CAMWorks 2008

Wire EDM
Tutorial
Disclaimer
Geometric Technologies, Inc. makes no warranties, either express or implied
with respect to this manual. Geometric Technologies 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 and FeatureManager™ is a trademark
of SolidWorks Corporation.
Microsoft® Windows® is a registered trademark of Microsoft Corporation in
the United States and/or other countries.
All other brands and names are property of their respective owners.

Copyright ©2003-2008 Geometric Technologies, Inc. All Rights Reserved.

Geometric Technologies is a subsidiary of Geometric Ltd.

CW60i January 2008

Table of Contents
CHAPTER 1 LEARNING WIRE EDM BASICS 1-1
Wire EDM 1 .................................................................................................... 1-2
What You'll Learn...................................................................................... 1-2
Steps to Generate EDM Toolpaths and NC Code................................ 1-2
Step 1: Model Part in SolidWorks or Import Part............................... 1-2
Step 2: Change to CAMWorks Feature Tree ...................................... 1-3
Step 3: Define the Machine................................................................. 1-4
Step 4: Define the Stock...................................................................... 1-6
Step 5: Define Machinable Features ................................................... 1-7
Step 6: Generate Operation Plan/Adjust Operation Parameters ......... 1-8
Step 7: Generate Toolpaths ............................................................... 1-10
Step 8: Post Process Toolpaths.......................................................... 1-13
CHAPTER 2 LEARNING 2 AXIS CONTOUR CUTTING 2-1
2-Axis Contour 1 ............................................................................................. 2-2
What You'll Learn...................................................................................... 2-2
Extracting Machinable Features and Customizing AFR...................... 2-2
Generating a 2 Axis Contour Operation and Toolpaths....................... 2-4
Simulating and Post Processing Toolpaths .......................................... 2-5
2-Axis Contour 2 ............................................................................................. 2-6
What You'll Learn...................................................................................... 2-6
Inserting 2.5 Axis EDM Features......................................................... 2-6
Generating Operations and Toolpaths.................................................. 2-8
Changing the Machining Order and Post Processing........................... 2-9
2-Axis Contour 3 ........................................................................................... 2-10
What You'll Learn.................................................................................... 2-10
Inserting a Part Setup ......................................................................... 2-10
Inserting Vertical and Tapered Open Profile Features....................... 2-11
2 Axis Contour 4 ........................................................................................... 2-14
What You'll Learn.................................................................................... 2-14
Changing the Processing Order.......................................................... 2-14
CHAPTER 3 LEARNING 4 AXIS CONTOUR CUTTING 3-1
4-Axis Contour 1 ............................................................................................. 3-2
What You'll Learn...................................................................................... 3-2
Defining the Machine, Stock and Machining Direction ...................... 3-2
Defining a 4 Axis Die Feature Interactively ........................................ 3-3
Generating a 4 Axis Contour Operation and Toolpaths....................... 3-4

i
Table of Contents

4-Axis Contour 2 ............................................................................................. 3-6

What You'll Learn...................................................................................... 3-6
Automatically Extracting Sync Curves to Define a 4 Axis Feature .... 3-6
Generating the 4 Axis Contour Operation and Toolpaths.................... 3-8
4-Axis Contour 3 ............................................................................................. 3-9
What You'll Learn...................................................................................... 3-9
Using Sketches to Define a 4 Axis EDM Feature................................ 3-9
Changing the Leadin Point................................................................. 3-11
4-Axis Contour 4 ........................................................................................... 3-12
What You'll Learn.................................................................................... 3-12
Picking Sync Curves to Define a 4 Axis EDM Feature..................... 3-12
INDEX

ii
Chapter 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\EDM
folder. This folder may be inside the CAMWorks folder (e.g., \Program
Files\CAMWorksxxxx\Examples\EDM) or inside a CAMWorks data folder (e.g.,
\CAMWorksData\CAMWorksxxxx\Examples\EDM).

Learning Wire EDM Basics 1-1

Wire EDM 1

Wire EDM 1
What You'll Learn
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.
2. Change to the CAMWorks Feature tree.
3. Set the machine type and machine parameters.
4. Define the stock shape and material.
5. Define machinable features.
6. Generate the operation plan and adjust operation parameters.
7. Generate toolpaths.
8. Post process the toolpaths.

The next series of exercises show you how to generate toolpaths on a SolidWorks part
model. In order to give you a general understanding of how to use 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 exercises in this manual. When you install CAMWorks,
these files are installed automatically.
Step 1: Model Part in SolidWorks or Import Part
A part is a solid that is created with SolidWorks or imported into SolidWorks from another
CAD system via an IGES, Parasolid, SAT file, etc. This exercise uses an existing
SolidWorks part.
1. Open the part file EDM2AX_1.SLDPRT in the \Examples\EDM
folder.
The FeatureManager design tree lists the features, sketches,
planes and axes in the part.
The tabs at the bottom or top are for moving between the
SolidWorks trees and the CAMWorks trees.
Step 2: Change to CAMWorks Feature Tree
1. Click the CAMWorks Feature Tree tab. The CAMWorks
Feature tree displays.
The Machine item may indicate that a mill machine is
currently selected. Step 3 on page 1-4 explains how to change the machine to an EDM
machine.

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 Wire EDM 1

CAMWorks toolbar

Feature Tree tab CAMWorks menu

Operation Tree tab

CAMWorks
Feature tree

Graphics area
Part model

CAMWorks Machining Trees

The CAMWorks trees provide an outline view of the machining information for the model.
Initially, the CAMWorks Feature tree shows the Configurations, 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 trees and the CAMWorks trees.
• Configurations - Multiple CAMWorks datasets are supported in part mode. Each
dataset is called a configuration. You can use configurations to support multiple
machines and SolidWorks configurations.
• Stock Manager
The stock is the material from which the part will be machined. You can define the stock
as a rectangular bounding box or as an extruded sketch. You can also specify the type of
material.
• Machine
The Machine item defines the machine type that will be performed on the part (i.e., mill,
turn, mill-turn or EDM). 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 in the CAMWorks Feature tree is used to store machinable features that
you do not intend to machine.

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Wire EDM 1

CAMWorks Menu
1. Click CAMWorks on the SolidWorks menu bar. The CAMWorks menu lists the
CAMWorks commands. The commands are explained in the CAMWorks online Help.
2. Right click on the NC Manager in the tree. This is a shortcut menu. The right-click
shortcut menus provide access to a variety of commands.
CAMWorks Toolbar
The CAMWorks toolbar provides access to the main CAMWorks commands found on the
CAMWorks menu. Clicking a toolbar button is the same as selecting a command from the
NC Manager level, regardless of the active item in the tree.
1. Locate the CAMWorks toolbar and click the
Options button.
2. In the Options dialog box, click each tab to view
the options and settings that you can change in CAMWorks.
3. Click the Help button at the bottom of the dialog box. Each tab is explained in the online
Help.
4. Click the Close button in the upper right corner of the Help window to close the window.
5. Click Cancel to close the Options dialog box.

Step 3: Define the Machine

The Machine item in the tree identifies the type of machine: mill, turn or wire EDM. The
machine type defines the machinable feature set that can be recognized automatically and
defined interactively.
The icons that display in the tree identify the current machine:
Mill Turn Mill-Turn Wire EDM
An alternative machine can be selected at any time to output different G-code programs for
alternative machine tools. If the machine type changes, then all features and operations will
be deleted.
Define the machine:
1. Right click the Machine item in the CAMWorks Feature tree.
The shortcut menu displays. Right-click shortcut menus display commands that are
appropriate for the item that is highlighted in the tree.
2. Select Edit Definition on the shortcut menu.

Did You Know ...

As an alternate to right clicking items in the tree and
selecting the Edit Definition command, you can double
click the following items: Stock Manager, Machine, Setup,
Features and Operations.

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 Wire EDM 1

The Machine dialog box displays

the Machine tab. Milling is the
default machining type that is set
when CAMWorks is first
installed. The default machining
type is specified in the
Technology Database. Before
using CAMWorks for milling
and turning to machine your
parts, make sure you define the
machine tools available in your
facility. EDM machines are not
currently defined in the
Technology Database.
3. In the Available machines list,
highlight Wire EDM Mode–in
and click the Select button.
4. Click OK.
5. Right click Wire EDM
Mode–in in the tree and click Select Machine on the shortcut menu.
6. In the Machine Selection dialog box, select
TUTORIAL for the Make and TUTORIAL for
the Model, then click OK.
Use this selection for the exercises in this manual.
When you use CAMWorks to machine your own
parts, select your machine Make and Model from
the drop down list.
7. Right click Wire EDM Mode–in
and select Edit Settings on the shortcut menu. The EDM Settings dialog box displays.
On the Machine Setup tab, the path to the CTC Database is identified. This database has
been set up for the TUTORIAL machine. The cutting condition database sets machine-
specific parameters for
power settings, etc.
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.

Learning Wire EDM Basics 1-5

Wire EDM 1

10. Click the Posting tab.

The Posting page identifies the
post processor. This post
processor has been set up for
the TUTORIAL machine and
does not need to be changed.
The options on this page
provide information used to
generate the NC program,
including the processing order.
11. For the Die process order, use
By Complete Feature.
With this option, the NC
program will be generated in
the following processing order:
for each feature, cut the rough
pass, glue stop cut off, then all
skim passes.
Step 4: Define the Stock
The stock is the material from which the part will be machined. The default stock is the
smallest bounding box that the part will fit into. You can change the stock definition by
offsetting the bounding
box from the part or by
defining the stock from a
sketch and a depth.
1. Double-click
Stock Manager in the
Feature tree. The
Manage Stock dialog
box displays.
For this exercise, use
the default bounding
box.
2. Click the Material
button, select
TOOLSTEEL and
click OK.
3. Click OK to close the
Manage Stock dialog
box.

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 Wire EDM 1

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 Insert 2.5 Axis EDM Feature and Insert 4 Axis EDM Feature commands. Using
the interactive method, you can define Die (Pocket), Punch (Boss) and Open Profile
machinable features.
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 is not machining the SolidWorks features directly. It creates a separate list of
Machinable Features instead. This is because design features are typically not the same as
manufacturing features.
Using Automatic Feature Recognition (AFR)
Define machinable features automatically:
1. Click the CAMWorks Options button on the CAMWorks toolbar.
2. Click the EDM Features tab, make sure Perimeter punch feature is not checked, then
click OK.
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.
3. Click the Extract Machinable Features button on the CAMWorks toolbar or right
click NC Manager in the tree and select Extract Machinable Features on the shortcut
menu.
4. If the CAMWorks Message Window is not displayed, click the Message Window
button on the CAMWorks toolbar.
This window reports the progress
and status of the current process.
Generating Setups is the last item.
You can control whether this window
displays temporarily or permanently
by clicking the Pushpin button.
CAMWorks generates the Part Setup
and machinable features. The items display in the CAMWorks Feature tree.

Learning Wire EDM Basics 1-7

Wire EDM 1

The 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 Part Setup is created
automatically; however, you can move the origin, and you can change the direction and
angles of the X and Y axes.
A Part Setup is created for each different tool orientation. There is only one Part Setup
for this part because all features can be machined using a single setup orientation. For
each Part Setup, the machinable features are listed in the order in which they were
recognized.
The Feature tree allows you to:
− Rename, suppress, and delete machinable features
− Change machinable feature parameters
− Set the default order in which the features are
machined
− Insert additional 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 ...
New features, interactively inserted features that have no operations and features
that could not produce operations because the feature conditions have not been
defined in the Technology Database display in a different color. 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. In some situations, the operations defined
for a feature may not be sufficient and additional operations may be required. You can insert
operations manually using the Insert Operation command. This command is explained in the
CAMWorks online Help.
1. Click the Generate Operation Plan button on the CAMWorks toolbar or right click
NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan.
Note that clicking the toolbar button is the same as selecting the command from the NC
Manager level, regardless of the active item in the tree.
CAMWorks generates the operation plan for all the machinable features in Part Setup1.
The operations are listed in the CAMWorks Operation tree, which displays automatically.
The CAMWorks Operation tree provides an outline view of the operations for the
machinable features. Initially, operations are listed under the Part Setup in the same order
as the machinable features. At the top of the tree is the NC Manager. The Stock Manager
and Machine items function the same as in the CAMWorks Feature tree.

1-8 Learning Wire EDM Basics

 Wire EDM 1

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
− Hide or show toolpath display
− 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.
Did You Know ...
If an operation displays in a color instead of black, then toolpaths have not been
generated. 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 on the
Display tab in the Options dialog box.
Generate Operation Plan generates one cutting operation per 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
post processing the part.
Edit operation parameters using the Edit Definition command on the shortcut menu:
1. Double click 2 Axis Contour1 in the Operation tree.
The 2 Axis Contour dialog box displays. This dialog box gives you access to all the
parameters used to create the toolpath.
2. On the EDM tab, set the following:
− Number of skims = 2
− Glue Stop = No Glue Stop
3. On the Leadin/Out tab, set the Leadin and Leadout to Parallel with a Length of 0.10in,
then click OK.
Note that if you click the Save button before clicking OK, the current settings on the
EDM and Leadin/Out tabs become the defaults for newly inserted or generated operations
on this part or other parts.
4. Double-click 2 Axis Contour2 in the tree.

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Wire EDM 1

5. On the EDM tab, set the following:

− Number of skims = 2
− Glue stop = Use Glue Stop
− Stop distance = 0.1in.
6. On the Leadin/Out tab, set the Leadin and Leadout to Perpendicular with a Length of
0.1in, then click OK.
Step 7: Generate Toolpaths
CAMWorks calculates toolpaths using the operation parameters and the feature's size and
shape.
1. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part
Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the
shortcut menu.
Clicking the toolbar button is the same as selecting the command from the NC Manager
level, regardless of the active item in the tree.
CAMWorks calculates the toolpaths for each operation in the Part Setup.
You can also generate toolpaths for each operation individually by right clicking on an
operation and clicking Generate Toolpath on the shortcut menu.
2. Click the + sign next to 2Axis Contour1 and 2 Axis
Contour2 in the tree, then click the + sign next to
Open Profile1 and Die1.
Under each machinable feature, the toolpath passes
that were generated for that feature are listed. Notice a
Tab cut is generated for the second operation since
you set the Glue Stop to Use and set a Stop distance.
3. Click the first operation in the tree.
The toolpaths for that operation display on the part.
4. Click each toolpath pass under the operation. The toolpath for that pass displays.
Note that the toolpaths for each cut are on center. Compensation for each pass will be
handled by the cutter compensation at the machine.
CAMWorks provides the ability to simulate the toolpath showing the tool movement and the
resulting shape of the part.
5. Click the Simulate Toolbar button of the CAMWorks toolbar or right click Part
Setup1 in the tree and select Simulate Toolpath.
The Simulate Toolpath toolbar displays. The toolbar controls allow you to:
− Customize the display of the stock, tool and tool holder (wireframe, translucent,
shaded, or no display).
− Run the simulation for all or selected operations.

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 Wire EDM 1

− 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 and dynamically change the orientation of the part using zoom,
pan, rotate, etc.
− Control the simulation speed by dragging the Simulation Speed Control slider up or
down.
If you want to simulate only the toolpaths for a given operation, you can right click that
operation, then select Simulate Toolpath.
6. Set the toolbar buttons as shown in the figure.

7. Click the Run button.

The simulation runs.

8. Click the Select Chips to Remove button. This button is enabled when the simulation
is complete and provides two methods for removing loose chips.
9. Pick the two loose stock chips to remove, then press the D (delete) or R (remove) key on
the keyboard. The loose chips are removed in the graphics area.

10. Click the Select Chips to Remove button to exit the function.
11. Click the Goto Start button and Run the simulation again.

12. Click the Select Chips to Remove button.

13. Hold down the Ctrl key and pick the stock piece you want to keep, then press the D or R
key on the keyboard.
If there are many loose chips to remove, picking the stock piece may be faster than
picking each chip.
14. Click the X button in the upper right corner to close the simulation and return to the
SolidWorks display.

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Wire EDM 1

CAMWorks also provides the ability to step through the toolpath using the Step Thru
Toolpath command.
1. Right click an operation in the tree and select Step Thru Toolpath. The Step Thru
Toolpath toolbar displays. Multiple step increment

Show toolpath points

Display tool

Single step Forward multiple steps Number of toolpath

segments to display
2. Click the Single Step button (single arrow) several times.
The active toolpath node is highlighted.
3. Set the Step Increment to 3 and click the Forward Multiple Steps button (double arrow)
several times.
4. Click the Goto End button. The toolpaths are completed.
5. Click the X button in the upper right corner to exit.
Did You Know ...
CAMWorks provides an option to display the XYZ position of the tool in the
Message Window during Simulation and Step Thru Toolpath. To activate this
option, select the Options command on the CAMWorks menu or the NC Manager
shortcut menu. On the General tab, select the Message Window option. On the
Simulation tab, select the Cutter coordinates in Message Window option.

Save the part with the machinable feature data:

1. Click the Options button the CAMWorks toolbar.
Note that you can also click CAMWorks on the menu bar or right click NC Manager in
the tree and select the Options command.
2. On the General tab, make sure the Save/Restore part option is checked, then click OK.
If this option is checked, when you save and close a part document, the machining data is
saved. When the part document is opened again, the machining data is restored along
with the part design information.
If this option is not checked, when you save and close a part document that contains at
least one CAMWorks Setup, a message indicates that Save/Restore is disabled. If you
click Yes, CAMWorks saves all CAMWorks data before closing the file. If you click No,
CAMWorks closes the part and discards any new CAMWorks data since the last save.
3. Click Save As on the File menu.
4. In the Save As dialog box, type cwedm1 and click the Save button.

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 Wire EDM 1

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 8: 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. This is a
text file that you can read, edit and print using a word processor or text editor.
In this exercise, you post process all the operations and generate the NC program:
1. Click the Post Process button on the CAMWorks toolbar or right click NC Manager
in the Operation tree and click Post Process on the shortcut menu.
The Post Output File dialog box
displays so you can name the NC
program file.
If you want the file in another
location, you can change the
folder.
If the Post Process command is
grayed out on the CAMWorks
menu or on a shortcut menu,
make sure that you have
generated the toolpaths.
2. 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.
3. Click Save.
You do not have to type the extension. Naming the post output file the same as the part
file is the most common way of saving parts and NC programs. Both files can have the
same name because they have different extensions.
The Post Process Output dialog box displays.

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Wire EDM 1

4. Click the Step button on the control bar

at the top.
CAMWorks starts to generate the NC Run
program and the first line of NC code
displays in the NC code output view Step
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 displays.
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 Post Process Output dialog box.

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Chapter 2 Learning 2 Axis Contour Cutting

This chapter provides an opportunity to learn CAMWorks Wire EDM through step-by-step
exercises. We recommend that you go through the exercise in Chapter 1 first.
The exercises in this chapter are intended to show you how to use CAMWorks Wire EDM
and may not correspond to actual machining practices.

Learning 2 Axis Contour Cutting 2-1

2-Axis Contour 1

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 Insert 2.5 Axis EDM
Feature function. A CAMWorks file can contain both types of features.
This exercise 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.

What You'll Learn

Extracting Machinable Features and Customizing AFR
1. Open the part file EDM2AX_2.SLDPRT in the \Examples\EDM folder.
2. Click the CAMWorks Feature Tree tab.
3. Double click the Machine item in the CAMWorks Feature tree.
The Machine dialog box displays.
4. In the Available machines list, highlight Wire EDM Mode-mm,
click the Select button, then click OK.
5. Right click Wire EDM Mode-mm in the tree and click
Select Machine on the shortcut menu.
6. In the Machine Selection dialog box, select TUTORIAL for the
Make and TUTORIAL for the Model, then click OK.
7. Right click Wire EDM Mode-mm in the tree and select Edit Settings on the shortcut
menu.
8. On the EDM Setup tab, make sure the Wire diameter is set to 0.20mm.
9. 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: for
each feature, cut rough pass, glue stop cut off, then all skim passes.
10. Double click Stock Manager in the Feature tree.
The Manage Stock dialog box displays.
11. For this exercise, click OK to use the default bounding box and material.

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 2-Axis Contour 1

CAMWorks allows you to control the types of features that are created by AFR:
1. Click the Options button on the CAMWorks toolbar.
2. On the EDM Features tab, make sure the Perimeter punch feature is checked and click
OK.
3. Click the Extract Machinable Features button on the CAMWorks toolbar or right
click NC Manager in the tree and select Extract Machinable Features on the shortcut
menu.
4. If the CAMWorks Message
Window is not displayed, click the
Message Window button on the
CAMWorks toolbar. This window
reports the progress and status of the
current process. Generating Setups is
always the last item. When you see it,
you know the AFR process is almost complete.
CAMWorks generates the Part Setup and machinable features.

5. Click each feature item in the tree to see the corresponding feature on the part.
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.

Learning 2 Axis Contour Cutting 2-3

2-Axis Contour 1

6. Click the Options button on the CAMWorks toolbar.

7. On the EDM Features tab, remove the check
marks from the Countersink holes, Counterbore
holes and Multi-step holes options and check the
On Rebuild Delete option for these features
types.

8. 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 (note that the values that displayed
when you opened this dialog box will be retained for the current part)
− All Possible - the current part as well as all new parts
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.
9. Click OK.
10. Click the Extract Machinable Features button on the CAMWorks toolbar or right
click NC Manager in the tree and select Rebuild.
The Circular Die features for the countersunk, counterbore and multi-step holes are now
in the Recycle Bin.
Generating a 2 Axis Contour Operation and Toolpaths
Generate operations and toolpaths, then post process:
1. Click the Generate Operation Plan button on the CAMWorks toolbar or right click
NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the
shortcut menu.

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 2-Axis Contour 1

When you select Generate Operation Plan, operations are 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 toolbar or right click the Part
Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the
shortcut menu.
Simulating and Post Processing Toolpaths
1. Click the Simulate Toolpath button on the CAMWorks toolbar or right click NC
Manager or Part Setup1 in the tree and select Simulate Toolpath.
2. Set the display:
− Stock, Tool and Holder = Shaded Display
− Target Part = No Display
3. Click the Run button.

4. Click the Select Chips to Remove

button.
5. Hold down the Ctrl key and pick the stock
piece you want to keep, then press the D or R
key on the keyboard.
The loose chips are removed in the graphics
area.
6. Click the X button in the upper right
corner to cancel the simulation and return to the SolidWorks display.
Post process the part and view the code:
7. Click the Post Process button on the CAMWorks toolbar or right click NC Manager
in the Operation tree and click Post Process on the shortcut menu.
8. In the Post Output File dialog box, click Save.

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

Learning 2 Axis Contour Cutting 2-5

2-Axis Contour 2

2-Axis Contour 2
What You'll Learn
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 exercise, AFR finds only the irregular die in the center of the
part. You interactively insert 2.5 Axis EDM features to cut the two dies on the sides and the
outside of the part.
Inserting 2.5 Axis EDM Features
1. Open the part file EDM2AX_3.SLDPRT in the \Examples\EDM folder.
2. Click the CAMWorks Feature Tree tab.
3. Double click the Machine item in the CAMWorks Feature tree.
The Machine dialog box displays.
4. In the Available machines list, highlight Wire EDM–in, click the Select button, then click
OK.
5. Right click Wire EDM–in in the tree and click Select Machine on the shortcut menu.
6. In the Machine Selection dialog box, make sure TUTORIAL is selected for the Make and
TUTORIAL for the Model, then click OK.
7. Right click Wire EDM–in in the tree and select Edit Settings.
8. On the Posting tab, make sure the Process order is By Complete Feature for both Die and
Punch, then click OK.
9. 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.
10. Double click Stock Manager in the Feature tree.
11. In the Manage Stock dialog box, click OK to use the default bounding box and material.
12. Click the Options button on the CAMWorks toolbar.
13. On the EDM Features tab, make sure the Perimeter punch feature is not checked and
click OK.
14. Click the Extract Machinable Features button on the CAMWorks toolbar. AFR finds
only the Irregular Die in the center of the part.

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 2-Axis Contour 2

15. 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.
When necessary, you can reverse the direction by right clicking Part
Setup1 in the tree, selecting Edit Definition and clicking the Reverse
Direction button in the Part Setup dialog box.
Note that the SolidWorks axis does not control CAMWorks machining.
However, it is used as a reference for certain CAMWorks functions (for
example, offsetting the stock).
Insert 2.5 Axis EDM features interactively:
1. Right click EDM Part Setup1 in the tree and select Insert 2.5 Axis EDM Feature on the
shortcut menu.

2. In the Feature Definition dialog box, make

sure Die is the selected Feature type.

3. Rotate the part and pick the bottom face.

Three Die features are shown in the Selected entities

for features box.
4. Click Die – 2 and Die – 3 to view the features on
the part.
5. Click Die – 1. This is the Irregular Die feature that has
already been found by AFR so you can delete it.
6. Highlight Die – 1 in the list and press the Delete key.
7. 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.
8. Click Insert 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:

9. Click the Punch button for the Feature type.

Learning 2 Axis Contour Cutting 2-7

2-Axis Contour 2

10. Pick the same face on the bottom of the part.

Punch – 1 is listed in the Selected entities for feature
box.
11. Click the End Condition tab. You can use the default
Upto Stock.
12. Click Insert. Punch1 displays in the tree.
13. Click Close to close the Feature Definition dialog box.

Generating Operations and Toolpaths

Generate operations and toolpaths:
1. Click the Generate Operation Plan button on the
CAMWorks toolbar or right click NC Manager or Part
Setup1 in the Feature tree and select Generate Operation
Plan on the shortcut menu.
2. Expand 2 Axis Contour4 in the Operation tree (click the
+ sign).
3. Right click Irregular Die1 and select Edit Leadin Point
on the shortcut menu.
The Lead in Location dialog box displays. You can set the
leadin/leadout location to be at the start-, mid- 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.
4. Leave the Lead in location set to Mid-point and pick
the segment shown in the figure.
5. Click OK to close the dialog box.
6. Click the Generate Toolpath button on the CAMWorks
toolbar or right click the Part Setup1 or NC Manager items in the
Operation tree and select Generate Toolpath on the
shortcut menu.
7. Click the + sign next to 2 Axis Contour 1 in the tree to
expand the operation, then expand Punch1.
The processing order is rough cut, skim passes, then
glue stop cut off. 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.
8. Click the + sign next to 2 Axis Contour 2 in the tree to
expand the operation, then expand Rectangular Die3.

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 2-Axis Contour 2

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.
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.
1. Highlight 2 Axis Contour1 in the tree and drag it on top
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
toolbar.
3. Click the File Output tab. The File Output tab contains
an option to automatically open the G-code file when you close the Post Process Output
dialog box.
4. 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 or \WINNT folder and click Open, then
click OK.
6. Click the Post Process button on the CAMWorks toolbar or right click NC Manager
in the Operation tree and click Post Process on the shortcut menu.
7. In the Post Output File dialog box, type a name for the file and click Save.
You do not have to type the extension.

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. Close the editor.

Learning 2 Axis Contour Cutting 2-9

2-Axis Contour 3

2-Axis Contour 3
What You'll Learn
In this exercise, 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 Insert 2.5 Axis EDM command.
Inserting a Part Setup
1. Open the part file EDM2AX_4.SLDPRT in the \Examples\EDM folder.
2. Click the CAMWorks Feature Tree tab.
3. Right click the Machine item in the CAMWorks Feature tree and select Edit Definition
on the shortcut menu.
The Machine dialog box displays.
4. In the Available machines list, highlight Wire EDM Mode–mm, click the Select button,
then click OK.
5. Right click Wire EDM Mode-mm in the tree and click Select Machine on the
shortcut menu.
6. In the Machine Selection dialog box, make sure TUTORIAL is selected for the Make and
TUTORIAL for the Model, then click OK.
7. Right click Wire EDM Mode-mm in the tree and select Edit Settings on the shortcut
menu.
8. On the Posting tab, set the Process order for Die to By Complete Feature, then click OK.
With this option, the NC program is generated in the following machining order: Rough
cut, glue stop cut off, 0 - 6 full skim passes.
9. Right click Stock Manager in the Feature tree and select Edit Definition on the
shortcut menu.
10. In the Manage Stock dialog box, click OK to use the default bounding box and material.
11. Click the Extract Machinable Features button on the CAMWorks toolbar or right
click NC Manager in the tree and select Extract Machinable Features on the shortcut
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.

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 2-Axis Contour 3

12. Right click Stock Manager in the tree and

select Insert Part Setup on the shortcut menu.
13. Pick the face on the top of the part,
then click OK in the Part Setup dialog box.
EDM Part Setup1 is listed in the tree.

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 Part Setup1 in the tree and select Insert 2.5 Axis EDM Feature on the shortcut
menu.

2. Select Open Profile for the

Feature type.
3. Pick the lower edge on the left, then
hold down the Ctrl key and pick the
lower edge on the right.
When you define an Open Profile
Feature from multiple edges, you can
chain select 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 the arrow indicates which side of the feature to cut on. In this case, you want to
cut on the other side.
4. Click Open Profile – 1 in the Selected
entities for features list, then click the
Flip direction check box.
The arrow direction is reversed.
5. Click the End Condition tab.
This feature is vertical and no changes
need to be made on this tab.
6. Click the Insert button.
Open Profile 1 is listed in the Feature tree. Next, you define the tapered open profile
feature.

Learning 2 Axis Contour Cutting 2-11

2-Axis Contour 3

7. Pick the top edge on the left side.

8. Hold down the Ctrl key and pick the
top edge on the right.
9. Click Open Profile – 1 in the
Selected entities for features list,
then click the Flip direction check
box.
10. Click the End Condition tab.
11. Zoom in on the right side of this feature. There is a 10-
degree taper.
12. Click the Taper On/Off button to turn it on.
13. Set the degrees to 10 and press the Tab key.
14. Rotate the part and notice that the feature outline
indicates the taper is going inward.
15. Click the Reverse Taper button to reverse the
taper so it is going outward. This button functions as a toggle.
16. Click Insert, then click Close.
17. Drag Tapered Open Profile2 after Open Profile1 in
the Feature tree.
This is the order the features will be processed
when the NC code is generated.
Generate operations and toolpaths:
1. Click the Generate Operation Plan button on
the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and
select Generate Operation Plan on the shortcut menu.
2. Double-click 2 Axis Contour1 in the Operation tree.
The 2 Axis Contour dialog box displays. This dialog box gives you access to all the
parameters used to create the toolpath.
3. On the EDM tab, set the following:
− Number of skims = 2
− Glue Stop = No Glue Stop
− Process = Die
4. On the Leadin/Out tab, set the Leadin and Leadout to Parallel, then click OK.
5. Right click on 2 Axis Contour2 in the tree and select Edit Definition on the shortcut
menu.
6. Make the same changes as for 2 Axis Contour1, then click OK.

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 2-Axis Contour 3

7. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part
Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the
shortcut menu.
8. Click the Simulate Toolbar button of the CAMWorks toolbar or right click Part
Setup1 in the tree and select Simulate Toolpath.
9. Set the display:
− Stock, Tool Holder and Target Part = Translucent Display
− Tool = Shaded Display
10. Click the Run button.
11. Click the X button in the upper right corner to cancel the simulation and return to the
SolidWorks display.
12. Click the Post Process button on the CAMWorks toolbar or right click NC Manager
in the Operation tree and click Post Process on the shortcut menu.
13. In the Post Output File dialog box, click Save.

14. Click the Run button in the Post Process Output dialog box.
15. When the post processing is finished, click OK.
The program file may open automatically in an editor if you enabled this option in the
previous exercise.
16. View the code, then close the editor.

Learning 2 Axis Contour Cutting 2-13

2 Axis Contour 4

2 Axis Contour 4
What You'll Learn
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 online Help.
Changing the Processing Order
1. Open the part file EDM2AX_5.SLDPRT in the \Examples\EDM folder.
2. Click the CAMWorks Feature Tree tab.
3. Right click the Machine item in the
CAMWorks Feature tree and select Edit
Definition on the shortcut menu.
The Machine dialog box displays.
4. In the Available machines list, highlight Wire
EDM Mode–mm, click the Select button, then
click OK.
5. Right click Wire EDM Mode–mm in the
tree and click Select Machine on the shortcut
menu.
6. In the Machine Selection dialog box, make sure TUTORIAL is selected for the Make and
TUTORIAL for the Model, then click OK.
7. Right click Wire EDM Mode–mm
in the tree and select Edit Settings on
the shortcut menu.
8. On the Posting tab, make sure the
Process order for Die is By Complete
Feature, then click OK.
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.

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 2 Axis Contour 4

9. Right click Stock Manager in the Feature tree and select Edit Definition on the
shortcut menu.
10. In the Manage Stock dialog box, click OK to use the default bounding box and material.
11. Click the Extract Machinable Features button on the CAMWorks toolbar or right
click NC Manager in the tree and select Extract Machinable Features on the shortcut
menu.
Rectangular Die1 and Circular Die2 are listed in the tree.
12. Click the Generate Operation Plan button on the CAMWorks toolbar or right click
NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the
shortcut menu.
13. Right click 2 Axis Contour1 in the Operation tree and select Edit Definition on the
shortcut menu.
14. On the EDM tab, set the following:
− Number of skims = 2
− Glue Stop = Use Glue Stop
− Stop distance = 2mm
15. On the Leadin/Out tab, set the Leadin and Leadout to Perpendicular with a Length of
6mm, then click OK.
16. Right click 2 Axis Contour2 in the tree and select Edit Definition.
17. Make the same changes on the EDM and Leadin/Out tabs.

18. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part
Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the
shortcut menu.
Post process the Die features and view the code:
1. Click the Options button on the CAMWorks toolbar.
2. Click the File Output tab.
The File Output tab contains an option to automatically open the G-code file. You can
browse and select the editor that you want to open the G-code file when you close the
Post Process Output dialog box.
3. Check the Open G-code file in editor option.
4. 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 or \WINNT folder and click Open, then click OK.
5. Click the Post Process button on the CAMWorks toolbar or right click NC Manager
in the Operation tree and click Post Process on the shortcut menu.

Learning 2 Axis Contour Cutting 2-15

2 Axis Contour 4

6. In the Post Output File dialog box, type die complete for the File name and click Save.
You do not have to type the extension.

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. Close the editor.
11. Right click Wire EDM Mode–mm in the tree and click Edit Settings on the shortcut
menu.
12. On the Posting tab, set the Process order for Die to Rough / Glue Stop / All Skims, then
click OK.
13. Post process the part again. Name the file die rough-tab-all skims.
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. Close the editor.
16. Right click Wire EDM Mode–mm in the tree and click Edit Settings on the shortcut
menu.
17. On the Posting tab, set the Process order for Die to Rough / Glue Stop / Skim Passes, then
click OK.
18. Post process the part again. Name the file die rough-tab-skim pass.
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.

2-16 Learning 2 Axis Contour Cutting

Chapter 3 Learning 4 Axis Contour Cutting

This chapter provides an opportunity to learn 4 Axis Contour cutting through step-by-step
exercises. We recommend that you go through the exercise in Chapter 1 first.
The exercises in this chapter are intended to show you how to use CAMWorks Wire EDM
and may not correspond to actual machining practices.

Learning 4 Axis Contour Cutting 3-1

4-Axis Contour 1

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 Insert 4 Axis EDM Feature command. The Insert 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.

What You'll Learn

Defining the Machine, Stock and Machining Direction
1. Open the part file EDM4AX_1.SLDPRT in the \Examples\EDM folder inside the
CAMWorks folder (e.g., \Program Files\CAMWorksxxxx\Examples\EDM).
2. Click the CAMWorks Feature Tree tab.
3. Double click the Machine item in the CAMWorks Feature tree.
The Machine dialog box displays.
4. In the Available machines list, highlight Wire EDM Mode–in, click the Select button,
then click OK.
5. Right click Wire EDM Mode–in in the tree and click Select Machine on the shortcut
menu.
6. In the Machine Selection dialog box, select TUTORIAL for the Make and TUTORIAL
for the Model, then click OK.
7. Right click Wire EDM Mode–in in the tree and select Edit Settings on the shortcut
menu.
8. On the Machine Setup tab, set the AWT minimum distance to 0.0in.
This parameter defines the minimum clearance required for the auto threader to work
properly when threading in an open cavity next to the part profile previously machined by
a rough cut. This would occur in automatic machining when re-threading the wire to
perform the skim cuts in a die cavity.
9. On the EDM Setup tab, make sure the Wire diameter is set to 0.01in.
10. On the Posting tab, make sure the Process order for dies 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, then all skim passes.

3-2 Learning 4 Axis Contour Cutting

 4-Axis Contour 1

11. Double click Stock Manager in the Feature tree.

The Manage Stock dialog box displays.
12. For this exercise, click OK to use the default bounding box and material.
13. Click the Extract Machinable Features button on the CAMWorks toolbar.
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.
14. Right click Stock Manager in the Feature tree and select Insert Part Setup on the shortcut
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 exercise, AFR is not used since there are no 2 Axis EDM features
on the part. You need to insert a Part Setup interactively.
15. Pick the top face and click OK.
Defining a 4 Axis Die Feature Interactively
Define a 4 Axis EDM feature interactively:
1. Right click EDM Part Setup1 and select Insert 4 Axis EDM Feature on the shortcut
menu.
The Insert 4 Axis EDM Feature dialog box displays.

2. Make sure Die is the selected Feature type.

3. For Curve-1, pick the top edge of the rectangular pocket as shown in the figure.
4. For Curve-2, pick the lower edge.
The start point on each curve is identified.
5. If the start points are not as shown in
the figure, 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.
6. Click Insert, then click Close.
Rectangular 4-Axis Die1 is listed in the tree.

Learning 4 Axis Contour Cutting 3-3

4-Axis Contour 1

Generating a 4 Axis Contour Operation and Toolpaths

Generate operations and toolpaths, then post process:
1. Click the Generate Operation Plan button on the CAMWorks toolbar or right click
NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the
shortcut menu.
2. Double click 4 Axis Contour1 in the Operation tree.
3. On the Leadin/out tab, set the Leadin and Leadout to Perpendicular with a .02in Length,
then click OK.
4. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part
Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the
shortcut menu.
5. Click the operation in the tree to view the toolpath.
6. Click the Simulate Toolpath button on the CAMWorks toolbar or right click NC
Manager or Part Setup1 in the tree and select Simulate Toolpath.
7. Set the display:
− Stock and Tool = Shaded Display
− Holder = No Display
− Target Part = No Display

8. Click the Run button.

9. Click the Select Chips to Remove

button.
This button is enabled when the
simulation is complete and provides
two methods for removing loose chips.
10. Hold down the Ctrl key and pick the
stock piece you want to keep, then
press the D or R key.
The loose chips are removed in the
graphics area.

11. Click the Select Chips to Remove button to exit the function.
12. Click the Goto Start button and Run the simulation again.

13. Click the Select Chips to Remove button.

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 4-Axis Contour 1

14. Pick the loose stock chip to remove and press the D or R key.
If there are many loose chips to remove, picking the stock piece may be faster than
picking each chip.
15. Click the X button in the upper right corner to cancel the simulation and return to the
SolidWorks display.
Post process the part and view the code:
1. Click the Post Process button on the CAMWorks toolbar or right click NC Manager
in the Operation tree and click Post Process on the shortcut menu.
2. In the Post Output File dialog box, click Save.

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

Learning 4 Axis Contour Cutting 3-5

4-Axis Contour 2

4-Axis Contour 2
What You'll Learn
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. 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 exercise, you insert the feature and automatically
extract sync curves.
Automatically Extracting Sync Curves to Define a 4 Axis Feature
1. Open the part file EDM4AX_2.SLDPRT in the \Examples\EDM folder.
2. Click the CAMWorks Feature Tree tab.
3. Double click the Machine item in the CAMWorks Feature tree.
The Machine dialog box displays.
4. In the Available machines list, highlight Wire EDM Mode–in, click the Select button,
then click OK.
5. Right click Wire EDM Mode–in in the tree and click Select Machine on the shortcut
menu.
6. In the Machine Selection dialog box, make sure TUTORIAL is selected for the Make and
TUTORIAL for the Model, then click OK.
7. Right click Wire EDM Mode–in in the tree and select Edit Settings.
8. On the Posting tab, make sure the Process order for Punch is set to By Complete Feature,
then click OK.
The processing order is rough cut leaving glue stop, 0 - 6 skim passes, then glue stop cut
off.
9. Double click Stock Manager in the Feature tree.
10. In the Manage Stock dialog box, click OK to use the default bounding box and material.

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 4-Axis Contour 2

11. Click the Extract Machinable Features button on the CAMWorks toolbar.
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.
12. Right click Stock Manager in the Feature tree and select Insert Part Setup on the shortcut
menu.
13. Pick the top face on the part and click OK.
Insert the 4 Axis EDM feature interactively:
1. Right click Part Setup1 in the tree and select Insert 4 Axis EDM Feature on the shortcut
menu.
The Insert 4 Axis EDM Feature dialog box displays.

2. Click the Punch button for the Feature type.

3. For Curve-1, pick the top face of the part.
4. For Curve-2, rotate the part and pick the bottom face.

5. 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.
6. Click Insert, then click Close.

Before Automatically Extracting Sync Curves After Automatically Extracting Sync Curves

Learning 4 Axis Contour Cutting 3-7

4-Axis Contour 2

Generating the 4 Axis Contour Operation and Toolpaths

Generate operations and toolpaths:
1. Click the Generate Operation Plan button on the CAMWorks toolbar or right click
NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the
shortcut menu.
2. Double click 4 Axis Contour1 in the Operation tree.
3. On the EDM tab, set the Glue stop to No Glue Stop, then click OK.
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.
4. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part
Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the
shortcut menu.
5. Click the operation in the tree to view the toolpath.
6. Click 4 Axis Contour1 in the tree, then click 4-Axis Punch1 to expand it. Notice that
there is no Tab cut.
7. Click the Simulate Toolpath button on the CAMWorks toolbar.
8. Set the display:
− Stock and Tool = Shaded Display
− Holder = No Display
− Target Part = No Display

9. Click the Run button.

10. Click the Select Chips to Remove button.

11. Hold down the Ctrl key and pick the stock
piece you want to keep, then press the D or R
key.
The loose chips are removed in the graphics
area.
12. Click the X button in the upper right corner
to cancel the simulation and return to the
SolidWorks display.

3-8 Learning 4 Axis Contour Cutting

 4-Axis Contour 3

4-Axis Contour 3
What You'll Learn
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.
Using Sketches to Define a 4 Axis EDM Feature
1. Open the part file EDM4AX_3.SLDPRT in the \Examples\EDM folder.
2. Click the CAMWorks Feature Tree tab.
3. Right click the Machine item in the CAMWorks Feature tree and select Edit Definition
on the shortcut menu.
4. In the Available machines list, highlight Wire EDM Mode–in, click the Select button,
then click OK.
5. Right click Wire EDM Mode–in in the tree and click Select Machine on the shortcut
menu.
6. In the Machine Selection dialog box, make sure TUTORIAL is selected for the Make and
TUTORIAL for the Model, then click OK.
7. Right click Wire EDM Mode–in in the tree and select Edit Settings on the shortcut
menu.
8. On the Posting tab, set the Process order for Punch to By Complete Feature, then click
OK.
9. Right click Stock Manager in the Feature tree and select Edit Definition on the
shortcut menu.
10. In the Manage Stock dialog box, click OK to use the default bounding box and material.
11. Click the Extract Machinable Features button on the CAMWorks toolbar.
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.
12. Right click Stock Manager in the Feature tree and select Insert Part Setup on the shortcut
menu.
13. Pick the Front reference plane and click the Reverse direction option.
14. Click OK.

Learning 4 Axis Contour Cutting 3-9

4-Axis Contour 3

Insert the 4 Axis EDM feature interactively:

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

2. Click the Punch button for the Feature type.

3. Pick Sketch2 for Curve-1.
4. For Curve-2, rotate the part and pick the
bottom face anywhere on the right side as
shown in the figure.

5. Rotate the part and notice the top and

bottom start points are not lined up.

6. Click the Move Start Point

Location button under Curve-1 until the
points line up.
The start point is used when Curve 1 and
Curve 2 contain the same number of
entities. Each time you click the button,
the start position for Curve 1 or Curve 2 is
moved from end point to end point.
7. Click Insert, then click Close.

3-10 Learning 4 Axis Contour Cutting

 4-Axis Contour 3

Changing the Leadin Point

Generate the operation and toolpath:
1. Click the Generate Operation Plan button on the CAMWorks toolbar or right click
NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the
shortcut menu.
2. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part
Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the
shortcut menu.
3. Click the + sign next to 4 Axis Contour1 in the tree to expand the item.
4. Right click 4-Axis Punch1 under the operation and select Edit Leadin Point on the
shortcut menu.
The Lead in Location dialog box displays
and a round marker on the feature identifies
the current leadin point.
5. Use the current settings in the Lead in
Location dialog box and pick the segment
shown in the figure.
The entry point marker displays at the
midpoint of the selected edge.
6. Change the Select profile option to Bottom
and pick the segment shown in the figure.
7. Click OK.
The toolpath is automatically updated.
8. Click the Simulate Toolbar button of
the CAMWorks toolbar or right click Part
Setup1 in the tree and select Simulate
Toolpath.
9. Set the display:
− Stock, Tool Holder and Target Part =
Translucent Display
− Tool = Shaded Display
10. Click the Run button.
11. Click the X button in the upper right
corner to cancel the simulation and return to
the SolidWorks display.

Learning 4 Axis Contour Cutting 3-11

4-Axis Contour 4

4-Axis Contour 4
What You'll Learn
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.
Picking Sync Curves to Define a 4 Axis EDM Feature
1. Open the part file EDM4AX_4.SLDPRT in the \Examples\EDM folder.
2. Click the CAMWorks Feature Tree tab.
3. Right click the Machine item in the CAMWorks Feature tree and select Edit Definition
on the shortcut menu.
4. In the Available machines list, highlight Wire EDM Mode–in, click the Select button,
then click OK.
5. Right click Wire EDM Mode–in in the tree and click Select Machine on the shortcut
menu.
6. In the Machine Selection dialog box, make sure TUTORIAL is selected for the Make and
TUTORIAL for the Model, then click OK.
7. Right click Wire EDM Mode–in in the tree and select Edit Settings on the shortcut
menu.
8. On the Posting tab, set the Process order for Punch to By Complete Feature, then click
OK.
9. Right click Stock Manager in the Feature tree and select Edit Definition on the
shortcut menu.
10. In the Manage Stock dialog box, click OK to use the default bounding box and material.
11. Click the Extract Machinable Features button on the CAMWorks toolbar.
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.
12. Right click Stock Manager in the Feature tree and select Insert Part Setup on the shortcut
menu.
13. Pick the top face and click OK.

3-12 Learning 4 Axis Contour Cutting

 4-Axis Contour 4

Insert the 4 Axis EDM Feature interactively:

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

2. Click the Punch button for the Feature type.

3. In the Insert 4 Axis EDM Feature dialog
box, pick Sketch2 for Curve-1.
4. Pick Sketch1 for Curve-2.
5. Click in the Sync Curves list box to set the
focus.
6. Pick the four segments shown in the figure
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 Insert, then click Close.
Note that 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.
Generate the operation and toolpath:
1. Click the Generate Operation Plan button on the CAMWorks toolbar or right click
NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the
shortcut menu.
2. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part
Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the
shortcut menu.
3. Click the Simulate Toolbar button of the CAMWorks toolbar or right click Part
Setup1 in the tree and select Simulate Toolpath.
4. Set the display:
− Stock, Tool Holder and Target Part = Translucent Display
− Tool = Shaded Display
5. Click the Run button.
6. Click the X button in the upper right corner to cancel the simulation and return to the
SolidWorks display.

Learning 4 Axis Contour Cutting 3-13

4-Axis Contour 4

3-14 Learning 4 Axis Contour Cutting

 Index

Index
2 Axis Contour dialog box 1-9, 2-12, 2-15 Insert 4 Axis EDM Feature dialog box
2.5 Axis EDM feature automatically extract sync curves 3-7, 3-13
defining automatically 1-7, 2-2, 2-6, 2-15 Move Start Point button 3-3, 3-10
defining interactively 2-6, 2-11 M
4 Axis EDM feature machinable features
inserting Die 3-3 customizing AFR 2-3
inserting Punch 3-7, 3-10, 3-13 defining 2.5 Axis EDM feature interactively 2-6,
using sketches 3-10 2-11
A defining 4 Axis EDM feature interactively 3-3, 3-7,
ATW minimum distance 3-2 3-10, 3-13
Auto save option 1-13 defining automatically 1-7, 2-2, 2-6, 2-10, 2-15
Automatic Feature Recognition 1-7, 2-2 features recognized automatically 1-7, 2-2
C interactively inserting Die feature 2-7, 3-3
CAMWorks interactively inserting Open Profile feature 2-11
machining trees 1-3 interactively inserting Punch feature 2-7, 3-7, 3-10,
menu 1-4 3-13
Message Window 1-7, 2-3 Machine
toolbar 1-4 editing settings 3-2, 3-6, 3-9, 3-12
Configurations 1-3 identifying type 1-3, 1-4, 2-2, 2-6, 2-10, 2-14, 3-2,
E
3-6, 3-9, 3-12
Edit Leadin Point command 2-8, 3-11 selecting make/model 1-5, 2-2, 3-2
Edit Settings command 3-2, 3-6, 3-9, 3-12 setup options 1-5
EDM Part Setup 1-8 Machine dialog box, Machine tab 1-5
EDM Part Setup, inserting 2-10, 3-3, 3-7, 3-9 Machine Selection dialog box 1-5, 2-2, 2-6, 2-10,
EDM Settings dialog box 1-5, 2-2, 2-6, 2-10, 2-14, 2-14, 3-2, 3-6, 3-9, 3-12
3-2, 3-6, 3-9, 3-12 Manage Stock dialog box 1-6
Extract Machinable Features command 1-7, 2-2, 2-6, N
2-10, 2-15, 3-3 NC program
F
file 1-13
Feature Definition dialog box 2-7, 2-11 generating 1-13
Feature tree 1-8 generating 2 files 2-6
file, NC program 1-13 setting machining order 2-14
steps to generate 1-2
G
Generate Operation Plan command 1-8, 2-4, 2-8, O
2-12, 2-15, 3-4, 3-8, 3-11, 3-13 Open Profile feature, defining interactively 2-11
Generate Toolpath command 1-10, 2-5, 2-8, 2-13, Operation tree 1-8
2-15, 3-4, 3-8, 3-11, 3-13 operations
glue stop option 3-8 changing machining parameters 1-9, 2-8, 2-12,
2-15, 3-4
I editing leadin point 2-8, 3-11
Insert 2.5 Axis EDM Feature command 2-6, 2-11 editing leadin/leadout 1-9, 2-12, 2-15, 3-4
Insert 4 Axis EDM Feature command 3-3, 3-7, 3-10, generating 2 Axis Contour 1-8, 2-4, 2-8, 2-12, 2-15
3-13 generating 4 Axis Contour 3-4, 3-8, 3-11, 3-13

i
Index

generating toolpaths 1-10, 2-5, 2-8, 2-13, 2-15, 3-4, T

3-8, 3-11, 3-13 toolpaths
glue stop option 3-8 generating 1-10, 2-5, 2-8, 2-13, 2-15, 3-4, 3-8, 3-
post processing 1-13, 2-5, 2-9, 2-14, 3-5 11, 3-13
simulating toolpaths 1-10, 2-5, 2-13, 3-4, 3-8, 3-11, post processing 1-13, 2-5, 2-9, 3-5
3-13 setting machining order 2-14
Options dialog box simulating 1-10, 2-5, 2-13, 3-4, 3-8, 3-11, 3-13
EDM Features tab 1-7, 2-3, 2-4 stepping through 1-12
File Output tab 2-9, 2-15 W
General tab 1-12 wire diameter, setting 1-5
P workpiece See Stock
Part Setup dialog box 2-11
parts used in exercises
edm2ax_1.sldprt 1-2
edm2ax_2.sldprt 2-2
edm2ax_3.sldprt 2-6
edm2ax_4.sldprt 2-10
edm2ax_5.sldprt 2-14
edm4ax_1.sldprt 3-2
edm4ax_2.sldprt 3-6
edm4ax_3.sldprt 3-9
edm4ax_4.sldprt 3-12
Perimeter punch feature 2-3
Post Output File dialog box 1-13, 2-5, 3-5
post process
generating NC program 1-13, 2-5, 2-9, 2-13, 3-5
selecting processing order 1-6, 2-2, 2-6, 2-10, 2-14,
3-2, 3-6, 3-9, 3-12
viewing code 1-14, 2-9, 2-15
Post Process command 1-13, 2-5, 2-14, 3-5
Post Process Output dialog box 1-14, 2-5, 3-5
Processing order, setting 1-6, 2-2, 2-6, 2-10, 2-14,
3-2, 3-6, 3-9, 3-12
Punch feature, inserting interactively 2-7
R
Recycle Bin 1-3
S
Save/Restore part option 1-12
shortcut menus 1-4
Simulate Toolpath command 1-10, 2-5, 2-13, 3-4,
3-8, 3-11, 3-13
Step Thru Toolpath command 1-12
steps to generate NC program 1-2
Stock 1-3, 1-6

ii