plans and can be customized for your facility's machining methodology. When you
do these exercises, your results may not be exactly the same as described in the steps and
illustrated in the figures. This is because the machining sequences and operations data in
your Technology Database may be different from the database used to produce the
documentation.

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Wire EDM 1
Steps to Generate EDM Toolpaths and NC Code
The following steps are used to generate Wire EDM toolpaths and NC code:
1. Model the part or open the part file in SOLIDWORKS/CAMWorks Solids.
2. Change to the CAMWorks Feature tree.
3. Define the Machine type and machine parameters.
4. Define the Stock definition.
5. Define machinable features and adjust feature parameters.
6. Generate the Operation Plan and adjust operation parameters.
7. Generate Toolpaths.
8. Simulate Material Removal.
9. Post Process the toolpaths.

START

Simulate toolpaths
Model part in Generate toolpaths
SOLIDWORKS or import

Adjust operation No Are

Change to CAMWorks parameters as needed toolpaths
Feature tree correct?

Yes
Generate operation
Define machine type
plan
and machine parameters
Post process

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

END

The following series of exercises show you how to generate finish toolpaths on a SOLIDWORKS or
CAMWorks Solids part model. In order to give you a general understanding of how to use

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CAMWorks, you work with a part that was previously modeled in SOLIDWORKS. When you define
the operations and toolpaths, you will follow steps that are not explained in depth. This is done to
show you the basics of generating toolpaths from start to finish without getting into the details at this
time.
Sample parts are provided for the tutorials in this manual. When you install CAMWorks, these files
are installed automatically.

Topics covered in this tutorial:

 Using the CAMWorks Command Manager or Workflow toolbar to execute commands
 Editing the Machine Definition
 Editing the Stock Definition
 Changing Default Settings using Options dialog box
 Defining Machinable Features Automatically
 Generating Operation Plan
 Generating Toolpaths
 Simulate Toolpaths
 Step Through Toolpath
 Post Process Toolpaths

Step 1: Model Part in SOLIDWORKS/CAMWorks Solids or

Import Part
A part is a solid that is created with SOLIDWORKS/CAMWorks Solids or imported into
SOLIDWORKS/CAMWorks Solids from another CAD system via an IGES, Parasolid, SAT file, etc.
This exercise uses an existing SOLIDWORKS part.
Open the part file EDM2AX_1.SLDPRT in the following folder.
Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM

EDM2AX_1.SLDPRT

Viewing the FeatureManager Design Trees

The FeatureManager design tree displays the list of the features, sketches, planes and axes
related to the part.

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To use CAMWorks, you need to move between SOLIDWORKS/CAMWorks Solids trees and the
CAMWorks Feature trees. Different tabs are provided to access the SOLIDWORKS/CAMWorks
Solids trees and the CAMWorks Feature trees. Click the Pin button to continuously view this
Tree area.

If the CAMWorks tabs [ , , ] are not visible, you can expand the size of the tree. Position
the cursor on the line that divides the tree area from the graphics area. When the cursor
changes to a bar, drag the bar to the right until the tabs display.

Step 2: Change to CAMWorks Feature Tree

Click the CAMWorks Feature Tree tab.
When the CAMWorks Feature tree is displayed, it initially lists Configurations, Stock Manager,
Machine and Recycle Bin items.

The icons that display for the ‘Machine’ are indicative of the machine which is
currently selected. Step 3 of this tutorial explains how to select an EDM machine
(shown in the images on the next page).

Operation Tree CAMWorks menu CAMWorks

Workflow Toolbar

CAMWorks Command
Manager Tab

Feature Tree
items

Graphics area

CAMWorks Machining Trees

The CAMWorks machining trees provide an outline view of the machining information for the
model. Initially, the CAMWorks Feature tree shows the Configurations, CAMWorks NC Manager,
Stock Manager, Machine and Recycle Bin items. As you follow the steps to generate an NC
program, this tree expands to include Part Setups and machinable features. The tabs are for
moving between the SOLIDWORKS/CAMWorks Solids trees and the CAMWorks trees.

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 Configurations
Multiple CAMWorks datasets are supported. Each dataset is called a configuration. You
can use configurations to support multiple machines and SOLIDWORKS configurations.
 Stock Manager
The turn stock is the material from which the part will be machined. You can define the
stock as a cylinder (for bar stock) or as a closed sketch (for a forging or casting) and
specify the type of material.

 Machine
Turn Mill Mill-Turn Wire EDM
The Machine item defines the machine tool that will be used to machine the part. For mill
and turn machines, the tool definitions and the machine controller (post processor) are
also specified. The machines are set up in the Technology Database.

 Recycle Bin
The Recycle Bin is used to store machinable features that you do not intend to machine.

CAMWorks Menu and CAMWorks NC

Manager
1. Click CAMWorks on the
SOLIDWORKS/CAMWorks Solids menu bar.
2. The CAMWorks NC Manager item is present in
both the Feature tree and the Operation tree.
Right click on the CAMWorks NC Manager in
the tree. A list of executable commands is
displayed on the context menu. These right-
click context menus provide access to a variety
of commands. The commands displayed on
the context menu for CAMWorks NC Manager
item in the Feature tree is different from that in
the Operation tree.
3. The CAMWorks commands are explained in
the CAMWorks Context-based Help.

CAMWorks Menu
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 Wire EDM Tutorial

CAMWorks Command Manager

Click CAMWorks on the SOLIDWORKS/CAMWorks Solids menu bar. This action displays the
CAMWorks Command Manager. The CAMWorks Command Manager provides access to the
main CAMWorks commands. The commands are explained in the CAMWorks Context-based
Help.

CAMWorks Command Manager

Customization of CAMWorks Command Manager

Command Manager is a context-sensitive toolbar that can be dynamically updates based on
the toolbar you want to access. It provides access to the main CAMWorks commands found
on the CAMWorks menu. By default, it has toolbars embedded in it.
The CAMWorks Command Manager can be customized. Right click anywhere on the
CAMWorks Command Manager and select Customize from the RMB context menu. The
Customize dialog box will be displayed. Use the Toolbars, Commands, Menus, Keyboard
shortcut, Mouse gesture and Options tab of this dialog box to customize the Command
Manager as per your requirements.

Alternative Access to CAMWorks Commands

All the commands executed from the CAMWorks Command Manager can also be
alternatively accessed from the RMB context menu of the CAMWorks NC Manager. This is a
context menu. To execute the command, right click on the CAMWorks NC Manager item in
the tree and select the desired command from the RMB context menu. In addition to the
Command Manager commands, this right click context menu also provides access to a
variety of commands.

CAMWorks Workflow Toolbar

The CAMWorks Workflow toolbar contains all the major commands of CAMWorks in a separate
toolbar. When executed in sequential order, they define the workflow in CAMWorks. The
workflow includes, setting up of the machine, stock and subsequent features, operations and
toolpaths.

CAMWorks Options

1. Click the Options button on the CAMWorks Command Manager.

OR
Click CAMWorks on the SOLIDWORKS/CAMWorks Solids menu bar and select Options
from the dropdown menu.

Options button on the CAMWorks Command

Manager

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The Options dialog box is displayed. This dialog box contains various tabs to customize
settings and options related to Saving data, Feature recognition, Display, Simulation,
Updation and Rebuild of CAMWorks data and File locations.
2. Click on each different tab in this dialog box and click the Help button. Each tab is explained
in the Context-based Help.
3. To close the Context-based Help, click the Close button in the upper right corner of the
Help window to close the window.
4. Click OK/Cancel to close the Options dialog box.

Step 3: Define the Machine

The machine definition specifies the type of machining that will be done for the current model and
the associated machine tool for proper generation of the NC program. Based on the selected
machine, the Extract Machinable Features command will recognize mill, turn or Wire EDM features.
The machine can be changed to produce NC code for an alternate machine tool of the same type. If
the machine type changes, then all features and operations will be deleted. The icons that display in
the tree identify the machine:
Turn Mill Mill-Turn Wire EDM
1. Right click the Machine item in the CAMWorks Feature tree and select the Edit Definition
from the context menu.
OR
Double click the Machine item in the Feature tree to edit the machine definition.
The Machine dialog box is displayed.

‘Edit Definition’ on the context menu

Did You Know: In the Feature and Operation trees, instead of right-clicking items and
selecting Edit Definition on the context menu, you can double-click the
item to open the corresponding dialog box for editing the Stock
Manager, Machine, Setups, Features and Operations.

In the Available machines list, make sure Wire EDM–Inch is selected as Active machine.

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 Wire EDM Tutorial

This is the machine used for all the tutorials for EDM machining in this manual. When you
use CAMWorks to machine your own parts, select the machine tool you want to use.
2. Click OK to close the Machine dialog box.

Selecting the Machine

3. Right click Machine [Wire EDM–Inch] in the CAMWorks Feature tree and click Select
Machine on the context menu.
4. In the Machine Selection dialog box, select SODICK for the Make and AG600L for the Model
from dropdown list.

Machine Selection Dialog Box

5. Click OK to close the dialog box.

Contact your CAMWorks Reseller for more information on obtaining and/or

customizing machines for your facility.

6. Right click Machine [Wire EDM–Inch] and select Edit Settings on the context menu.
The EDM Settings dialog box is displayed.

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Wire EDM Tutorial

7. Observe that in the Machine Setup tab, the path to the CTC Database is identified.
This database has been set up for the SODICK machine. The cutting condition database
sets machine-specific parameters for power settings, etc.

Machine Setup Tab on EDM Settings Dialog box

8. Click the EDM Setup tab.

This tab allows you to set the wire diameter, maximum taper angle, etc.
9. Click the down arrow next to the Wire diameter and select 0.008 from the list.
10. Click the Posting tab.
This tab identifies the post processor. This post processor has been set up for the SODICK
machine and will be used for machining in this tutorial (does not need to be changed). The
parameters on this tab provide information used to generate the NC program.
11. Make sure By Complete Feature option is selected from dropdown list for Punch and Die
Process Order.
With this option, the NC program will be generated in the following machining order:
- For each Die feature: Cut rough pass, Glue stop cut off, and then all skim passes.
- For each Punch feature: The order is rough cut leaving glue stop, 0 - 6 skim passes,
and then Glue stop cut off.
12. Click OK to apply the changes and close the dialog box.

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EDM Settings dialog box

Step 4: Define the Stock

The stock is the material from which the part will be machined. The default stock is the smallest
cube (bounding box) that the part will fit into. Typically, this
is not the size of the stock you will be using. You can
change the stock definition either by offsetting the bounding
box from the part or by defining the stock from a sketch and
a depth (extruded sketch) or from an STL file.
1. Double click Stock Manager in the Feature tree.
The Stock Manager dialog box is displayed.
2. For this tutorial, leave the stock set as a default
Bounding Box.
3. Click the Material button, select Steel from
dropdown list.
4. Click OK to apply the changes and close the
Material dialog box.

5. Click OK to close the Manage Stock dialog box.

Stock Manager dialog box

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Wire EDM Tutorial

Step 5: Define Machinable Features

In CAMWorks, machining can be done only on machinable features. You use the following two
methods to define machinable features:
 Automatic Feature Recognition (AFR)
Automatic Feature Recognition analyzes the part shape and attempts to define Die
(Pocket) and Open Profile machinable features for Wire EDM.
 Interactively created features
If AFR does not recognize a feature you want to machine, you need to define the feature
using the New 2.5 Axis EDM Feature and New 4 Axis EDM Feature commands. Using
the interactive method, you can define Die (Pocket), Punch (Boss) and Open Profile
machinable features.

How AFR analyses a Solid Part

The idea of AFR is to analyze the part for features that can be machined. This process is
much the same as what you would do if you were to pick up a part that you had to machine.
You would look it over, take measurements, and begin deciding how to define areas or
features to machine and what machining processes you would need.
CAMWorks does not machine the SOLIDWORKS/CAMWorks Solids features directly. It
creates a separate list of Machinable Features instead. This is because design features are
typically not the same as manufacturing features and may have several areas that need to
be machined in different ways with different tools.

Using Automatic Feature Recognition (AFR)

Define machinable features automatically:

1. Click the CAMWorks Options button on the CAMWorks Command Manager.

2. Click the EDM Features tab and make sure the Perimeter Punch feature option is not
checked.
3. Click OK to apply the changes and close the dialog box.
The Extract machinable features section on this tab allows you to control whether or not AFR
finds certain feature types and how it classifies them.

4. In the Feature tree, click the Extract Machinable Features button on the CAMWorks
Command Manager.
OR
Right click CAMWorks NC Manager in the tree and select Extract Machinable Features on
the context menu.
The CAMWorks Message Window displays automatically to report the progress and status of
the process.

5. Click the Message Window button on the CAMWorks Command Manager, if the
CAMWorks Message Window is not displayed.

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CAMWorks Message Window

6. You can control whether this window displays temporarily or permanently by clicking the
Pushpin button on Message Window.
OR
Click on the CAMWorks Options button on the CAMWorks Command Manager.
The Options dialog box is displayed.
7. Check the Message Window option on the General tab of this dialog box to view this window
continuously.

General Tab of CAMWorks Options dialog box

8. Click OK to close the Options dialog box.

CAMWorks generates the EDM Part Setup and machinable features. The items display in
the CAMWorks Feature tree .
The EDM Part Setup is the 2 axis plane that the tool movement will be based on. It has an
origin location, and X, Y, and Z direction vectors. The EDM Part Setup is created
automatically; however, you can move the origin, and change the direction and angles of the
X and Y axes.
An EDM Part Setup is created for each different tool orientation. There is only one EDM Part
Setup for this part because all features can be machined using a single tool orientation. For
each EDM Part Setup, the machinable features are
listed in the order in which they were recognized.
The Feature tree allows you to:
- Copy, rename, suppress, combine and delete
machinable features
- Change machinable feature parameters
- Change the order in which the features are
machined

Features recognized by AFR

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Wire EDM Tutorial

- Insert 2.5 Axis and 4 Axis EDM features

- Search for a feature based on item name
- Hide or show feature display in graphics area
- Generate an Operation Plan and find the first operation for a feature

Did You Know: Features display in a different color when they have no operations
generated. Once operations are successfully generated, they display
in another color. If operations are not generated for certain features
(this occurs when feature conditions have not been defined in the
Technology Database), then they retain their original color indicating
non-generation of operations. You can set the color on the Display tab
in the Options dialog box.

Step 6: Generate Operation Plan and Adjust Machining

Parameters
An Operation Plan contains information on how each machinable feature is to be machined and how
the NC code will be output. When Generate Operation Plan is run, operations for each machinable
feature are created automatically based on information in the Technology Database. In some
situations, the operations defined for a feature may not be sufficient and additional operations may
be required. You can insert operations interactively using the New Operation command. This
command is explained in the CAMWorks Context-based Help.

Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the Feature tree and select
Generate Operation Plan on the context menu.
Note:
 If you execute the Generate Operation Plan command from the Command Manager
or the CAMWorks NC Manager level, then operations will be generated for all
prismatic features in the tree, regardless of the active item in the tree.
 If you execute the Generate Operation Plan command from the EDM Part Setup
level, then operations will be generated only for those prismatic features listed
under the given EDM Setup.
 If you execute the Generate Operation Plan command at the feature level (by right-
clicking on a feature listed in the Feature tree and executing Generate Operation
Plan command from the RMB context menu), then operations will be generated
only for the selected feature.

CAMWorks generates the operation plan for all the machinable features in EDM Part Setup1. The
operations are listed in the CAMWorks Operation tree, which displays automatically. The Operation
tree can also be accessed by clicking the CAMWorks Operation Tree tab.

The CAMWorks Operation tree provides an outline view of the operations for the machinable
features. Operations are listed under the EDM Part Setup in the same order as the machinable
features. At the top of the tree is the CAMWorks NC Manager. The Stock Manager and Machine

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 Wire EDM Tutorial

items are same as in the CAMWorks Feature tree. You can change the stock size and shape to
produce G-code.
The CAMWorks Operation tree allows you to:
- Insert, rename, suppress, and delete operations
- Drag and drop copy operations and features
- Change operation parameters
- Change the machining order
- Generate toolpaths
- Simulate toolpaths
- Post process the toolpaths Operations generated on
- Hide or show toolpath display executing GOP command
- Search based on item name
- To the left of each toolpath operation is a plus sign ( ). Clicking a plus sign displays the
name of the Machinable Feature that this operation is going to machine. These
Machinable Feature items can be used to view geometric information.

Display tab of Options dialog box

Did You Know: If an operation displays in a color instead of black, then toolpaths have
not been generated for that particular operation. This occurs when you
insert a new operation interactively, you insert a new feature
interactively and generate operations for the new feature, or
CAMWorks cannot generate the toolpath for an operation because of
an error in the toolpath algorithm or a parameter is not correct. You
can set the color for operations without toolpaths on the Display tab in
the Options dialog box.

Adjusting Operation Parameters

Generate Operation Plan command generates one cutting operation per each machinable
feature. Each operation contains machining parameters that affect how the toolpath is created
and specific parameters that will be output to the NC program. These parameters can be edited
before generating the toolpath and post processing the part.

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Wire EDM Tutorial

Edit operation parameters:

1. Double click 2 Axis Contour1 in the
Operation tree.
OR
Right click on 2 Axis Contour1 and
select Edit Definition on the context
menu.
The 2 Axis Contour dialog box is
displayed. This dialog box gives you
access to all the parameters used to
create the toolpath.
2. Click on the EDM tab and set the
following parameters:
- Number of skims to 2
- Glue Stop to No Glue Stop ‘Edit Definition’ command on the context menu
3. Click on the Leadin/Out tab,
- In Leadin group box, set Leadin to Parallel with length 0.1in.
- In the Leadout group box, make sure the Same as Leadin is checked.
When the Same as Leadin is checked, CAMWorks set the parameters of Leadout as
same as Leadin. When Same as Leadin is not checked, you can set the different
required parameters for Leadin and Leadout.

Leadin/Out Tab on 2 Axis Contour dialog box

4. Click OK to apply the changes and close the dialog box.

5. Double click 2 Axis Contour2 in the Operation tree.
OR
Right click on 2 Axis Contour2 and select Edit Definition on the context menu.
The 2 Axis Contour dialog box is displayed.
6. Click on the EDM tab and set the following parameters:

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- Number of skims = 2
- Glue stop = Use Glue Stop
- Stop distance = 0.1in

EDM Tab on 2 Axis Contour dialog box

7. Click on the Leadin/Out tab,

- In Leadin group box, set Leadin to Perpendicular with length 0.10in
- In the Leadout group box, make sure the Same as Leadin is checked.
8. Click OK to apply the changes and close the dialog box.

Step 7: Generate Toolpaths

CAMWorks calculates toolpaths using the operation parameters and the feature's size and shape.
After toolpath is generated for a particular operation, then that operation is displayed in black-
colored font in the Operation tree.

1. Click the Generate Toolpath button on the CAMWorks Command Manager.

OR
Right click the EDM Part Setup1 or CAMWorks NC Manager in the Operation tree and select
Generate Toolpath on the context menu.
CAMWorks calculates the toolpaths for each operation in the EDM Part Setup.
Note:
Just like the Generate Operation Plan command, the scope of the Generate
Toolpath command too depends from which level the command is executed.
 Executing the Generate Toolpath command from the CAMWorks NC Manager
level generates toolpaths for all the operations.
 Executing the Generate Toolpath command at EDM Part Setup level generates
toolpaths only for operations listed under the given EDM setup.

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

2. Click the ( ) plus sign next to 2Axis Contour1 and 2

Axis Contour2 in the Operation tree, then click the
( ) plus sign next to Open Profile1 and Circular
Die1.
3. Highlight the first operation in the Operation tree.
This action displays the toolpath for that operation
on the part.
4. Highlight the each toolpath pass under the
operation. The toolpath for that corresponding
operation is displayed.
Note that the toolpaths for each cut are on center.
Compensation for each pass will be handled by the
Operation tree after generation of
cutter compensation at the machine.
Toolpaths

Step 8: Simulate Toolpath

CAMWorks provides the ability to simulate the toolpath showing the tool movement and the resulting
shape of the part.

1. Click the Simulate Toolpath button of the CAMWorks Command Manager.

OR
Right click EDM Part Setup1 in the tree and select Simulate Toolpath on the context menu.
The Toolpath Simulation toolbar is displayed.
The toolbar controls allow you to:

- Run the simulation in Tool or Turbo mode.

- Display the simulated part, the design part and a comparison of the two by clicking
on the Show Difference button .
- Customize the display of the stock, tool and tool holder (wireframe, translucent,
shaded, or no display) in Tool mode.
- Note that these options are disabled in Turbo mode.
- Run the simulation for all or selected operations.
- When simulating an operation, the simulation can be for the current operation or for
all previous operations up to the selected operation.

- Pause the simulation using Pause button in both Tool and Turbo mode.
- Dynamically change the orientation of the part using zoom, pan, rotate, etc.
- Control the simulation speed by dragging the Simulation Speed Control slider
left or right.
If you want to simulate only the toolpaths for a given operation, you can right click
that operation, and then select Simulate Toolpath in context menu.

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2. Set the simulation mode to Tool mode by clicking on the Tool mode button .

3. Click the Run button.

The simulation runs in Tool mode.

4. Click the Select Chips and Press Ctrl+D

Key button. This button is enabled when the
simulation is complete. CAMWorks provides
two methods for removing loose chips. Follow
the steps:
i. Pick the two loose stock chips to remove,
then press the Ctrl+D key on the keyboard.
ii. The loose chips are removed in the
graphics area.
Simulation Mode
iii. Click the Select Chips and Press
Ctrl+D Key button to exit the function.

iv. Click the Goto Start button and click run the simulation again.

v. Click the Select Chips and Press Ctrl+D Key button.

vi. Hold down the Ctrl key and pick the stock piece you want to keep, then press the Ctrl+D
key on the keyboard.

If there are many loose chips to remove, picking the stock may be faster than
picking each chip.

5. Click the Close button in the upper right corner to close the simulation and return to the
SOLIDWORKS/CAMWorks Solids display.

Step Through Toolpath

CAMWorks also provides the ability to visualize the tool motion and verify tool positions using
the Step Thru Toolpath command.
1. Executing the Step Thru Toolpath command: Both the Simulate Toolpath and Step Thru
Toolpath commands can be executed at the global, setup and operation levels.
 Global level: To step through the toolpaths of all the operations in the Operation tree,
right click on the CAMWorks NC Manager in the Operation tree and select Step Thru
Toolpath command in the context menu.
OR

Select Step Thru Toolpath command on the Command Manager.

 Setup Level: Right click on the EDM Part Setup1 and select Step Thru Toolpath
command in the context menu.
 Operation level: Right click on the desired operation in the Operation tree and select
Step Thru Toolpath in the context menu.

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On execution of the Step Thru Toolpath command using one of the above methods, the Step
Thru Toolpath dialog box is displayed.
2. Use controls given in the Display Options group box to set the options as to how the toolpath
will be displayed during the Step Through process.
3. In the Play Tool Until dropdown list, leave the end condition set to the default End.
4. Use the Animation speed slider to adjust the animation speed.

5. Click the Play button to continuously back-plot the tool till the end condition specified in
the Play Tool Until field is reached.

OK button

Play button

Animation speed
slider
Tool Position
slider

Controls to set the

options for
Toolpath display

Information on the current

toolpath move

Displays information on
the current operation being
back- plotted

Step Through Toolpath dialog box

6. During animation, the Play button display changes to Pause button . Click the Pause
button to pause the animation while it is in progress.

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7. When the animation has not yet begun or when it is paused, the Forward Single Step, Goto
End of Current Toolpath and Goto End buttons are active.

- Use the Forward Single Step button to move one toolpath record forward each
time the button is clicked.

- Use the Goto End of Current Toolpath button to move the tool position to the
last toolpath record of the current operation.

- Use the Goto End button to move the tool position to the last toolpath record of
the very last operation.

The last operation varies depending on which level the Step Through
Toolpath command is executed from. For example, if this command was
executed from the EDM Setup level, then the last operation would be the
last operation under that particular setup.
8. When the animation has been completed or when it is paused, the Reverse Single Step,
Goto Start of current Toolpath and Goto Start buttons are active.

- Use the Reverse Single Step button to move one toolpath record backwards
each time the button is clicked.

- Use the Goto Start of Current Toolpath button to move the tool position to the
first toolpath record of the current operation.

- Use the Goto Start button to move the tool position to the first toolpath record of
the very first operation.
9. If you are unsure about the use of any parameter within this dialog box, click on the Help
button at the upper right corner. This action will display the Context-based Help for Step
Thru Toolpath command.

10. Click the OK button in the upper left corner to close the dialog box.

Save the part with the machinable feature data

1. Click the Options button the CAMWorks Command Manager.

OR
Select the Options command from the RMB context menu of the CAMWorks NC Manager in
the tree.
The Options dialog box is displayed.
2. On the General tab, make sure the Save/Restore part option is checked.
3. Click OK to apply the settings and close the dialog box.
If this Save/Restore part option is checked, when you save and close a part document, the
machining data is saved and restored with the part design information when the part
document is reopened.

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If this option is not checked, when you save and close a part document that contains at least
one Setup, a message indicates that Save/Restore is disabled. If you click Yes, CAMWorks
saves all machining data before closing the file. If you click No, CAMWorks closes the part
and discards any new machining data since the last save.
4. Select Save As on the File menu. Browse to the location where you wish to save the file.
5. In the Save As dialog box, assign the desired file name and click the Save button.

SAVE FREQUENTLY!
 When you open a file, you are actually working on a copy of the file. The original is
still stored on disk. Periodically saving your file ensures that your latest work is
retained.
 CAMWorks provides an Auto save option on the General tab in the Options dialog
box for automatically saving your CAMWorks data.
 Frequent saves prevent having to redo a time-consuming model or CAM operation.
If a power failure occurs, you will lose whatever you have been working on.

Step 9: Post Process Toolpaths

Post processing is the final step in generating the NC program file. This step translates generalized
toolpath and operation information into NC code for a specific machine tool controller. CAMWorks
creates NC code for each toolpath in the order the operation appears in the Operation tree and the
Process order specified on the Posting tab in the EDM Settings dialog box. When you post process
a part, CAMWorks creates the NC program file. These are text file that you can read, edit and print
using a word processor or text editor.
In this tutorial, you post process all the operations and generate the NC program:

1. Click the Post Process button on the CAMWorks Command Manager.

OR
Right click CAMWorks NC Manager in the Operation tree and click Post Process on the
context menu.
The Post Output File dialog box is displayed so you can name the NC program file.
Typically, the NC program file is stored in the folder that contained the last part that was
opened. If you want these files in another location, you can change the folder location.

If the Post Process command is grayed out on the CAMWorks Command Manager
or on any context menu, make sure that you have generated the toolpaths.
2. In the Post Output File dialog box, click the down arrow to the right of the Save as type box.
CAMWorks provides a list of commonly used extensions that you can select. For this
exercise, use the .txt extension.

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Post Output File Dialog box

3. In the File name textbox, type the suitable file name, and then click Save button.
The Post Process Output dialog box is displayed.

4. Click the Step button on the control bar at the top.

CAMWorks starts to generate Step Run
the NC program and the first
line of NC code displays in the
NC code output view box. The
post processing mode is set to
post process one line of code
at a time (Step mode).
5. Click the Step button. The next
line of NC code is displayed.

6. Click the Run button . Post

processing continues until it is
completed.
7. When the post processing is
finished, view the code using
the vertical scroll bar.
8. Click OK to close the dialog
box.

Post Process Output dialog box

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2. LEARNING 2 AXIS CONTOUR CUTTING

This chapter provides an opportunity to learn CAMWorks Wire EDM through step-by-step exercises.
The tutorials in this chapter are intended to show you how to use CAMWorks Wire EDM and may
not correspond to actual machining practices.
Before you begin with the tutorials given in this chapter, ensure that you are through with the
concepts explained in Chapter 1.
The tutorial parts are installed when you install CAMWorks and are in the
\Examples\Tutorial_Parts\EDM folder on your computer. This folder is inside the CAMWorks data
folder.
(Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM).

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

operations to features. The Technology Database contains the data for the machining
process plans and can be customized for your facility's machining methodology. When you
do these exercises, your results may not be exactly the same as described in the steps and
illustrated in the figures. This is because the machining sequences and operations data in
your Technology Database may be different from the database used to produce the
documentation.

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2 Axis Contour 1
CAMWorks is a feature-based machining system. Feature-based machining provides numerous
benefits because the definition of the feature enables a higher level of automation when creating
machining operations and associated toolpaths. Adding to this benefit, CAMWorks provides both an
automatic method of extracting features called Automatic Feature Recognition (AFR), and an
interactive method using the New 2.5 Axis EDM Feature function. A CAMWorks file can contain both
types of features.
This tutorial demonstrates some of the features that are identified automatically by the Extract
Machinable Features command and explains how to control the types of features found by AFR.

Open the Part and Defining the Machine and Stock

1. Open the part file EDM2AX_2.SLDPRT in the following folder.
Drive:\CAMWorksData\CAMWorks201x \Examples\Tutorial_Parts\EDM

2. Click the CAMWorks Feature Tree tab.

3. Double click the Machine item in the CAMWorks
Feature tree.
The Machine dialog box is displayed.
4. In the Available machines list, highlight Wire EDM-
Metric, and click the Select button.
5. Click OK to apply changes and close the Machine
dialog box.
EDM2AX_2.SLDPRT
6. Right click Machine [Wire EDM-Metric] in the tree
and select the Select Machine on the context menu.
7. In the Machine Selection dialog box,
select SODICK for the Make and
AG600L for the Model from dropdown
list.
8. Click OK to close the dialog box.

9. Right click Machine [Wire EDM-

Metric] in the Feature tree and select
Edit Settings on the context menu.
The EDM setting dialog box is displayed.
10. On the EDM Setup tab, make sure the Machine Selection Dialog Box
Wire diameter is set to 0.20mm.
11. On the Posting tab, make sure the Process order for Die is set to By Complete Feature.
12. Click OK to close the dialog box.
- With this option, the NC program will be generated in the following machining order:
- For each Die feature: Cut rough pass, Glue stop cut off, and then all skim passes.

13. Double click Stock Manager in the Feature tree.

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The Stock Manager dialog box is displayed.

14. Click OK to use the default Bounding box and Material.

Extracting Machinable Features and Customizing AFR

CAMWorks allows you to control the types of features that are created by AFR.

1. Click the Options button on the CAMWorks Command Manager.

2. On the EDM Features tab, make sure the Perimeter punch feature is checked.
3. Click OK to close to dialog box.

4. Click the Extract Machinable Features

button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager in the tree
and select Extract Machinable Features on the
context menu.
The CAMWorks Message Window is displayed
automatically to report the progress and status
of the process.

5. Click the Message Window button on the

CAMWorks Command Manager, if the
CAMWorks Message Window is not displayed.
6. CAMWorks generates the EDM Part Setup and
machinable features. The items display in the
Feature tree .

Features recognized by AFR

CAMWorks Message Window

7. Highlight the first feature item in the Feature tree, hold down the Shift key, then highlight the
last feature item.

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AFR generated features

This action displays all features on the part (in the graphics area).
AFR has generated all possible Open Profile and Die features. However, you may not want
to use Wire EDM to machine all of these features, for example the countersink, counterbore
and multi-step holes. You can delete these features individually by highlighting the features
and pressing the Delete key or you can customize AFR to omit recognizing these features.

8. Click the Options button on the CAMWorks Command Manager to display Options
dialog box.
9. On the EDM Features tab, remove the check marks from the features type option in the
Extract machinable features group box:
- Countersink holes
- Counterbore holes
- Multi-step holes options
10. Check the On Rebuild Delete option for these same features types as shown in the image
on next page:
- Countersink holes
- Counterbore holes
- Multi-step holes
11. Optionally, change the Apply to setting.
This option allows you to select how the settings on this tab will be applied:
- Active Document - The part that you are currently working on.
- System Default - All new parts that are created.
- All Possible - The current part as well as all new parts.

The values that displayed when you opened this dialog box will be retained
for the current part.
12. Reset the Active Document option in Apply to setting.

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EDM Features tab on Options dialog box

Did You Know: CAMWorks data is saved in part and assembly template documents.
For new part/assembly documents, the CAMWorks settings in the
selected template will be used, not the CAMWorks System Defaults.
Templates allow you to maintain as many different documents for
parts or assemblies as you need. For example, you can create
separate part templates for Mill, Turn and Wire EDM with the machine
type stored.
If you want the System Defaults to apply, disable the Save/Restore part
or Save/Restore assembly option on the General tab in the CAMWorks
Options dialog box, then save the template with a new name.

13. Click OK to close the Options dialog box.

14. Click the Extract Machinable Features button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager in the tree and select Rebuild on the context menu.

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Note that the Circular Die features for the Countersunk holes, Counterbore holes and Multi-
step holes are now move in the Recycle Bin.

Recognized operations

Generating a 2 Axis Contour Operation and Toolpaths

1. Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the Feature tree and select
Generate Operation Plan on the context menu.
When you select Generate Operation Plan, operations will be created for every selected
feature. Operations are not generated for suppressed features and features in the Recycle
Bin.

2. Click the Generate Toolpath button on the CAMWorks Command Manager.

OR
Right click the EDM Part Setup1 or CAMWorks NC Manager items in the Operation tree and
select Generate Toolpath on the context menu.

Simulating and Post Processing Toolpaths

Simulation Toolpath
1. Click the Simulate Toolpath button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the tree and select Simulate
Toolpath on the context menu.

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The Toolpath Simulation dialog box is displayed.

2. Set the display parameters:

- Stock: Shaded Display

- Tool: Shaded Display

- Tool Holder : Shaded Display

- Target Part : No Display

3. Click the Run button.

4. Click the Select Chips and Press the Ctrl+D Key button.
5. Hold down the Ctrl key and pick the stock piece you want to keep, and then press the Ctrl+D
key on the keyboard.
The loose chips are removed in the graphics area.
6. Again, click the Select Chips and Press Ctrl+D Key button to exit the function.

Simulation Toolpath

7. Click the Close button in the upper right corner to cancel the simulation and return to
the SOLIDWORKS/CAMWorks Solids display.

Post Process Toolpath

1. Click the Post Process button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager in the Operation tree and click Post Process on the
context menu.
The Post Output File dialog box is displayed.
2. Browse to the folder where you wish to save the file.

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If you are running CAMWorks in Demo mode, the Post Process functionality
will be disabled.
3. If you do not wish to save the file with the default file name, assign another file name in the
File name field.
4. Click Save to save the file.
The Post Process Output dialog box is displayed.

5. Click the Play button.

This command generates the NC code. The generated NC code can be viewed in the NC
code output area of the dialog box by using the vertical scroll.
6. After viewing the code, click OK to close the dialog box.

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2 Axis Contour 2

Topics covered in this tutorial:

Automatic Feature Recognition may not be able to find all features on a part or may not
recognize all the features that you want to machine. When this occurs, you can define these
features interactively. In this tutorial, AFR finds only the irregular die in the center of the part.
You can interactively insert New 2.5 Axis EDM features to cut the two dies on the sides and
the outside of the part.

Open the Part and Defining the Machine and Stock

1. Open the part file EDM2AX_3.SLDPRT in the following folder.
Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM

2. Click the CAMWorks Feature Tree tab.

3. Double click the Machine item in the CAMWorks Feature
tree.
The Machine dialog box is displayed.
4. In the Available machines list, make sure Wire EDM–Inch
is selected as Active machine.
5. Click OK to close the dialog box.

6. Right click Machine [Wire EDM–Inch] in the tree and

click Select Machine on the context menu.
7. In the Machine Selection dialog box, make sure SODICK
is selected for the Make and AG600L for the Model from EDM2AX_3.SLDPRT
dropdown list.
8. Click OK to close the dialog box.

9. Right click Machine [Wire EDM–Inch] in the tree and select Edit Settings on the context
menu.
10. On the Posting tab, make sure By Complete Feature is selected from dropdown list for both
Punch and Die Process order.
11. Click OK to apply changes and close the dialog box.
With this option, the NC program will be generated in the following machining order: for each
Die feature, cut rough pass, glue stop cut off, then all skim passes. For each Punch feature,
the processing order is rough cut leaving glue stop, 0 - 6 skim passes, glue stop cut off.

12. Double click Stock Manager in the Feature tree.

13. In the Stock Manager dialog box, click OK to use the default Bounding box and Material.

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Extract Machinable Features

1. Click the Options button on the CAMWorks Command Manager.

2. On the EDM Features tab, make sure the Perimeter Punch feature is not checked and click
OK.

3. Click the Extract Machinable Features button on the

CAMWorks Command Manager.
AFR finds only the Irregular Die in the center of the part.
4. Click EDM Part Setup1 in the tree and notice the Z
machining direction.
The red arrow on the triad indicates the negative Z
direction. The direction is correct for this part. AFR Generated Features
When necessary, you can reverse the direction by double
clicking EDM Part Setup1 in the tree and clicking the Reverse
Setup Direction option in the EDM Setup dialog box.

The SOLIDWORKS/CAMWorks Solids axis does not

control CAMWorks machining. However, it is used as a
reference for certain CAMWorks functions (for example,
offsetting the stock).

Z axis machining
direction

Inserting 2.5 Axis EDM Features Interactively

1. Rotate the part so that the bottom face is visible.
2. Right click EDM Part Setup1 in the Feature tree and select New 2.5 Axis EDM Feature on
the context menu.
The 2.5 EDM Feature dialog box is displayed.

3. On the Feature Definition tab, make sure Die

is the selected as Feature type.
4. Pick the bottom face of the part.
Three Die features are displayed in the Selected
Entities group box.
5. Click Die – 2 and Die – 3 to view the features on
the part.
Pick the bottom face of the
6. Click Die – 1. This is the Irregular Die feature that has Part
already been found by AFR so you can delete it.
7. Highlight Die – 1 in the list and press the Delete key on keyboard.
Now, only two Die features are available in the Selected Entities group box.

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8. Click the End Condition tab.

The End Condition page provides options to define
the end condition for the features you are inserting.
The default Upto Stock defines the depth to the
material face. This amount is calculated
automatically based on the position of the stock.

9. Click OK to use the default End Condition and

insert the features.
Rectangular Die2 and Rectangular Die3 are listed in
the Feature tree.

Define the feature to machine the outside of

the part:
10. Once again right click EDM Part Setup1 in the tree
and select New 2.5 Axis EDM Feature on the context
menu.
The 2.5 EDM Feature dialog box is displayed.

11. Click the Punch button for the Feature type.

12. Pick the same face on the bottom of the part.
Punch – 1 is listed in the Selected Entities list box for
feature.
13. Click the End Condition tab. You can use the default
Upto Stock.

14. Click OK to use the default End Condition and

insert the features.
Punch1 is listed in the Feature tree.
15. Use mouse to drag and drop the features in the 2 Axis EDM Feature Dialog Box
order as shown in the right side image.

Re-arranged order of features

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Generating Operations Plan and Toolpaths

1. Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or
EDM Part Setup1 in the Feature tree and
select Generate Operation Plan on the
context menu.
2. Rotate the part so that the top face is
visible.
3. Click plus sign ( ) next to 2 Axis
Contour4 to expand in the Operation
tree.
4. Right click Irregular Die1 and select Edit
Leadin Point on the context menu.
The Lead in Location dialog box is
displayed.
You can set the leadin/leadout location to Select Edit Leadin Point on the context menu
be at the start-point, mid-point or end-
point of a segment. The current location is indicated on the feature. Rotate the part and
notice that this location may gouge the part.
5. Leave the Lead in location set to Mid-point and pick the segment shown in the image.

Pick the segment

6. Click OK to close the dialog box.

7. Click the Generate Toolpath button on the CAMWorks Command Manager.

8. Click the ( ) plus sign next to 2 Axis Contour1 in the Operation tree to expand the operation,
and then expand Punch1.
The processing order is rough cut and then skim passes. You set the Process order for
Punch to By Complete Feature on the Posting tab in the EDM Settings dialog box and the
code for all Punch features will be output based on this order.
9. Click the ( ) plus sign next to 2 Axis Contour 2 in the Operation tree to expand the operation,
and then expand Rectangular Die2.

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The processing order is rough cut, glue stop cut off, then skim passes. You set the Process
order to By Complete Feature on the Posting tab in the EDM Settings dialog box and the
code for all Die features will be output based on this order.

Operation tree after generated

toolpath

Changing the Machining Order and Post Processing

CAMWorks processes the punches and dies according to the order of the items in the Operation
tree. The operation for the Punch feature is listed first in the tree, so you can reorder the operations
before post processing.

Re-arranged order of features

1. Highlight 2 Axis Contour1 in the tree and drag it on bottom of 2 Axis Contour4.
The operations for the Die features will now be post processed before the operation for the
Punch feature.

2. Click the Options button on the CAMWorks Command Manager.

The Options dialog box is displayed.
3. Click the File Locations tab.
The File Output tab contains an option to automatically open the G-code file when you close
the Post Process Output dialog box.

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4. In the Post processing group box, check the Open G-code file in editor option.
5. Browse and select the editor
- If you know the location of the editor, you use to modify NC program files. Click the
Browse button, open the folder and select the program.
- Otherwise, select Notepad.exe in the Windows\WINNT folder, click Open, and then
click OK.

Browse the location of editor

6. Click the Post Process button on the CAMWorks Command Manager.

OR
Right click CAMWorks NC Manager in the Operation tree and click Post Process on the
context menu.
7. In the Post Output File dialog box, type a name for the file and click Save.

8. Click the Run button in the Post Process Output dialog box.
9. When the post processing is finished, click OK.
The program file opens automatically in the editor you selected.
10. Notice that G-code has been generated for the Die features and then the Punch feature.
11. Click the button to close the editor.

Opened the G-code file in Editor

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Wire EDM Tutorial

2 Axis Contour 3

Topics covered in this tutorial:

In this tutorial, the only features you want to machine are the vertical and tapered open
profiles at the end of the part. AFR does not find these features, so you need to insert a Part
Setup, then define the 2 features interactively using the New 2.5 Axis EDM command.

Open the Part and Defining the Machine and Stock

1. Open the part file EDM2AX_4.SLDPRT in the following folder.
Drive:\CAMWorksdata\CAMWorks201x\Examples\Tutorial_Parts\EDM

2. Click the CAMWorks Feature Tree tab.

3. Double click the Machine item in the CAMWorks
Feature tree.
The Machine dialog box is displayed.
4. In the Available machines list, highlight Wire EDM–
Metric, click the Select button.
5. Click OK to close the Machine dialog box.

6. Right click Machine [Wire EDM-Metric] in the tree

and click Select Machine on the context menu.
7. In the Machine Selection dialog box, make sure EDM2AX_4.SLDPRT
SODICK is selected for the Make and AG600L for the
Model from dropdown list.
8. Click OK to close the dialog box.

9. Right click Machine [Wire EDM-Metric] in the tree and select Edit Settings on the context
menu.
The EDM setting dialog box is displayed.
10. On the Posting tab, set the Process order for Die to By Complete Feature.
11. Click OK to close the dialog box.
With this option, the NC program is generated in the following machining order:
- Rough cut, glue stop cut off, 0 - 6 full skim passes.

12. Double click Stock Manager in the Feature tree.

13. In the Stock Manager dialog box, click OK to use the default Bounding box and material.

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Extract Machinable Features and Interactively Inserting a Part

Setup
1. Click the Extract Machinable Features button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager in the tree and select Extract Machinable Features on
the context menu.
You should run AFR even when you know AFR cannot find any features on a part. Running
AFR sets up information for associativity that is
necessary for the Rebuild function.

2. Right click Stock Manager in the Feature tree

and select New Part Setup on the context menu.
The EDM Setup dialog box is displayed.
3. Pick the face on the top of the part.
Face1 is listed in the Entity field.

4. Click OK to apply changes and close the dialog

box.
EDM Part Setup1 is listed in the tree. Pick the top face

Inserting Vertical and Tapered Open Profile Features

The yellow faces define a vertical wall. The blue faces define a tapered wall. First, you define the
vertical open profile feature, then the tapered open profile feature.
1. Right click EDM Part Setup1 in the tree and select New 2.5 Axis EDM Feature on the context
menu.
The 2.5 Axis EDM Feature dialog box is diaplayed.

2. Select Open Profile for the Feature type.

3. Pick the lower edge on the left side of solid part, then hold down the Ctrl key and pick the
lower edge on the right of the solid part as shown in the image.

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Left Side Edge

Right Side Edge

Pick the Lower Left and Right Side Edge

When you define an Open Profile Feature from multiple edges, you can select the chain
between the first and last edges of the feature.
- If the Shift key is pressed, the chaining direction is based on the fewest number of
edges between the first and last selected edges.
- If the Ctrl key is pressed, the chaining direction is based on the greatest number of
edges between the first and last selected edges.
Notice that the arrow direction indicates which side of the feature to cut on. In this tutorial,
you will cut the feature from other
side.
4. Click Open Profile – 1 in the
Selected Entities for features list,
then click the Flip direction to cut
check box in Feature type group
box.
The arrow direction is reversed.
5. Click the End Condition tab.
This feature is vertical and no
changes are required to be made
on this tab.
Indicating the reversed arrow direction
6. Click OK button to apply the
changes.
Open Profile 1 is listed in the Feature tree.
7. Next, you will define the tapered open profile feature.
8. Right click EDM Part Setup1 in the Feature tree and select New 2.5 Axis EDM Feature on
the context menu.
The 2.5 Axis EDM Feature dialog box is displayed.

9. Select Open Profile for the Feature type.

10. Pick the upper edge on the left side of solid part, then hold down the Ctrl key and pick the
upper edge on the right of the solid part as shown in the image.

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Left Side Edge

Right Side Edge

Pick the Upper Left and Right Side Edge

11. Click Open Profile – 1 in the Selected
Entities for features list, then click the Flip
direction to cut check box in the Feature
Type group box.
The arrow direction is reversed.
12. Click the End Condition tab.
13. Zoom in on the right side of the taper
feature of the part. There is a 10-degree
taper.

14. Click the Taper On/Off button to Indicating the reversed arrow direction
turn it on.
15. Set the degrees to 10 and press the Tab key on the
keyboard.
16. Rotate the part and notice that the feature outline
indicates the taper is going inward.

17. Click the Reverse Taper button to reverse the

taper so it is going outward. This button functions as a
toggle.

18. Click OK button to apply the changes. Set the Taper Feature on
End Condition tab
19. Tapered Open Profile 2 is listed in the Feature tree. This is
the order the features will be processed when the NC code is generated.

Inserted Vertical and Taper Open Profile

Feature in Feature tree

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Generate Operations Plan and Toolpaths

1. Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the Feature tree and select
Generate Operation Plan on the context menu.
The 2 Axis Contour1 and 2 Axis Contour2 operations are generated and listed in Operation
tree.
2. Double click 2 Axis Contour1 in the Operation tree.
The 2 Axis Contour dialog box is displayed. This dialog box gives you access to all the
parameters used to create the toolpath.
3. On the EDM tab, set the following parameters:
- Number of skims = 2
- Glue Stop = No Glue Stop
- Process as = Die Select Process as Die on the
EDM tab
4. Click on the Leadin/Out tab, set the Leadin to Parallel.
5. In the Leadout group box, make sure the Same as Leadin is checked.
When the Same as Leadin is checked, CAMWorks set the parameters of Leadout as same
as Leadin. When Same as Leadin is not checked, you can set the different required
parameters for Leadin and Leadout.
6. Click OK to apply the changes and close the dialog box.
7. Double click 2 Axis Contour2 in the Operation tree.
8. Follow the steps from 3 to 5 and make the same changes as for 2 Axis Contour1.
9. Click OK to apply the changes and close the dialog box.

10. Click the Generate Toolpath button on the CAMWorks Command Manager.
OR
Right click the EDM Part Setup1 or CAMWorks NC Manager items in the Operation tree and
select Generate Toolpath on the context menu.

Simulation and Post process Toolpath

1. Click the Simulate Toolpath button of the CAMWorks Command Manager.
OR
Right click EDM Part Setup1 in the tree and select Simulate Toolpath on the context menu.
2. Set the display parameters:

- Stock: Translucent Display

- Tool Holder: Translucent Display

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- Target Part: Translucent Display

- Tool: Shaded Display

3. Click the Run button.

4. Click the button in the upper right corner to cancel the simulation and return to the
SOLIDWORKS/CAMWorks Solids display.

5. Click the Post Process button on the CAMWorks Command Manager.

OR
Right click CAMWorks NC Manager in the Operation tree and click Post Process on the
context menu.
6. In the Post Output File dialog box, type a name for the file and click Save.

7. Click the Run button in the Post Process Output dialog box.
8. When the post processing is finished, click OK.
The program file opens automatically in the editor if you enabled this option in the previous
tutorial.
9. Notice that G-code has been generated for the Vertical and Tapered feature.
10. Click the button to close the editor.

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2 Axis Contour 4

Topics covered in this tutorial:

Post processing translates generalized toolpath and operation information into NC code for a
specific machine tool controller. CAMWorks creates NC code for each toolpath in the order
the operation appears in the Operation tree and the Process order specified on the Posting
tab in the EDM Settings dialog box. In this exercise, you generate operations and toolpaths
for two die features, then post process using each of the Process order options for dies and
compare the code that is generated. For more information on the Process order options, see
the Posting Tab topic in the Wire EDM Context-based Help.

Open the Part and Defining the Machine and Stock

1. Open the part file EDM2AX_5.SLDPRT in the following folder
Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM

2. Click the CAMWorks Feature Tree tab.

3. Double click the Machine item in the CAMWorks
Feature tree.
The Machine dialog box is displayed.
4. In the Available machines list, highlight Wire EDM–
Metric, click the Select button.
5. Click OK to close the Machine dialog box.

6. Right click Machine [Wire EDM–Metric] in the tree

and click Select Machine on the context menu.
EDM2AX_5.SLDPRT
7. In the Machine Selection dialog box, make sure
SODICK is selected for the Make and AG600L for the Model from the dropdown list.
8. Click OK to close the dialog box.

9. Right click Machine [Wire EDM–Metric] in the tree and select Edit Settings on the context
menu.
The EDM setting dialog box is displayed.
10. On the Posting tab, make sure the Process order for Die is By Complete Feature.
11. Click OK to close the dialog box.
With this option, the NC program is generated in the following machining order:
- Rough cut leaving glue stop, Glue stop cut off, 0 - 6 full skim passes.

12. Double click Stock Manager in the Feature tree.

13. In the Stock Manager dialog box, click OK to use the default Bounding box and Material.

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Extract Machinable Features

1. Click the Options button on the CAMWorks Command Manager.

2. On the EDM Features tab, remove the check mark from Perimeter punch and click OK.

3. Click the Extract Machinable Features button

on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager in the tree and
select Extract Machinable Features on the context
menu.
Rectangular Die1, Punch1 and Circular Die2 are
listed in the tree.

Features recognized by AFR

Generate Operation Plan and Toolpath

1. Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the Feature tree and select
Generate Operation Plan on the context menu.
The 2 Axis Contour1, 2 Axis Contour2 and 2 Axis Contour3 operations are generated and
listed in the Operation tree.
2. Double click 2 Axis Contour1 in the Operation tree.
The 2 Axis Contour dialog box is displayed.
3. On the EDM tab, set the following parameters:
- Number of skims = 2
- Glue Stop = Use Glue Stop
- Stop distance = 2mm

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EDM Tab on 2 Axis Contour dialog box

4. Click on the Leadin/Out tab, set the Leadin to Perpendicular with Length of 6mm.
5. In the Leadout group box, make sure the Same as Leadin is checked.
When the Same as Leadin is checked, CAMWorks set the parameters of Leadout as same
as Leadin. When Same as Leadin is not checked, you can set the different required
parameters for Leadin and Leadout.
6. Click OK to apply the changes and close the dialog box.
7. Double click 2 Axis Contour2 in the tree.
The 2 Axis Contour dialog box is displayed.
8. Follow the steps from 3 to 5 and make the same changes as on the 2 Axis Contour1.
9. Click OK to apply the changes and close the dialog box.

10. Click the Generate Toolpath button on the CAMWorks Command Manager.
OR
Right click the EDM Part Setup1 or CAMWorks NC Manager items in the Operation tree and
select Generate Toolpath on the context menu.

Post Process the Die Features

1. Click the Options button on the CAMWorks Command Manager.

The Options dialog box is displayed.
2. Click the File Locations tab.

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The File Output tab contains an option to automatically open the G-code file when you close
the Post Process Output dialog box.
3. In the Post processing group box, check the Open G-code file in editor option.
4. Browse and select the editor
- If you know the location of the editor, you use to modify NC program files. Click the
Browse button, open the folder and select the program.
- Otherwise, select Notepad.exe in the Windows\WINNT folder, click Open, and then
click OK.

Browse the location of editor

5. Click the Post Process button on the CAMWorks Command Manager.

OR
Right click CAMWorks NC Manager in the Operation tree and click Post Process on the
context menu.
6. In the Post Output File dialog box, type a name for the file and click Save.

7. Click the Run button in the Post Process Output dialog box.
8. When the post processing is finished, click OK.
The program file opens automatically in the editor you selected.
9. View the code and notice the following processing order:
- Rough cut leaving glue stop
- Glue stop cut off
- 0 - 6 full skim passes
10. Click the button to close the editor.

11. Right click Machine [Wire EDM–Metric] in the Feature tree and click Edit Settings on the
context menu.
12. On the Posting tab, set the Process order for Die to Rough / Glue Stop / All Skims, then click
OK.
13. Follow the same steps from 5 to 8 and assigned the desired file name.
14. View the code and notice the following processing order:
- Cut all rough passes from first feature to last
- Glue stop cut off on each feature from last to first
- Perform all skim passes on each feature from first feature to last
15. Click the button to close the editor.

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16. Again, right click Machine [Wire EDM–Metric] in the tree and click Edit Settings on the
context menu.
17. On the Posting tab, set the Process order for Die to Rough / Glue Stop / Skim Passes, then
click OK.
18. Follow the same steps from 5 to 8 and assigned the desired file name.
19. View the code and notice the following processing order:
- Cut all rough passes from first feature to last
- Glue stop cut off on each feature from last to first
- Skim pass one on each feature from first to last
- Skim pass two on each feature from last to first
- Etc.

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3. LEARNING 4 AXIS CONTOUR CUTTING

This chapter provides an opportunity to learn 4 Axis Contour cutting through step-by-step exercises.
The tutorials in this chapter are intended to show you how to use CAMWorks Wire EDM and may
not correspond to actual machining practices.
Before you begin with the tutorials given in this chapter, ensure that you are through with the
concepts explained in Chapter 1.
The tutorial parts are installed when you install CAMWorks and are in the
\Examples\Tutorial_Parts\EDM folder on your computer. This folder is inside the CAMWorks data
folder.
(Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM).

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

operations to features. The Technology Database contains the data for the machining
process plans and can be customized for your facility's machining methodology. When you
do these exercises, your results may not be the same as described in the steps and
illustrated in the figures. This is because the machining sequences and operations data in
your Technology Database may be different from the database used to produce the
documentation.

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4 Axis Contour 1
Automatic Feature Recognition (AFR) is a powerful tool, but it cannot always recognize every
feature on every part, nor does it currently support features where the side walls of the feature are
not all vertical or not all constant taper. To machine these areas, you need to define features
interactively using the New 4 Axis EDM Feature command. The New 4 Axis EDM Feature command
allows you to define 4 axis features. These include Pocket (Die), Boss (Punch) and Open Profile
features.
In this exercise, you insert a 4 Axis Die feature.

Open the Part and Defining the Machine and Stock

1. Open the part file EDM4AX_1.SLDPRT in the following folder.
Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM

2. Click the CAMWorks Feature Tree tab.

3. Double click the Machine item in the CAMWorks
Feature tree.
The Machine dialog box is displayed.
4. In the Available machines list, highlight Wire EDM–
Inch, click the Select button.
5. Click OK to close the dialog box.

6. Right click Machine [Wire EDM–Inch] in the tree

and click Select Machine on the context menu.
7. In the Machine Selection dialog box, select SODICK
for the Make and AG600L for the Model from the EDM4AX_1.SLDPRT
dropdown menu.
8. Click OK to close the dialog box.

9. Right click Machine [Wire EDM–Inch] in the tree and select Edit Settings on the context
menu.
10. On the EDM Setup tab, make sure the Wire diameter is set to 0.01in.
11. On the Posting tab, make sure the Process order for Die is set to By Complete Feature, then
click OK.
With this option, the NC program will be generated in the following machining order:
- Cut rough pass, Glue stop cut off, and All skim passes

12. Double click Stock Manager in the Feature tree to open Stock Manager dialog box.

13. For this exercise, click OK to use the default Bounding box and Material.

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Extract Machinable Features and Interactively Inserting Part

Setup
1. Click the Extract Machinable Features button on the CAMWorks Command Manager.
You should run AFR even when you know AFR cannot find any features on a part. Running
AFR sets up information for associativity that is necessary for the Rebuild function.
2. Right click Stock Manager in the Feature tree and select New Part Setup on the context
menu.
The EDM Part Setup in the Feature tree is used to
define the Z machining direction. AFR creates the
Part Setups necessary to machine the features that
are recognized automatically. In this tutorial, AFR is
not used since there are no 2 Axis EDM features on
the part. You need to insert a Part Setup
interactively.
3. Pick the top face of the part (highlighted in blue
color).

4. Click OK to insert the Part Setup.

EDM Part Setup1 is listed in the Feature tree. Pick the top face

Defining a 4 Axis Die Feature Interactively

1. Right click EDM Part Setup1 and select New 4 Axis EDM Feature on the context menu.
The New 4 Axis EDM Feature dialog box is displayed.

2. Make sure Die (Pocket) is the selected Feature type.

3. Click on Curve-1 field to set the focus.
4. Pick the top edge of the rectangular pocket as
shown in the image.
5. Click on Curve-2 field to set the focus.
6. Pick the lower edge of the rectangular as shown in
image.
The start point on each curve is identified.
7. If the start points are not as shown in the
image, click the Move Start Point button for one of
the curves to change the position. The Move Start
Point buttons are used when Curve 1 and Curve 2
contain the same number of entities.
Pick the top and lower edges
8. Click OK to insert and close the dialog box.
4-Axis Die1 is listed in the tree.

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Generating a 4 Axis Contour Operation and Toolpaths

1. Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the Feature tree and select
Generate Operation Plan on the context menu.
2. Double click 4 Axis Contour1 in the Operation tree.
3. Click on the Leadin/Out tab, set the Leadin to Perpendicular with Length of 0.02in.
4. In the Leadout group box, make sure the Same as Leadin is checked.
When the Same as Leadin is checked, CAMWorks set the parameters of Leadout as same
as Leadin. When Same as Leadin is not checked, you can set the different required
parameters for Leadin and Leadout.
5. Click OK to apply the changes and close the dialog box.

6. Click the Generate Toolpath button on the CAMWorks Command Manager.

OR
Right click the EDM Part Setup1 or CAMWorks NC Manager items in the Operation tree and
select Generate Toolpath on the context menu.
7. Click the operation in the tree to view the toolpath.

Simulation and Post Process Toolpath

1. Click the Simulate Toolpath button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the tree and select Simulate
Toolpath on the context menu.
2. Set the display parameters:

- Stock: Shaded Display

- Tool: Shaded Display

- Tool Holder: No Display

- Target Part: No Display

3. Click the Run button.

4. Click the Select Chips and Press Ctrl+D Key button. This button is enabled when the
simulation is complete.
5. Pick the loose stock part to remove, and then press the Ctrl+D key on the keyboard.
The loose chips are removed in the graphics area.

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6. Click the Select Chips and Press Ctrl+D Key button to exit the function.\

Simulation Toolpath

7. Click the Close button in the upper right corner to close the simulation and return to the
SOLIDWORKS/CAMWorks Solids display.

8. Click the Post Process button on the CAMWorks Command Manager.

OR
Right click CAMWorks NC Manager in the Operation tree and click Post Process on the
context menu.
9. In the Post Output File dialog box, type the desired file name and then click Save.

10. Click the Run button in the Post Process Output dialog box.
11. When the post processing is finished, use the vertical scroll bar to view the code.
12. Click OK to close the dialog box.

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4 Axis Contour 2

Topics covered ion this tutorial:

When defining 4 Axis Features, sync curves are required when the number of entities in
Curve 1 is not equal to the number of entities in Curve 2. Sync curves must be a single linear
segment and can be selected from edges or 3D sketch objects. The sync curves are used to
define sync points on the feature. As the wire cuts around the two curves defining the
feature, the wire will arrive at the end points of each sync curve at the same time. Sync
curves are similar to the guide curves used to create a loft feature in
SOLIDWORKS/CAMWorks Solids. If the number of entities in Curve 1 and Curve 2 is equal,
then the sync curves are ignored.
In the part below, the number of entities in Curve 1 is not equal to the number of entities in
Curve 2 of the 4 Axis feature. In this tutorial, you insert the feature and automatically extract
sync curves.

Open the Part and Defining the Machine and Stock

1. Open the part file EDM4AX_2.SLDPRT in the following folder.
Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM

2. Click the CAMWorks Feature Tree tab.

3. Double click the Machine item in the CAMWorks
Feature tree.
The Machine dialog box is displayed.
4. In the Available machines list, highlight Wire EDM–
Inch, click the Select button.
5. Click OK to close the dialog box.

6. Right click Machine [Wire EDM–Inch] in the

tree and click Select Machine on the context menu.
EDM4AX_2.SLDPRT
7. In the Machine Selection dialog box, make sure
SODICK is selected for the Make and AG600L for the Model from dropdown list.
8. Click OK to close the dialog box.

9. Right click Machine [Wire EDM–Inch] in the tree and select Edit Settings on the context
menu.
10. On the Posting tab, make sure the Process order for Punch is set to By Complete Feature.
11. Click OK to close the dialog box.
The processing order is rough cut leaving glue stop, 0 - 6 skim passes, then glue stop cut
off.

12. Double click Stock Manager in the Feature tree.

13. In the Stock Manager dialog box, click OK to use the default Bounding box and Material.

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Extract Machinable Features and Interactively Inserting Part

Setup
1. Click the Extract Machinable Features button on the CAMWorks Command Manager.
You should run AFR even when you know AFR
cannot find any features on a part. Running AFR
sets up information for associativity that is
necessary for the Rebuild function.

2. Right click Stock Manager in the Feature tree

and select New Part Setup on the context menu.
3. Pick the top face on the part (highlighted in blue
color).
4. Click OK to insert the changes.
EDM Part Setup1 is listed in the Feature tree.
Pick the top face

Inserting and Automatically Extracting Sync Curves to Define a

4 Axis EDM Feature
1. Right click EDM Part Setup1 in the tree and select New 4 Axis EDM Feature on the context
menu.
The New 4 Axis EDM Feature dialog box is displayed

2. Click the Punch button for the Feature type.

3. Click in the Curve-1 field to set the focus, pick the top face of the part.
Loop 1 is selected in the Curve-1 area.
4. Click in the Curve-2 field to set the focus.
5. Rotate the part and pick the bottom face of the part.
6. Alternatively, you can pick any edge of the bottom face.
Loop 2 is selected in the Curve-2 area.

7. Click the Automatically extract sync curves button. CAMWorks extracts the sync curves.
Did You Know: CAMWorks cannot extract sync curves automatically when a sketch is
used for either Curve 1 or Curve 2 or both. In such a case, the
‘Automatically extract sync curves’ button is disabled.

8. Click OK to insert the changes.

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Before Automatically After Automatically Extracting

Extracting Sync Curves Sync Curves

Generating the 4 Axis Contour Operation and Toolpaths

1. Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the Feature tree and select
Generate Operation Plan on the context menu.
2. Double click 4 Axis Contour1 in the Operation tree.
The 4 Axis Contour dialog box is displayed.
3. On the EDM tab, make sure Glue Stop is set to No Glue Stop.
4. Click OK to apply the changes.
The Glue stop option controls whether a tab is created automatically. When No Glue Stop is
selected, a tab is not created and the NC program will not contain a glue stop.

5. Click the Generate Toolpath button on the CAMWorks Command Manager.

OR
Right click the EDM Part Setup1 or CAMWorks NC Manager items in the Operation tree and
select Generate Toolpath on the context menu.
6. Click the operation in the tree to view the toolpath.
7. Click ( ) plus sign to expand next to 4 Axis Contour1 in the tree, then again click ( ) plus
sign to expand 4-Axis Punch1.
8. Notice that there is no Tab cut.

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4 Axis Contour 3
Topics covered in this tutorial:
Faces and loops can be used to define a 4 Axis EDM feature if the faces/loops are on a
plane that is parallel to the setup axis. In this exercise, since the top face on the part is not
parallel, you select a sketch to define the top of the 4 Axis EDM feature.

Open the Part and Defining the Machine and Stock

1. Open the part file EDM4AX_3.SLDPRT in the following folder.
Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM

2. Click the CAMWorks Feature Tree tab.

3. Double click the Machine item in the CAMWorks
Feature tree.
4. In the Available machines list, highlight Wire EDM–
Inch, click the Select button.
5. Click OK to close the dialog box.

6. Right click Machine [Wire EDM–Inch] in the

tree and click Select Machine on the context menu.
7. In the Machine Selection dialog box, make sure
SODICK is selected for the Make and AG600L for
EDM4AX_3.SLDPRT
the Model from dropdown list.
8. Click OK to apply the changes.

9. Right click Machine [Wire EDM–Inch] in the tree and select Edit Settings on the context
menu.
The Edit Settings dialog box is displayed.
10. On the Posting tab, set the Process order for Punch to By Complete Feature.
11. Click OK to close the dialog box.

12. Double click Stock Manager in the Feature tree.

13. In the Stock Manager dialog box, click OK to use the default Bounding box and Material.

Extract Machinable Features and Using Sketches to Define a 4

Axis EDM Feature
1. Click the Extract Machinable Features button on the CAMWorks Command Manager.
You should run AFR even when you know AFR cannot find any features on a part. Running
AFR sets up information for associativity that is necessary for the Rebuild function.

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2. Right click Stock Manager in the Feature tree and select New Part Setup on the context
menu.
3. In the graphics area, double click on EDM4AX_3 to expand and highlight the Front reference
plane.

4. Click the Reverse selected entity button to reverse the machining direction.

5. Click OK to insert the Part Setup and close the dialog box.

Inserting EDM Part Setup

Interactively Inserting the 4 Axis EDM Feature

1. Right click EDM Part Setup1 in the tree and select New 4 Axis EDM Feature on the context
menu.

2. Click the Punch button for the Feature type.

3. Pick Sketch2 from the Available Sketches for Curve-1.
This action will list the Sketch2 in the
Curve-1.
4. Rotate the part so that the bottom face is
visible.
5. Click in the Curve-2 to set the focus, pick
the bottom face anywhere on the right side
of the part as shown in the image.
6. Rotate the part to the top direction again
and notice the top and bottom start points
are not lined up.
7. Click in the Curve-1 to set the focus.

Pick the Right side of the part

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8. Click the Move Start Point Location button under Curve-1 until the points line up as
shown in the image below.
The start point is used when Curve 1 and Curve 2 contain the same number of entities. Each
time when you click the button, the start position for Curve 1 or Curve 2 is moved from end
point to end point.

9. Click OK to insert the changes.

Before top and bottom points are not After top and bottom points are lined up
lined up

Generate Operation Plan and Toolpath

1. Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the Feature tree and select
Generate Operation Plan on the context menu.

2. Click the Generate Toolpath button on the CAMWorks Command Manager.

OR
Right click the EDM Part Setup1 or CAMWorks NC Manager items in the Operation tree and
select Generate Toolpath on the context menu.

Changing the Leadin Point

1. Click the ( ) sign next to 4 Axis Contour1 in the Operation tree to expand the item.
2. Right click 4-Axis Punch1 under the operation and select Edit Leadin Point on the context
menu.
The Lead in Location dialog box is displayed and a round marker on the feature identifies the
current leadin point.
3. Rotate the part to adjust the lead locations as shown in the image.

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4. Use the current settings in the Lead in

Location dialog box and pick the top
segment shown in the image.
The entry point marker displays at the
midpoint of the selected edge.
5. Change the Select profile option to Bottom in
the Select profile group box and pick the
bottom segment shown in the image.
6. Click OK to apply changes and close the
dialog box.
The toolpath is automatically updated.

Lead Locations

Toolpath Simulation
1. Click the Simulate Toolpath button of the CAMWorks Command Manager.
OR
Right click EDM Part Setup1 in the tree and select Simulate Toolpath on the context menu.
2. Set the display parameters:

- Stock: Translucent Display

- Tool Holder: Translucent Display

- Target Part: Translucent Display

- Tool : Shaded Display

3. Click the Run button.

4. Click the button in the upper right corner to cancel the simulation and return to the
SOLIDWORKS/CAMWorks Solids display.

Simulation Toolpath

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4 Axis Contour 4

Topics covered in this tutorial:

In exercise 4-Axis Contour 2, you used the automatic synchronization to insert a 4 Axis EDM
feature that had an unequal number of entities in the top and bottom curves. In this exercise,
you insert a 4 Axis EDM feature that has an unequal number of entities in the top and bottom
curves. Because you use sketches for the curves, however, you pick each of the sync curves
instead of using the automatic function.

Open the Part and Defining the Machine and Stock

1. Open the part file EDM4AX_4.SLDPRT in the following folder.
Drive:\CAMWorksData\CAMWorks201x\Examples\Tutorial_Parts\EDM

2. Click the CAMWorks Feature Tree tab.

3. Double click the Machine item in the CAMWorks
Feature tree.
4. In the Available machines list, highlight Wire
EDM–Inch, click the Select button.
5. Click OK to close the dialog box.

6. Right click Machine [Wire EDM–Inch] in the

tree and click Select Machine on the context
menu.
7. In the Machine Selection dialog box, make sure
SODICK is selected for the Make and AG600L for EDM4AX_4.SLDPRT
the Model from dropdown list.
8. Click OK to close the dialog box.

9. Right click Machine [Wire EDM–Inch] in the tree and select Edit Settings on the context
menu.
The EDM Settings dialog box is displayed.
10. On the Posting tab, set the Process order for Punch to By Complete Feature.
11. Click OK to close the dialog box.

12. Double click Stock Manager in the Feature tree.

13. In the Stock Manager dialog box, click OK to use the default Bounding box and Material.

Extract Machinable Features and Inserting Part Setup

1. Click the Extract Machinable Features button on the CAMWorks Command Manager.

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You should run AFR even when you know AFR

cannot find any features on a part. Running AFR
sets up information for associativity that is
necessary for the Rebuild function.
2. Right click Stock Manager in the Feature tree and
select New Part Setup on the context menu.
3. Pick the top face on the part.

4. Click OK to insert the changes.

5. EDM Part Setup 1 is listed in the feature tree.
Pick the top face

Interactively Inserting and Picking Sync Curves to Define a 4

Axis EDM Feature
1. Right click EDM Part Setup1 in the Feature tree and select New 4 Axis EDM Feature on the
context menu.

2. Click the Punch button for the Feature type.

3. Pick the Sketch2 from the Available Sketches for Curve-1.
This action will list Sketch2 in the Curve-1.
4. Pick Sketch1 from the Available Sketches for Curve-2.
This action will list Sketch1 in the Curve-2.

5. The Automatically extract sync curve

button is disabled since a sketch was used for
Curve-2. Click in the Sync Curves list box to
set the focus.
6. Pick the four segments as shown in the image
to define the sync points.
In most cases, the order you pick the
segments does not matter; however, picking
the segments in sequential order is
recommended.
7. Click OK to insert the changes.
Pick the four segments

You can also insert this feature by

picking the top and bottom faces or edges and using automatic synchronization.
Sketches were used for demonstration purposes.

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 Wire EDM Tutorial

Generate Operation Plan and Toolpath

1. Click the Generate Operation Plan button on the CAMWorks Command Manager.
OR
Right click CAMWorks NC Manager or EDM Part Setup1 in the Feature tree and select
Generate Operation Plan on the context menu.

2. Click the Generate Toolpath button on the CAMWorks Command Manager.

OR
Right click the EDM Part Setup1 or CAMWorks NC Manager items in the Operation tree and
select Generate Toolpath on the context menu.

Simulate Toolpath
1. Click on the Simulate Toolpath button of the Command Manager.
OR
Right click EDM Part Setup1 in the tree and select Simulate Toolpath command from the
context menu.
2. Set the displays:

- Stock : Translucent Display

- Tool Holder: Translucent Display

- Target Part: Translucent Display

- Tool: Shaded Display

3. Click the Run button.

4. Click the button in the upper right corner to cancel the simulation and return to the
SOLIDWORKS/CAMWorks Solids display.

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APPENDIX A: LINKING EDM POST FILES &

ADDING EDM MACHINES/MODELS

If you use the CAMWorks module for Wire EDM machining, then this Appendix section explains the
following:
 The EDM Post files and their folder location within the CAMWorks Installation Folder.
 Restoring customized EDM Post Files after upgrading existing CAMWorks Installation
with a Service Pack
 Restoring customized EDM Post Files after installing a new CAMWorks Release
 Adding EDM Machines and Models
 Verifying the successful addition/edit of a Machine Make/Model

EDM Post Files

CAMWorks comes pre-installed with a set of Machine Makes/Models and post-specific
information. You can add/modify any Machine Makes/Models or post-specific information.

Folder Location of EDM Post Files

These files are located in within the CAMWorks Installation Folder typically at the following
location:
Drive:\CAMWorksData\CAMWorks2017x64\EDM

Files required for EDM Post Processing

The following files are used for EDM post processing in CAMWorks:
 Wire EDM post file (*.pst) – This is a unique post file for each Machine Make/Model
(example: Agie123_A.PST)
 Post information files – These files are dependent on the make and model.
 MachineSetup.bin - A binary file that contains the list of Machine Makes and Models
and post-specific information used by CAMWorks.
This file cannot be edited directly. The EDM Machine Setup utility
(CWEdmMachinesSetupx64.exe) is provided for editing it.
CAMWorks comes pre-installed with a set of Machine Makes/Models and post-
specific information. If you add/modify any Machine Makes/Models or post-specific
information, then the MachineSetup.bin file will be updated.
 MachineSetup.txt - The MACHINESETUP.TXT file is used by the EDM Machine
Setup Utility to generate the MachineSetup.bin file.
 Wire EDM Cutting conditions file (*.brcc, *.ecc, *.sbcc or *.sdcc) - A Cutting
Conditions Database if supported by the make/model (ex: Agie123_A.ecc).

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EDM Updating from a Previous CAMWorks Release

Restoring customized EDM Post Files after installing a Service Pack
If you have customized EDM post files, then on updating your existing CAMWorks Installation
with a fresh Service Pack, you need to copy the post files from their Backup folder locations to
their original data folder locations within the CAMWorks Data folder.

Backup Folder Location

When you install a Service Pack, the CAMWorks Installation Wizard automatically creates
backups of all customized data files.
1. All the EDM Post files except the cutting conditions Database present in the following
folder location are backed up and stored in the Backup\backup_xx sub-folder
located within the same folder:
Drive:\CAMWorksData\CAMWorks2017x64\EDM\Posts

2. Any customized CTC databases present in the following folder location are backed
up and stored in the Backup\backup_xx sub-folder located within the same folder:
Drive:\CAMWorksData\CAMWorks2017x64\EDM\EDMCuttingConditions

Note: The “xx” of the backup_xx folder indicates a two digit numerical
indicating the number of times the CAMWorks installation was
upgraded. In case of multiple backups, the backup files must always be
retrieved from the latest backup folder. Such a folder is easily
identifiable as the affixed number in its folder name is higher than those
of other backup folders.

Linking customized EDM Post Files after installing Service Pack

After installing the Service pack, copy the EDM post files and CTC databases from their
respective backup folders to their original locations. In the case of MachineSetup.bin and
MACHINESETUP.TXT, you have to overwrite the files installed by the Service pack.
Example:
If you upgraded CAMWorks 2016 SP1 to CAMWorks 2016 SP2, then:
a. Copy the EDM Post files from:
Drive:\CAMWorksData\CAMWorks2016x64\EDM\Posts\backup\backup_xx
to
Drive:\CAMWorksData\CAMWorks2016x64\EDM\Posts

b. Copy customized Cutting Conditions Database file from:

Drive:\CAMWorksData\CAMWorks2016x64\EDM\EDMCuttingConditions\backup\ba
ckup_xx
to

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Wire EDM Tutorial

Drive:\CAMWorksData\CAMWorks2016x64\EDM\Posts

c. Verify the successful linking of the EDM Post files with the Machine.

Restoring customized EDM Post Files after installing a new

CAMWorks Release
Each annual CAMWorks Release is installed as a separate installation without affecting the previous
CAMWorks release already installed. To link the customized EDM Post Files with the newly installed
CAMWorks release, you need to import them by copying them to the data folder location within the
new CAMWorks installation.

1. The following EDM Post files need to be copied from their data folder location of previous
CAMWorks release to the corresponding folder location in the new release.
a. Wire EDM post file (*.pst)
b. Post Information Files, if applicable.
c. MACHINESETUP.TXT
d. MachineSetup.bin

Overwrite the MachineSetup.bin and MACHINESETUP.TXT files present in the new

CAMWorks release’s data folder with the files from the previous release.
Example:
On upgrading from CAMWorks 2016 to CAMWorks 2017, copy the EDM Post files from
Drive:\CAMWorksData\CAMWorks2016x64\EDM\Posts
to
Drive:\CAMWorksData\CAMWorks2017x64\EDM\Posts.

2. Customized Wire EDM Cutting Conditions files need to be copied from the data folder
location of previous release to the corresponding folder location in the new release.
Example:
From Drive:\CAMWorksData\CAMWorks2016x64\EDM\EDMCuttingConditions
to
Drive:\CAMWorksData\CAMWorks2017x64\EDM\EDMCuttingConditions.

3. Copying the EDM post files to the data folder location thus links them to the newly installed
CAMWorks release.

Procedure to Add Machines and Models

If your particular EDM machine and/or model are not listed in the Machine Selection dialog box, you
can add the machine and model as explained in this section. To add a new machine/model or a
custom post from an existing installation, following are the steps:

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 Wire EDM Tutorial

1. Copy the custom Wire EDM Post processor file (*.pst) and any additional post information
files to the applicable post folder. The typical path would be:
Drive:\CAMWorksData\CAMWorks2017x64\EDM\Posts

2. If a Cutting conditions Database is supported by the EDM machine Make/ Model you intend
to add, then copy the custom Wire EDM Cutting conditions file (*.brcc, *.ecc, *.sbcc or
*.sdcc, etc.) to the applicable cutting conditions folder. The typical path would be:
Drive:\CAMWorksData\CAMWorks2017x64\EDM\EDMCuttingConditions

3. If SOLIDWORKS or CAMWorks Solids application is open, then exit the application.

Note: It is vital that SOLIDWORKS/ CAMWorks Solids not be open when you add a
new EDM Machine Make/Model. The reason is that any changes/additions
made to the EDM Machines are saved to the MachineSetup.bin file. If the
CAMWorks Add-In is open with the SOLIDWORKS/CAMWorks Solids
application, then the MachineSetup.bin will be overwritten when you later
close the application, thus undoing the EDM machine addition you made.

4. Open the EDM\Posts folder under the CAMWorks data folder and double-click
CWEdmMachinesSetup.exe.
A typical path would be:
Drive:\CAMWorksData\ CAMWorks2017x64\EDM\Posts
Alternatively, you can click on the Windows Taskbar and select
Start>>Programs>>CAMWorks2017x64>>EDM Post Utilities>>EDM Machine Setup.

Location of CWEDMMachineSetupx64.exe Accessing the EDM Machine Setup

Utility from the Windows Start menu

5. The EDM Machine Setup dialog box will be displayed.

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Wire EDM Tutorial

a. To add a new machine, click the Add Machine button under the Make dropdown lost.
b. New_Machine displays in the Make list box.

Click on the ‘Add Machine’ button in the Machines tab of EDM Machine Setup dialog box

6. Click on the Settings tab.

IMPORTANT: The settings on this tab are based on how the post processor was
written and must match the information provided by Geometric
Americas, Inc.

a. In the Machine group box:

i. Select the Machine Type from the dropdown list.
ii. Type the Make name and Model name.
b. In the Post group box:
i. From the Type dropdown list, select the type of code you need to output (G code
or Command/Iso)
ii. Click the Select button. Use the Open dialog box to browse and select the Post
processor that goes with this machine.
c. In the NC group box:
i. Click on the File path button and use the Browse for Folder dialog box to set the
path where the output file generated is to be saved.
ii. In the File extension field, set the file extension. (For example: .txt)
d. If a Cutting conditions database is supported by the Machine Make/Model you intend to
add, then in the Cutting Conditions database group box:
i. Check the Cutting Cond Allowed and Database Allowed checkboxes.
ii. Click the Select button. Use the Open dialog box to select the applicable cutting
conditions database.
e. In the Parameters section:

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 Wire EDM Tutorial

i. Adjust the settings to correspond to the post processor.

ii. Check applicable checkboxes.
7. Click the Save button. This action saves the newly added Machine Make/Model to the
MachineSetup.bin file.
8. Click the Close button to exit the EDM Machine Setup utility.

Settings tab of EDM Machine Setup dialog box

Verifying the successful addition/edit of a Machine Make/Model

Once an EDM Machine Make/Model has been added/ edited, you can verify whether the Machine
Makes/Models have been successfully listed and whether the paths of associated files are correct.

1. Launch CAMWorks as an Add-In within SOLIDWORKS/CAMWorks Solids.

2. Double click the Machine item in the Feature tree.
The Machine dialog box will be displayed.
3. Select the Wire EDM machine on the Machine tab and click OK.
4. Right-click the Wire EDM Machine in the CAMWorks Feature tree and click Select Machine
from the context menu.
5. In the Machine Selection dialog box, select the applicable Machine and Model and click OK.
6. If you added a new Machine Make/Model, then verify that the machine is listed in this dialog
box.

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7. Right-click the Wire EDM Machine in the CAMWorks Feature tree and select Edit Settings
from the context menu.
The Edit settings dialog box will be displayed.
8. On the Machine Setup tab, verify that the correct Cutting Conditions Database has been
selected.
9. On the Posting tab, verify the paths for post processor and NC File Path.
10. Click OK after verifying the changes to close the dialog box.

74 Appendix A: Linking EDM Post Files & Adding EDM Machines/Models