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CAMWorks 3 Axis Essentials
2022
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 Disclaimer
Geometric Americas, Inc. makes no warranties, either express or implied with

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respect to this manual. Geometric Americas, Inc. reserves the right to revise and
improve products as it sees fit, and to revise the specifications and information

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contained herein without prior notice. Due to continuing product development,
specifications and capabilities described in this manual are subject to change
without notice.

Trademarks

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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 Americas, Inc.
All other brands and names are property of their respective owners.

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 CAMWorks Essentials – 3 Axis

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Contents

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Introduction ......................................................................................................................................5
About this course and manual .................................................................................................................. 5
Prerequisites ............................................................................................................................................. 5
Lab exercises ............................................................................................................................................. 5

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Course Length ........................................................................................................................................... 5
Training files .............................................................................................................................................. 5
Technology Database for this course ........................................................................................................ 6
Lesson 1—CAMWorks Basics and User interface .................................................................................7

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3 Axis Operations ...................................................................................................................................... 8
User Interface ........................................................................................................................................... 8
Process overview .................................................................................................................................... 10
Case Study: Generate 3 Axis Toolpath and NC Code .............................................................................. 12
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Exercise 1 – Generate 3 axis toolpath and G Code ................................................................................. 27
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Lesson 2—Multi-Surface Features .................................................................................................... 32
Case Study: Create 3 Axis Toolpaths with Multi Surface Features ......................................................... 34
Exercise 2 – Insert Multi Surface feature method, All Displayed ........................................................... 49
Exercise 3 – Insert Multi Surface feature, Faces and Surfaces ............................................................... 52
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Exercise 4 – Insert Multi Surface feature, STL file................................................................................... 56

Exercise 5 – Insert Multi Surface feature, Surface finish ........................................................................ 60
Lesson 3—Avoid and Contain Areas, toolpath limits.......................................................................... 64
Case Study: Contain and Avoid Areas ..................................................................................................... 65
Case Study: Limiting toolpaths with Limits and Automatic Contain Areas ............................................. 73
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Exercise 6 – Insert Contains and Avoids ................................................................................................. 86

Exercise 7—Insert Automatic Contain area and using Z Limits .............................................................. 95
Lesson 4—Inserting operations, Common Operation Parameters ...................................................... 98
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Types of 3-Axis operations ...................................................................................................................... 99

Case Study: Modifying common operation parameters ....................................................................... 102
Exercise 8 – Insert 3 Axis Operations and adjust common operation parameters .............................. 126

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 Exercise 9 – Insert Avoid Areas and Avoid Surfaces ............................................................................. 131
Lesson 5—Area Clearance and Z Level Operation Parameters .......................................................... 134

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Case Study: Area Clearance and Flat Area operation parameters........................................................ 135

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Case Study: Z Level Operation Parameters ........................................................................................... 147
Exercise 10 – Insert Area Clearance Operation (Part 1) ....................................................................... 157
Exercise 11 – Insert Area Clearance Operation (Part 2) ....................................................................... 162
Exercise 12 – Z Level operation............................................................................................................. 166

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Lesson 6—Pattern Project .............................................................................................................. 170
Case Study: Working with the Pattern Project Operations—Slice pattern part 1 ................................ 172
Case Study: Working with the Pattern Project Operations – Slice Pattern part 2 ................................ 182
Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns ..................... 193

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Case Study: Working with the Pattern Project Operations—Flowline patterns................................... 203
Exercise 13 – Insert Pattern project operation using Slice pattern ...................................................... 213
Exercise 14 – Insert Pattern Project operation using Radial and Spiral Patterns ................................. 221
Exercise 15 – Insert Pattern Project operation using Flowline pattern ................................................ 225
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Lesson 7—Constant Stepover ......................................................................................................... 228
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Case Study: Constant Stepover Operation parameters ........................................................................ 229
Exercise 16 – Insert Constant Stepover Operation ............................................................................... 245
Lesson 8—Pencil Mill ..................................................................................................................... 254
Case Study: Working with a Pencil Mill Operation ............................................................................... 255
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Exercise 17 – Pencil Mill Operation ...................................................................................................... 269

Lesson 9—Curve Project ................................................................................................................. 277
Case Study: Working with a Curve Project operation........................................................................... 278
Exercise 18 – Curve Project Operation ................................................................................................. 285
Lesson 10—3 Axis Undercut ........................................................................................................... 290
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Case Study: 3-Axis Undercutting using a Z-Level Operation ................................................................. 292

Case Study: 3 Axis Undercutting using a Multi Axis Operation ............................................................ 296
Exercise 19 – 3 Axis Undercutting ......................................................................................................... 311
Index ............................................................................................................................................. 315
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 Introduction

Introduction

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About this course and manual
This course is intended to teach the user how to use CAMWorks to create 3 axis toolpaths for the

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machining of parts created in SOLIDWORKS and CAMWorks Solids.
This manual is intended to be used in a classroom environment with an experienced CAMWorks
instructor. The instructor is expected to cover the lesson material as part of a live demonstration and
provide addition instruction and guidance during the lab exercises. It is not intended to be a self-paced

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tutorial.
Self-paced tutorials are available with every installation of CAMWorks. They are in C:\Program
Files\CAMWorks20XXx64\CAMWorks_VC140\lang\English\Manuals\Mill_Tutorial.pdf starting on page
139. It is generally recommended to review this material before attending the course.
Since it is hard to cover every minute detail of 3 axis machining in a short class time, this course with
examine the fundamental skills and concepts needed for the successful use of CAMWorks.

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The case studies and Lab exercises in this course are intended to show you how to use CAMWorks for 3
Axis Mill operations and may not correspond to actual machining practices.
It is recommended to use this course material as a supplemental to and not a replacement to the
documentation and help files.
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Prerequisites
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Student attending this course are expected to have the following:
• CAMWorks 2.5 axis training (SOLIDWORKS CAM Standard Training)
• Experience with SOLIDWORKS Design Software
• Experience with CNC Machining
Lab exercises
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Lab exercises provide the opportunity to apply and practice the concepts covered in each lesson. They
are modest in scope to allow the user enough time to complete in the allotted time
Course Length
Recommend minimum course length is 3 days
Training files
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A complete set of training files will be provided by the instructor.

The files are organized by lesson number. The Case Study folder contains all the files the instructor will
use during the lessons. The Exercises folder will contain any file that required for the lab exercises. In
each of these folders a Finished Parts folder contains the files in their completed state.
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 Introduction

Technology Database for this course

This course was designed to be used with the default technology database that is installed with a new

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installation of CAMWorks. If a different technology database is used, some of the resulting toolpath
might be different from the manual.

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Your instructor can provide you with a default technology database if necessary.

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 Lesson 1—CAMWorks Basics and User interface

Lesson 1—CAMWorks Basics and User interface

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Upon successful completion of this lesson, you will be able to:
• Understand the types of 3 Axis operation use in CAMWorks

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• Identify the elements of the CAMWorks user interface
• Know the process for creating and post processing toolpaths for CAMWorks 3 axis operations
• Define Machine
• Define Stock
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Define Coordinate System
• Define Multi Surface Features for 3 axis operations
• Simulate tool path
• Post process tool path

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 Lesson 1—CAMWorks Basics and User interface

3 Axis Operations
In CAMWorks, we can create 3 axis toolpaths using the following operation types:

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• Area Clearance
• Z Level

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• Flat Area
• Pattern Project
• Constant Stepover
• Pencil Mill
• Curve Project

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• Legacy Rough Mill
• Legacy Finish Mill
Here is a basic description of what these operations do. We will examine these operations in greater
detail later in this course, but as we learn about multi-surface feature creation, it is good to know what
the operations that are going to come from these features.

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Area Clearance is used for 3 axis roughing. Like 2.5 axis roughing, this operation removes volumes of
material using Pocket in, Pocket out, Zig Zag pattern types to move the tool. With CAMWorks 3 Axis, we
have the added machining patterns of Adaptive Roughing and Volumill.
Flat Area operations clean up flat surfaces that are normal to the setup direct of the mill.
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Z Level, Pattern Project, Constant Stepover and Pencil Mill will be used for Finishing and Semi-Finishing
operations.
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Legacy Rough Mill and Legacy Finish Mill operations are older operations in the software to
accommodate older CAMWorks data. These operations are not taught in this class or supported by the
development team. They are in there to accommodate older files.
User Interface
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CAMWorks User Interface is an extension to the SOLIDWORKS native Windows interface and behaves in
much the same way. Here is a list of the important parts of the interface:
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 Lesson 1—CAMWorks Basics and User interface

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 Lesson 1—CAMWorks Basics and User interface

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SOLIDWORKS
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SOLIDWORKS Feature Manager Design Tree – Displays all the features of the part or assembly file in

CAMWorks Feature Tree – Displays the machinable features and setups of the part or assembly.
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CAMWorks Operations Tree – Displays the machining operations of the part or assembly.
CAMWorks Tool Tree – Show the tool crib, or list of available tools in the part or assembly file.
CAMWorks Command Manager Tool bar – Contains easy access to the CAMWorks commands.
CAMWorks Pull Down Menu – Provides access to the CAMWorks commands
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CAMWorks Message Window – Reports on what processes have occurred.

CAMWorks Task pane – Provides an interface within CAMWorks to provide for better communication
with end user about effective utilization and potential of CAMWorks, product updates and version,
learning tools and resources
Process overview
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With CAMWorks we can create 3 axis toolpaths through automated and interactive methods. Using the
knowledgebase that can be captured in the Technology database, toolpaths can be automatically
inserted base on the features.
Here is the process we use to generate 3 axis toolpaths in CAMWorks:
1. Model the part in SOLIDWORKS or CAMWorks Solids
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2. Select the CAMWorks Feature Tree

3. Define Machine Controller Parameters
4. Define Stock
5. Define Machinable Features

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 Lesson 1—CAMWorks Basics and User interface

6. Generate Operation Plan

7. Adjust Operation Parameters and Required

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8. Generate toolpath
9. Simulate toolpath

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10. Post process
11. Transmit file to the CNC

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 Lesson 1—CAMWorks Basics and User interface, Case Study: Generate 3 Axis Toolpath and NC Code

Case Study: Generate 3 Axis Toolpath and NC Code

In this case study, we will create 3 axis milling toolpaths and generate NC code on a SOLIDWORKS part.

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This case study uses an existing SOLIDWORKS part file
1. Open Part

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a. Open the part Funnel.SLDPRT in the …\Lesson_01\Case Study folder
2. Select CAMWorks Tab
a. Click on CAMWorks CommandManager Tab and the CAMWorks Feature tree tab

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In the CAMWorks Feature manager tree there are the following icons:
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Configuration Manager – We can define a separate data set inside a part file using a configuration. This
can be used in conjunction with SOLIDWORKS configurations or within a single SOLIDWORKS
configuration.
Machine – Defines which machine tool, tools and post processor will be used for the part or assembly
file.
• Machine tab – Selects the type of machine from a list of predefined machines. These machines
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can be customized and defined in the technology database

• Tool crib tab – Allows for the selection of a custom list of tools to be used on the part or
assembly
• Post processor tab – Allows for the selection of the post processor
• Posting – Defines custom parameters for the part relative to the post processor
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Stock manager—defines the initial stock or workpiece the part or assembly will be cut out of
Coordinate system—Used to define a coordinate system that can be used to define a Fixture Coordinate
System. In Assembly mode, the Fixture Coordinate System is the "home point" or main zero position on

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 Lesson 1—CAMWorks Basics and User interface, Case Study: Generate 3 Axis Toolpath and NC Code

the machine. While G-code output can be based on this point, it is meant to be used as a reference
point. Setting the position does more than set the origin; it also sets the positive X, Y, and Z directions to

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be used for all moves on this machine. When outputting subprogram format, an alternative part setup
origin is referenced, however the X, Y, and Z directions set by the Fixture Coordinate System are still

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used.
Recycle Bin—Stores deleted features. CAMWorks generally does not use the CRTL+Z undo button when
a feature is deleted. Instead, it stores deleted features in the recycle bin to be restored later if needed.
3. Define the machine.

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a. Double click on the Machine icon to open the Machine dialogue

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b. Click the Machine tab and under available machines, select the Mill – Metric machine
and click on the Select button
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c. Click the Tool Crib tab. Make sure Tool Crib 2 (Metric) is the active tool crib.

d. Click the Post Processor tab. Select the M3AXIS-Tutorial as the active post processor
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e. Click OK

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 Lesson 1—CAMWorks Basics and User interface, Case Study: Generate 3 Axis Toolpath and NC Code

Next, we will define the stock to be machined. This is done by editing the stock manager in the
CAMWorks feature tree

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To edit the stock, click on the Stock Manager on the CAMWorks Command Manager

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Alternatively, we can double click on the Stock Manager Icon in the CAMWorks Feature manager or right
click on the Stock Manager Icon and select Edit Definition.

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CAMWorks Stock Manager
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Material
Under the Material section, we can tell CAMWorks what material the part is being machined out of. This
setting is different from and not link in any way to the material defined in the SOLIDWORKS design tree.
By applying a CAMWorks material to the part, we utilize the Feed and Speed library in the operations
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that are generated.

Stock Type
In CAMWorks part mode, there are six ways the Stock Type can be defined

Bounding Box – Defines the stock by the smallest box that fits around the part. The size of the
stock can be offset in each direction.
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Pre-defined Bounding Box – Defines the stock using a pre-defined bounding box size that has
been saved in the Technology Database
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Extruded Sketch – Defines the stock using a SOLIDWORKS Sketch extruded at a specified depth

Cylindrical Stock – Defines a cylindrical stock for the mill part model centered on the part

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STL File – Defines the stock from an external STL file or simulated stock model.

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SOLIDWORKS Part – Defines the stock from either the existing part, a configuration of the same

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existing part, or by a secondary part file
4. Stock Definition
a. Edit the Stock Manager by double clicking on the Stock Manager icon on the CAMWorks
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b. For Material, select 6061-T6
c. For Stock Type select Bounding Box
d. Leave the X, Y and Z values at 0 in the Bounding Box Offset settings

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e. Click OK
The Coordinate system is used to define the fixture coordinate system. It can be edited by clicking on
the Coordinate System icon on the CAMWorks Command Manager
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Alternatively, the Coordinate system can be edited by double clicking on the Coordinate System icon in
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the CAMWorks feature tree or by right clicking on the Coordinate system icon and selecting Edit
Definition

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The Coordinate system can be defined from either an existing SOLIDWORKS coordinate system or from
selecting on geometry in the model.
5. Define Coordinate System

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a. Double Click on Coordinate System
b. Under Method, select User Defined
c. Select Part bounding box vertex option
d. Select the Top Center of the part and Click OK
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In SOLIDWORKS CAM and CAMWorks 2.5 axis features can be defined either automatically through
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Automatic Feature Recognition (AFR) or interactively through Interactive Feature Recognition (IFR). With
3 Axis CAMWorks we can only define features interactively. However, we can still leverage the
Technology Database for operations.
In addition to recognizing features, AFR will also automatically define a Mill Part Setup, or the machining
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direction, for those features. Since we are defining things interactively, we will need to create our own
Mill Part Setup interactively.
6. Insert Mill part setup
a. Right click on the stock manager and select Mill Part Setup…

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b. Select on the top face of the part to define the direction

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By inserting mill part setup manually, we have the option to insert certain features on the fly. A custom
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feature strategy can be selected for each feature type that is inserted
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 Lesson 1—CAMWorks Basics and User interface, Case Study: Generate 3 Axis Toolpath and NC Code

Face— A face feature will be inserted automatically.

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Perimeter—This will insert a Perimeter feature when a Mill
part setup is inserted. A Boss or Open Pocket Part Perimeter

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feature will be inserted base on the selected

Multi Surface Feature— This will insert a multi surface

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Curve feature for chamfering— This will insert a curve
feature for chamfer machining

Constant Stepover
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c. Check the Multi surface feature check box. For Strategy, select Area Clearance,
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d. Click OK to insert the mill part setup.
A Mill Part Setup is added to the CAMWorks Feature tree. In addition to that, a Multi surface feature is
also added to the Mill Part Setup.
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Notice how the color of the text is blue. This is a visual indicator telling us that there are no operations
associated to this feature.
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Like with 2.5 axis features, we can automatically insert operations by generating an operation plan.
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7. Generate the Operation Plan

a. Right Click on the Multi Surface Feature1 and select Generate Operation Plan… or
click on the Generate Operation Plan icon on the CAMWorks CommandManager

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CAMWorks will generate the operations for this Feature based on the strategy Area Clearance, Constant
Stepover. Two operations, an Area Clearance and a Constant stepover are generated on the CAMWorks
Operation tree.

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8. Generate Toolpath
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a. Generate the tool path for these operations.
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Notice how the color of the text of the operations is blue. This is a visual indicator that a toolpath has
not been generated yet on these operations
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CAMWorks can simulate the tool movement, material removal and preview the shape of the machined
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part.
The following settings are available in the Toolpath simulation dialogue:
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9. Simulate Toolpath
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a. Simulate the toolpath to see what the results are. Click on the Simulate Toolpath icon
on the CAMWorks CommandManager Toolbar
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b. Select Tool Mode

c. Set the holder display to shaded display
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d. Run the simulation
e. Notice that the tool for the finish operation is not long enough to reach the bottom of

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the cavity
We will need to modify some parameters to get it to generate good toolpath. The tool is too small to
reach to the depth of the cavity.
Changing the tool for an operation can be done in two ways. (1) Edit the operation, go to the Tool tab,
Tool Crib, select a different tool and click Select.
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And (2) going to the CAMWorks Tool Tree tab and dragging an operation from one tool to another.
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10. Change the tool of the constant stepover operation.

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a. Edit the Constant stepover Operation and select the tool.
i. Right Click on Constant Stepover1 and select Edit Definition…
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ii. Go to the Tool tab, Tool Crib
iii. Select on T09 – 12 Ball Nose
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iv. Click on Select to assign this tool to the operation
v. Click on yes to the CAMWorks warning message to replace the corresponding
holder
vi. Click OK
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It is not necessary to have the Constant Stepover operation machine to the top surface of the part. This
top surface can be machined more efficiently in other operations, like a face fill operation. In
CAMWorks, we can use a Contain area to establish a boundary for a toolpath.
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11. Insert Contain area

a. Right Click on the operation Constant Stepover1 and select the option new contain area.

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b. For Selection Mode set the Face Selection to Single face and Edge Selection to
Constant Depth Loop
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c. Select the top edge of the cavity

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d. Click OK

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12. Regenerate the toolpath
a. Right Click on Mill Part Setup1 and select Generate Toolpath
13. Simulate
a. Simulate Mill Part Setup1
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Post processing is the final step in the process of generating G-Code for 3 Axis machining operations.
This takes the toolpaths in CAMWorks and converts it into the NC code that the machine tools can read.
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The post Process dialogue box shows the options for post processing the G-Code:

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14. Post Process
a. Click on the Post Process icon on the CAMWorks CommandManager toolbar
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b. Select the location of the post processed file.

c. Check on the option to open the G-Code file in CAMWorks NC Editor
d. Run the post processing
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e. Examine the G-Code in CAMWorks NC Editor. Display the backplot window

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 Lesson 1—CAMWorks Basics and User interface, Exercise 1 – Generate 3 axis toolpath and G Code

Exercise 1 – Generate 3 axis toolpath and G Code

Use the CAMWorks workflow to create 3 axis toolpaths and NC code for a SOLIDWORKS part.

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This lab exercise will reinforce the following skills:
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• Define machine, stock and coordinate system
• Insert Mill Part Setup and Multi-surface feature with custom strategy
• Generate 3 axis operations
• Change the tool of an operation
• Insert a contain area
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• Generate 3 axis toolpath

• Simulate toolpath
• Post process toolpath
Procedure:
1. Open Part
a. Open Cavity.SLDPRT from the …\Lesson_01\Exercises folder
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2. Define machine
a. Use the following parameters:
i. Machine: Mill – Metric
ii. Tool Crib: Tool Crib 2 (Metric)
iii. Post Processor: M3AXIS-TUTORIAL
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3. Define Stock
a. The following parameters should be used to define the stock size in the Stock Manager:
i. Material: 6061-T6
ii. Stock Type: Bounding Box

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 Lesson 1—CAMWorks Basics and User interface, Exercise 1 – Generate 3 axis toolpath and G Code

iii. The stock size should be X:250mm Y:50mm Z:150mm

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4. Define Coordinate System
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a. Define the coordinate system to use the top center stock position as shown. Make sure
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the Z direction is correct.
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5. Insert Mill Part Setup

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a. Insert Mill Part Setup using the top face of the part
b. Check on the Multi surface feature checkbox
c. Select the Area Clearance, Constant Stepover strategy

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d. Click OK
6. Generate Operations and Toolpaths
a. Generate the Operation Plan
b. Click on the CAMWorks Operation tab
c. Edit the Constant Stepover operation,
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d. Go to Constant Stepover tab, set the Constant cut amt. setting to 1mm
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e. Click OK
f. Insert New Contain area around the top edge of the cavity for the Constant stepover
operation
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g. Generate toolpath with the contain area

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7. Simulate toolpath
a. Use simulate toolpath to examine the toolpath.
b. Use turbo mode to skip to the end of the toolpath
c. Compare machined geometry to the part
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8. Generate NC Code
a. Post process to create the G-Code
9. Save and close the part e
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 Lesson 2—Multi-Surface Features

Lesson 2—Multi-Surface Features

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Upon successful completion of this lesson, you will be able to:
• Interactively insert a Mill Part Setup

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• Insert Multi-surface features using the following methods:
o Faces or surfaces
o All Displayed
o STL File
o Faces by Color

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o Faces by Surface Finish
• Control the generated toolpath using Rest Machining
• Define the Automatic contain area

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 Lesson 2—Multi-Surface Features

CAMWorks utilizes feature-based machining as its driving concept. We define features that can then be
assigned operations automatically using the knowledge captured in the Technology Database.

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In 2.5 axis CAMWorks we can insert these features using Automatic Feature Recognition (AFR) and
Interactive Feature Recognition (IFR). For 3-Axis CAMWorks, we only use IFR as the means to define

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features.
In addition to showing some of the processes used to create 3-axis toolpath on the above list, this lesson
focuses primarily on the creation of Multi-Surface Features used for 3-axis machining.

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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

Case Study: Create 3 Axis Toolpaths with Multi Surface Features

1. Open part

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a. Open the part Controller_Cavity.SLDPRT in the …\Lesson_02\Case Study folder
b. Click on the CAMWorks Feature tab and CAMWorks 2022 CommandManager tool bar

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Following the process flow from the previous lesson, we will need to do the following to get this part
ready for creating toolpath:
2. Define the Machine
a. Click Define Machine from the CAMWorks 2022 CommandManager toolbar. Or, double-

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click on the Machine icon in the CAMWorks Feature tree

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b. On the Machine tab select Mill – Metric and then click on the Select button
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c. On the Tool Crib tab select Tool Crib 2 (Metric) and then click on the Select Button
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d. On the Post Processor tab select M3AXIS-TUTORIAL from the list of available post
processors. Click on the Select button
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If the M3AXIS-TUTORIAL post is not on the list of available post processors click on the Browse…
button, browse to the C:\CAMWorksData\CAMWorks2022x64\Posts directory and select the M3Axis-
Tutorial.CTL post processor.
e. Click OK

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3. Define the Stock
a. Double click on the Stock Manager in the CAMWorks Feature Tree
b. For Material, select 6061-T6 from the dropdown list
c. Use the default Stock Type Bounding Box
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d. Click OK
4. Define the Coordinate System
a. Double click on the Coordinate System Icon in the CAMWorks Feature tree to define the
coordinate system
b. Set the Method to User Defined
c. Set the Origin to Part bounding box vertex
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d. Place this on the top center of the part with Z in the up position as shown

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Now we are ready to define the Multi Surface feature, but first, we need to define the machining
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direction. This is done by inserting a Mill Part Setup.

Mill part setups are defined by either clicking on the Setup – Mill Setup icon on the CAMWorks
CommandManager toolbar:
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Or, by right clicking on the Stock Manager in the CAMWorks Feature tree:
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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

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When defining a Mill Part Setup, we are essentially defining the machining direction. The following
entities can be selected to define the direction of the Mill Part Setup:
• Edges – the direction of a straight edge defines the Mill Part Setup Direction

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• Flat faces on the part or assembly model – the direction will be defined as perpendicular to the
flat face of the part
• SOLIDWORKS reference planes – the direction will be defined perpendicular to the reference
plane
The preview arrow in the graphics area only shows the machining direction. The program zero point is
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defined in the Mill Part Setup defining box on the CAMWorks Operations tree
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5. Insert Mill Part Setup
a. Right-Click on the Stock manager and select Mill Part Setup
b. This part does not have any flat faces on the top of the part so select the Front
SOLIDWORKS reference plane as the Entity.
c. Make sure the blue preview origin is pointing down into the part.
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d. Under the Features section, check the Multi-Surface feature checkbox.

e. Select the Area Clearance, Constant Stepover strategy.
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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

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f.

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Click OK to insert the setup and notice that a Multi-Surface Feature has been inserted
into the CAMWorks feature tree automatically.
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We have just inserted a Multi Surface Feature while creating a new Mill Part Setup “on the fly”. Editing
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this new Multi Surface feature we can see from the Multi Surface Feature dialog that the Feature Type
is All Displayed
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This Multi-Surface Feature is defined from all the displayed surfaces on the model. This is the preferred
method of Surface definition for most 3-Axis operations.
Here are the methods by which Multi-Surface Features can be defined:

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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

• Faces or Surfaces – When this option is selected, CAMWorks allows you to create a multi
surface feature by selecting desired faces/surfaces on the part.

2
• All Displayed – When this option is selected, CAMWorks will dynamically collect and machine all
the visible faces and surfaces at the time of generating toolpath. This is the recommended

02
method for defining a multi surface feature and has the following benefits:
• Extremely fast creation. Regardless of the number of visible faces and surfaces, creating
a multi surface feature using this option is instantaneous.
• Feature rebuild, and toolpath creation time is improved for models that contain
thousands of faces and surfaces.

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• Associativity between the toolpath and the displayed current model shape and size is
maintained because whatever is displayed, will be machined.
Features defined using the All Displayed option have the following characteristics:
• No face names or number of faces will be displayed in the Selected Faces list.
• When selecting the feature or an operation machining the feature in the tree views, the

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feature will not highlight
• STL File – When this option is selected, CAMWorks allows the multi surface feature to be
defined from an STL file.
• Faces by Color – When this option is selected, CAMWorks allows the multi surface feature to be
defined from surfaces with specific colors define in SOLIDWORKS.
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• Faces by Surface Finish – When this option is selected, CAMWorks allows the Multi Surface
Feature to be defined from surfaces with specific Surface Finish or Roughness values. The part
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faces will be grouped and listed in the New Multi Surface Feature dialog box based on its Surface
Finish Type or Roughness values.
We can interactively insert more Multi-Surface features for other operations. We can insert a Multi
Surface feature using the Faces or Surfaces method in the Multi Surface Feature dialog
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6. Insert an Additional Multi-Surface Feature

a. On the SOLIDWORKS feature tree, under the Surface Bodies folder, show the surface
body Boundary-Surface1
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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

b. Go back to the CAMWorks Features tree

c. Right click on the Mill Part Setup1 or select on the Feature icon on the CAMWorks

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Command Manager toolbar and select Multi-Surface Feature.

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d. For the Feature Type select Faces or Surfaces
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When the Feature Type method is set to Faces or Surfaces in the Multi Surface Feature dialog following
face selection options are available:
• Select Faces – This option allows us to select each face individually. When a face on the part is
selected in the graphics area the face will be listed in the Selected Faces area of the Multi
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Surface Feature Dialog.

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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

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• Window Selection – This option allows us to use a selection box to select the surfaces on the

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part. To use this tool, draw a box around the faces that are to be defined as the Multi Surface
Feature. The faces inside the box will be selected.
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• Select Adjacent – When this option is used, the adjacent surfaces of the selected face are also
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selected. The image below shows what is selected when the surface in the center of the part.
The adjacent surfaces are selected.
Subsequent clicks on the same surface will select additional adjacent faces as shown in the
picture below in the center and on the right.
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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

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• Select All Faces – When this option is used, all the faces of the solid model are selected for the

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Multi Surface Feature similar to the All Displayed Feature Type method. This is different from
the All Displayed method in that the feature surfaces will display and this feature will not be
associative to future model changes.

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• Clear Face – This will clear the first face in the Selected Faces box
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• Clear All Faces – This will clear all the faces in the Selected Faces box
• Highlight faces – Toggles on and off the highlight of the face in the graphics area
• Show normal check box and Reverse direction icon are not used in 3 axis milling
When using the Feature Type Method, Faces or Surfaces, we select faces from the model in the graphics
area. We can also select faces of surface bodies in the SOLIDWORKS Feature tree.
e. Expand the SOLIDWORKS Feature tree and select the Boundary-Surface1. Notice that
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the faces of the surface are added to the selected faces in the property manager.
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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

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f. Select the other model faces of the model as shown.

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g. Set the Strategy to Area Clearance, Pattern Project

h. Click OK to insert the feature.
7. Re-order the features
a. Re-order the features so that Multi Surface Feature2 is above Multi Surface Feature1 in
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the CAMWorks Feature tree.

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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

8. Hide the SOLIDWORKS Surface Body

a. Go back to the SOLIDWORKS feature tree and hide the surface body

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9. Generate the operation plan
a. Generate the operation plan for the two multi surface features
10. Generate and examine toolpaths
a. Generate toolpaths of the generated operations
b. Select on Area Clearance1 and then Area Clearance2

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Notice that Area Clearance2 is removing material that has already been removed from Area Clearance1
Also note that the tool selected for Area Clearance2 in T05 – 20mm Flat End. A smaller tool will get us
closer to the shape of the cavity. We will want to use a smaller tool for this operation without making
moves in places that material has been removed
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We will use a separate tool that will fit better into the cavity to rough it out.
Since part of the stock is already removed and has been machined away from the first Area Clearance
operation, we will use Rest Machining for the subsequent operations, so we aren’t cutting air.
In the next steps we will edit the operation parameters to change the tool and enable the rest
machining. Like 2.5 Axis operations, the operation parameters control all the aspects of the tool
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movement. We will explore the settings in each operation type later in this course.
11. Change the Tool for Area Clearance2
a. Go to the CAMWorks Tool Tree and drag and drop Area Clearance2 from T05 – 20 Flat
End to T02 – 10 Flat End
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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

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b. Also, the tool can be changed from the operation parameters.
c. On the CAMWorks Operation tree, edit Area Clearance2 (Double click on it or
right click and select Edit Definition…)

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d. Go to the Tool – Tool Crib tab.
e. Select on T01 – 10mm Flat End and click Select
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12. Enable Rest Machining for Area Clearance2

a. Edit the Area Clearance2 operation and go to the Rest tab.
b. Under Rest machining, Method, select From WIP.
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c. Click OK to the operation parameters

We can do the same to the Constant Stepover operation so that it stays within the cavity.

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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

13. Enable Rest Machining for Constant Stepover1

a. Edit Constant Stepover1 operation and go to the Rest tab

2
b. Under Rest machining, Method, select From WIP
c. Click OK to the operation parameters
14. Regenerate toolpath

02
We need one more toolpath for this part. We need to finish the cavity with another endmill. For this
operation, we will use another Multi-Surface Feature. This time we will define the Multi Surface feature
using the face color of the cavity.

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15. Insert new Multi Surface Feature
a. Go to the CAMWorks Feature Tree
b. Right click on Mill Part Setup1 and select Multi-Surface Feature…
c. For the Feature Type Method, select Faces by Color
d. Set the Strategy to Area Clearance, Constant Stepover
e. Check the box next to the Yellow face color
f. Click OK

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16. Generate Operation Plan for the new Multi Surface Feature
a. Generate operation plan for Multi Surface Feature3
b. The Area Clearance operation is not needed and can be deleted
17. Change tool
a. Go to the CAMWorks Tool Tree and drag and drop Constant Stepover2 from T08 – 10
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Ball Nose to T07 – 4 Ball Nose

b. Alternatively, the tool can be changed from the operation parameters.
c. On the CAMWorks Operation tree, edit Constant Stepover2 (Double click on it or right
click and select Edit Definition… )
d. Go to the Tool – Tool Crib tab.
e. Select on T07 – 10mm Ball Nose and click Select
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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

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18. Set Containment for the operation
a. Edit Constant Stepover2
b. Click on the Geometry tab
c. Set the Automatic contain area Method to Outer Silhouette
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d. Set the Tool condition to On Center
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19. Set additional operation parameters

a. Go to the Constant Stepover tab
b. Under Pass option, set the Constant cut amt. to 1mm
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20. Generate Toolpath

a. Generate the toolpath for the operations
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 Lesson 2—Multi-Surface Features, Case Study: Create 3 Axis Toolpaths with Multi Surface Features

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21. Simulate Toolpath
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a. Set the Mode to Turbo mode and the end condition to Next Operation
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b. Examine the simulation after each operation.
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 Lesson 2—Multi-Surface Features, Exercise 2 – Insert Multi Surface feature method, All Displayed

Exercise 2 – Insert Multi Surface feature method, All Displayed

Insert Multi Surface Feature to create 3 axis toolpaths on a SOLIDWORKS part

2
Change tool on the contour mill finishing operation
Contain the toolpath by using the Rest machining options

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This lab will reinforce the following skills from Lesson 2:
• Insert Multi-Surface Feature using IFR
• Generate Operation plan and toolpath
• Change Tool
• Apply rest machining to the operations
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• Change Stepover
Procedure:
1. Open Part
a. Open Electric_Socket_Mold.SLDPRT from the …\Lesson_02\Exercises folder
2. Define machine
a. Use the following parameters:
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i. Machine: Mill – Metric

ii. Tool Crib: Tool Crib 2 (Metric)
iii. Post Processor: M3AXIS-TUTORIAL
3. Define Stock
a. The following parameters should be used to define the stock size in the Stock Manager:
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i. Material: 1005
ii. Stock Type: Bounding Box
iii. The stock size should be X:150mm Y:35mm Z:120mm
4. Define Coordinate System

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 Lesson 2—Multi-Surface Features, Exercise 2 – Insert Multi Surface feature method, All Displayed

a. Define the coordinate system to use the top center stock position as shown. Make sure
the Z direction is correct.

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5. Create Mill Part Setup

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a. Create Mill Part Setup normal to the top face of the part
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6. Create Multi Surface Feature

a. Create Multi Surface Feature
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b. Use Feature Type Method: All Displayed

c. Set Strategy to Area Clearance, Constant Stepover

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 Lesson 2—Multi-Surface Features, Exercise 2 – Insert Multi Surface feature method, All Displayed

2
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7. Generate Operation Plan

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a. Generate Operation plan
8. Generate Toolpath
a. Generate Toolpath
9. Change the tool used for Constant Stepover Operation
a. Change the tool used for the Constant Stepover operation to a 4mm Ball Nose

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10. Enable Rest Machining options
a. Enable the Rest machining option for the Constant Stepover operation
b. Set the Method: From WIP
11. Change Stepover amount
a. Change the Constant cut amt. to 1mm
12. Generate toolpath
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13. Simulate toolpath
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14. Save and Close part

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 Lesson 2—Multi-Surface Features, Exercise 3 – Insert Multi Surface feature, Faces and Surfaces

Exercise 3 – Insert Multi Surface feature, Faces and Surfaces

Insert Multi Surface Feature to create 3 axis toolpaths on a SOLIDWORKS part by selecting faces and

2
surfaces
Contain the toolpath by using the Automatic Contain Area

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This lab will reinforce the following skills from Lesson 2:
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• Insert Multi-Surface Feature using IFR using Feature Type Method: Faces or Surfaces
• Generate Operation plan and toolpath
• Contain the toolpath using Automatic Contain Area
Procedure:
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1. Open Part
b. Open FS_01_123.SLDPRT from the …\Lesson_02\Exercises folder
2. Define machine
a. Use the following parameters:
i. Machine: Mill – Metric
ii. Tool Crib: Tool Crib 2 (Metric)
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iii. Post Processor: M3AXIS-TUTORIAL

3. Define Stock
a. The following parameters should be used to define the stock size in the Stock Manager:
i. Material: 1005
ii. Stock Type: Bounding Box
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iii. The stock size should be X:235mm Y:30mm Z:155mm

4. Define Coordinate System
a. Define the coordinate system to use the top center stock position as shown. Make sure
the Z direction is correct.

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 Lesson 2—Multi-Surface Features, Exercise 3 – Insert Multi Surface feature, Faces and Surfaces

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5. Create Mill Part Setup
a. Create Mill Part Setup normal to the top face of the part

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6. Create Multi Surface Feature

a. Create Multi Surface Feature
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b. For Feature Type set the Method to Faces or Surfaces

c. Set the Strategy to Area Clearance, Constant Stepover
d. Select the surfaces of the cavity in the graphics area (see below)
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 Lesson 2—Multi-Surface Features, Exercise 3 – Insert Multi Surface feature, Faces and Surfaces

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e. Click OK
7. Generate Operation Plan
a. Generate the Operation Plan
8. Generate Toolpath
a. Generate Toolpath
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b. Notice that area clearance generates toolpath that gouges the part on the Area
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Clearance operation
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9. Set the Automatic Contain Area

a. Edit the Area Clearance1 operation
b. On the Geometry tab, set the Automatic contain area Method to All Silhouettes

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 Lesson 2—Multi-Surface Features, Exercise 3 – Insert Multi Surface feature, Faces and Surfaces

c. Set the Tool condition to On Center

d. Click OK

2
10. Generate Toolpath
11. Simulate toolpath

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12. Save and Close Part
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 Lesson 2—Multi-Surface Features, Exercise 4 – Insert Multi Surface feature, STL file

Exercise 4 – Insert Multi Surface feature, STL file

Create a Mill Part Setup using a SOLIDWORKS reference plane to define the direction.

2
Define the stock from a SOLIDWORKS Sketch
Insert a Multi Surface Feature using the Feature Type Method: STL File

02
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This lab will reinforce the following skills from Lesson 2:
• Create a Mill Part Setup from a SOLIDWORKS reference plane
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• Define Stock from a SOLIDWORKS Sketch

• Insert Multi-Surface Feature using IFR using Feature Type Method: STL File
• Contain the toolpath using Automatic Contain Area
Procedure:
1. Open Part
a. Open MILL_EX22.SLDPRT from the …\Lesson_02\Exercises folder
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2. Define machine
a. Use the following parameters:
i. Machine: Mill – Metric
ii. Tool Crib: Tool Crib 2 (Metric)
iii. Post Processor: M3AXIS-TUTORIAL
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3. Define Stock
a. The following parameters should be used to define the stock size in the Stock Manager:
i. Material: 6061-T6
ii. Stock Type: Extruded Sketch

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 Lesson 2—Multi-Surface Features, Exercise 4 – Insert Multi Surface feature, STL file

iii. Select Sketch1 for the sketch to extrude

iv. Set the end condition to Blind

2
v. Set the extrude depth to 125mm
vi. The stock size should be X:200mm Y:175mm Z:125mm

02
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vii. Click OK
4. Define Coordinate System
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a. Define the coordinate system to use the top center stock position as shown.
b. Make sure the Z direction is correct.
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5. Create a Mill Part Setup

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 Lesson 2—Multi-Surface Features, Exercise 4 – Insert Multi Surface feature, STL file

a. Create a Mill Part Setup using the Front SOLIDWORKS reference plane
b. Make sure the arrow is pointing in the direction shown

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02
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c. Click OK
6. Create new Multi Surface feature
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a. Create new Multi Surface Feature
b. For the Feature Type select STL File
c. Browse to the file GoodlookingHandsomeFace.STL in the …\Lesson_02\Exercises
folder
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d. Click OK to the file open dialogue

e. For Strategy, select Area Clearance, Constant Stepover
f. Click OK
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7. Generate Operation Plan

8. Set the Automatic Contain Area
a. Edit Area Clearance1 and go to the Geometry Tab
b. Under Automatic contain area, set the Method to Outer Silhouette

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 Lesson 2—Multi-Surface Features, Exercise 4 – Insert Multi Surface feature, STL file

c. Edit Constant Stepover1

d. Go to the Geometry tab

2
e. Under Automatic contain area, set the Method to Outer Silhouette

02
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f. Go to the Constant Stepover tab
g. Under Pass options, set the Constant cut amt: to 1mm

9. Generate Toolpath
10. Simulate Toolpath
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11. Save and Close

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 Lesson 2—Multi-Surface Features, Exercise 5 – Insert Multi Surface feature, Surface finish

Exercise 5 – Insert Multi Surface feature, Surface finish

Define a Multi Surface Feature from faces with a Surface Finish annotation (Method: Faces by Surface

2
Finish)
Contain the toolpath by using the Automatic Contain Area

02
This lab will reinforce the following skills from Lesson 2:
• Insert Multi-Surface Feature using IFR using Feature Type Method: Faces by Surface Finish
• Generate Operation plan and toolpath
• Contain the toolpath using Automatic Contain Area

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Procedure:
1. Open Part
a. Open SUR_FIN.SLDPRT from the …\Lesson_02\Exercises folder
2. Define machine
a. Use the following parameters:

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i. Machine: Mill – Metric
ii. Tool Crib: Tool Crib 2 (Metric)
iii. Post Processor: M3AXIS-TUTORIAL
3. Define Stock
a. The following parameters should be used to define the stock size in the Stock Manager:
i. Material: 6061-T6
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ii. Stock Type: Bounding Box
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iii. The stock size should be X:250mm Y:50mm Z:175mm
4. Define Coordinate System
a. Define the coordinate system to use the top center stock position as shown. Make sure
the Z direction is correct.
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5. Create Mill Part Setup

a. Create Mill Part Setup normal to the top face of the part

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 Lesson 2—Multi-Surface Features, Exercise 5 – Insert Multi Surface feature, Surface finish

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6. Create Multi Surface Feature
a. Create Multi Surface Feature
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b. Use Feature Type Method: Faces by Surface Finish
c. Set Strategy to Area Clearance, Constant Stepover
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d. Click on the checkbox for the .005-5 roughness
e. Click OK
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7. Generate Operation Plan

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a. Generate the Operation Plan

8. Generate Toolpath
a. Generate Toolpath

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 Lesson 2—Multi-Surface Features, Exercise 5 – Insert Multi Surface feature, Surface finish

b. Notice that area clearance generates toolpath that gouges the part on the Area
Clearance operation

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9. Set the Automatic Contain Area
a. Edit Area Clearance1
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b. Go to the Geometry tab, set the Automatic contain area Method to All Silhouettes
c. Set the Tool condition to On Center
d. Click OK
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e. Edit Constant Stepover1
f. Go to the Geometry tab, set the Automatic contain area Method to All Silhouettes
g. Set the Tool condition to On Center
h. Go to the Constant Stepover tab
i. Under Pass options set the Constant cut amt. to 1mm
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j. Click OK
10. Generate Toolpath
11. Simulate toolpath
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 Lesson 2—Multi-Surface Features, Exercise 5 – Insert Multi Surface feature, Surface finish

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12. Save and Close Part
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 Lesson 3—Avoid and Contain Areas, toolpath limits

Lesson 3—Avoid and Contain Areas, toolpath limits

2
Upon successful completion of this lesson, you will be able to:
• Use contain and avoid areas to control tool path

02
• Limit the Z level of a toolpath using Z limits.
• Control the extents of a toolpath using the Automatic contain area
• Control the XY and Z extents of a toolpath with Rest Machining settings

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Contain and Avoid Areas

Case Study: Contain and Avoid Areas

In CAMWorks 2.5 axis milling and SOLIDWORKS CAM we can limit generated toolpath to certain areas

2
using Contain and Avoid Areas. An avoid area can be used to define a clamp or fixture where we do not
want the tool to machine. We can also limit the toolpath to a certain area using a contain area.

02
So far in this course, we have had a couple of simple examples of the automatic contain areas. In these
examples, we used a SOLIDWORKS sketch to define the contain and avoid areas. We can also use part
geometry like planar and non-planar model edges and faces.
1. Open part

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a. Open the part C_A.SLDPRT in the …\Lesson_03\Case Study folder
b. Click on the CAMWorks Operation tree and CAMWorks CommandManager tool bar.
An Area Clearance and Pattern Project operation have already been defined on this part.
2. Insert contain area
a. Right click on Pattern Project1 and select New Contain Area…

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Contain areas can also be inserted from the operation parameters. If we edit the operation parameters
on any 3-axis operation, there is a Geometry tab where we can also add Contain and Avoid areas.
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Contain and Avoid Areas

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By clicking on the button, it will launch the Contain Area property manager
The Contain area property manager dialogue contains the following sections:
Selection Mode – The shape of the avoid area can be defined from
faces, edges, and sketches. This section sets up the selection method
used in defining the contain area.
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Selected Contours – Shows a list of the contour that are selected
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Allowed Sketches – List of the sketches in the part file that can be
used for defining a contain area.

By default, the list only contains those sketches that have a single
closed contour defined and are parallel to the XY machining plane.
We can also use sketches with more than one closed contour by
selecting the Multiple Icon in the Shape section
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Shape – Defines the shape of the contain area as it relates to

selected geometry.
• Silhouette conforms the shape of the contain area to the
exact shape of the geometry.
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• Bounding box put a box around the selected geometry.

• The Multiple option allows for the selection of more than
one contour for the contain area. The resulting contain area
follows the silhouette of each of the selected contours

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Contain and Avoid Areas

Offset – We can define an additional offset in X and Y to the contain

2
area geometry. When an offset is applied we can force the sharp
corners of the offset geometry to be rounded.

02
Tool condition – an important setting in defining a contain area or
avoid area is how the tool interfaces with the boundary of the area.
This can be defined in one of three ways

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Tool Upto Curve – For a contain area, the tool
diameter will be fully inside the contain area.

Tool On Curve – The resulting toolpath center

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will be on the defined contain area geometry.
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Tool Past Curve – For a contain area, the full

tool diameter will be outside the contain
area.
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b. Under the allowed sketches, select Contain_01

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Contain and Avoid Areas

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c. Set the tool condition to Tool Upto Curve

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d. Click OK and let the toolpath regenerate
e. Examine the toolpath

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3. Modify the contain area

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a. Expand Pattern Project1 by clicking on the symbol to the left of the Pattern Project1
icon in the CAMWorks operation tree
b. Right click on the new contain area and select Edit Definition. You can also double-click
on it
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c. You can also edit the operation, go to the Geometry tab, highlight the Contain area
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under the User defined contain area section and click on the Edit button.

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Contain and Avoid Areas

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d. Under the shape section, select Multiple. Notice the change in the Allowed sections
area

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e. Select Contain_02 from the list of Allowed Sketches, replacing Contain_01
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f. Click OK and regenerate the toolpath

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Contain and Avoid Areas

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4. Insert Avoid area
a. Right click on Pattern Project1 and select New Avoid Area…

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b. Alternatively, we can edit the operation parameters and click on the Geometry tab.
Under User defined avoid area, click on the Create button
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Contain and Avoid Areas

The Avoid Area property manager dialogue has the exact same sections and options as the contain area.
These sections are used in the exact same way in defining an avoid area as they are in defining a contain

2
area.
In addition, the Avoid Area property manager had the Avoid Area section.

02
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Avoid Areas – These options control whether the toolpath machines over or around the avoid area.
Machine Around – The toolpath is will machine
around the avoid area perimeter

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Machine Over – The toolpath will machine over
the avoid area as if it were parallel to the XY plane.
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c. Set the avoid area to Machine Around icon

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d. Click OK and regenerate the toolpath

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Contain and Avoid Areas

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02
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5. Modify the Avoid area
a. Right click on the Avoid Area1 and select Edit definition
b. Set the avoid area to Machine Over

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c. Click OK and regenerate the toolpath
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

Case Study: Limiting toolpaths with Limits and Automatic Contain Areas
3 Axis toolpaths can be further contained using some of the parameters inside of the operation

2
parameter. This Case Study examines these techniques.
1. Open part

02
a. Open the part ACFA0102.SLDPRT in the …\Lesson_04\Case Study folder

e2
2. Define the Stock
e
a. Click on the CAMWorks Feature Tree
b. Right Click on the Stock and select Edit Definition
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c. For the Stock Type, select Part file
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d. For the Solid Model select Current Part then select the SOLIDWORKS configuration
Stock.
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This part file has another SOLIDWORKS configuration defined with additional geometry. This option
allows us to define another configuration of this same SOLIDWORKS part as the stock.

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

e. Click OK
f. Click Yes to the CAMWorks Waring message

2
02
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3. Define the Coordinate System
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a. Edit the Coordinate System by double clicking on the Coordinate System icon in the
CAMWorks Feature Tree
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b. From the Method dropdown, select User Defined
c. For the Origin, select Stock bounding box vertex
d. Set the orientation of the axes as shown
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e. Click OK

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

4. Create New Multi Surface Feature

a. Insert a new Multi surface feature by Right clicking on Mill Part Setup1 and select Multi

2
Surface Feature
b. For the Feature Type Method, select All Displayed
c. For the Strategy select Area Clearance, Z Level

02
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d. Click OK
5. Generate Operation Plan
6. Change the Tool for Area Clearance1
a. Go to CAMWorks Tool Tree
b. Drag and drop Area Clearance1 from T05 – 20 Flat End to T01 – 6 Flat End.
e
This will change the tool for this operation to T01 – 6 Flat End.
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7. Modify Operation Parameters for Area Clearance1

a. Click on the CAMWorks Operation Tree
b. Edit Area Clearance1
c. Click on the Pattern tab
d. Set the Pattern Type to Pocket in – Core.
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

e. Click OK
8. Generate Toolpath for Area Clearance1

2
02
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both in Z and in X and Y
Toolpath Limits
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As we examine this toolpath we can see that it extends far beyond the geometry of the part. The first Z
move is also way above the part and the last Z level end way below. We may want to limit the toolpath

To limit the toolpath in Z we can use the Limits setting on the Area Clearance Tab. A similar setting is
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available for the other 3 Axis operation types.
The following settings can be used to control the Z depth of a 3 Axis operation:
First cut from: – This options sets where the toolpath
starts in Z.
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• Top of Stock will calculate the toolpath from

the top of the defined stock.
• Top of Feature will calculate the first cut of the
toolpath from the highest Z value on the
selected feature.
• User Defined will calculate the first cut from
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the specified Z start. The Z start can be explicitly defined or reference a point on the part model.

Pick point button displays the Define Point dialog box that allows you to specify the Z start of the
toolpath. You can define the applicable location relative and associative to a vertex, planar arc edge or
arc segment defined in a sketch on the part.
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Z Start – When the User Defined option is selected as the First cut from option, Z Start will let us enter in
an addition value to offset the toolpath in Z from the user selected point
Offset – When Top of Stock or Top of Feature is selected as the First cut from option, the Offset lets us
enter in an additional value in Z from where the toolpath will start

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

Last Cut at: – This option sets lower limit of the generated toolpath. Similar to the First cut from options,
the following options are available to define the Last cut:

2
• Bottom of stock will calculate the last cut based on
the bottom of the defined stock

02
• Bottom of feature will calculate the last cut based
on the lowest Z value of the selected feature
• User defined will calculate the last cut based on a
user-defined endpoint. The Z endpoint can be
explicitly defined or reference a point on the part

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model select from the Pick point button

Pick point button – Displays the Define Point dialog box that allows you to specify the Z end of the
toolpath. You can define the applicable location relative and associative to a vertex, planar arc edge or
arc segment defined in a sketch on the part.
Z End – When the User Defined option is selected as the Last cut at option, Z End will let us enter in an

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addition value to offset the toolpath in Z from the user selected point
Offset – The last cut is offset from the bottom of the stock or the bottom of the feature by the specified
value.
9. Edit operation parameters
e
a. Right Click on Area Clearance1 and select Edit definition
b. Go to the Area Clearance tab
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Notice from the depth parameters that this operation is set to cut at a constant depth of 2.5mm.
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

Currently, the toolpath’s first cut is at a depth 2.5mm below the top of the defined stock.
c. Under Limits, set the First cut from to Top of feature

2
02
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d. Click on the Preview button

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Notice that the start depth has changed to 2.5mm below the top surface of the feature instead of the
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stock.
e. Click the X in the upper right corner of the Operation parameter to expand the
operation parameters dialogue
f. Set Last cut at to User Defined.
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g. Click on the pick point icon

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h. Select a vertex on the second to top face of the part as shown.

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

2
02
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i.
j.
Click OK to the define Point dialogue
Click preview the toolpath. e ng
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Notice that we have now constrained the depth of the toolpath.

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For this example, we will go back and set the depth of the toolpath to the bottom of the feature
k. Click the X in the upper right corner of the Operation parameter to expand the
operation parameters dialogue
l. Change the Last cut at to Bottom of feature
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m. Click OK and regenerate the toolpath

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

2
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Automatic Contain Area

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To limit the X and Y extents of a 3-axis toolpath we can use the Automatic contain area options on the
Geometry tab of the Operation parameters dialogue

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Automatic contain area uses either the part or stock to determine the area to be machined. We have
the following four options:
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Stock – The XY shape of the contain area
is based on the original stock shape.

If the stock shape is defined from a

sketch and the current setup is normal to
the sketch, the contain area will be the
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same as the sketch.

Otherwise the contain area will be based

on the minimum XY bounding box of the
stock.
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

Bounding Box – The XY shape of the contain

area is based on the minimum XY bounding

2
box of the faces in the Multi Surface feature.

02
The bounding box will be based only on the
Faces to Cut in the Multi Surface feature.

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All Silhouettes – The XY shape of the contain
area is based on an XY silhouette of the faces
to cut in the Multi Surface feature.

The silhouette will be based only on the Faces

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to Cut in the Multi Surface feature.

The silhouette will include the outer shape of

the faces as well as any internal shape based
on through features.
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The internal silhouette areas will be treated
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automatically as avoid areas.
Outer Silhouettes – The XY shape of the
contain area is based only on an outer XY
silhouette of the faces to cut in the Multi
Surface feature.
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Tool condition – This option defines which side of the automatic contain the toolpath will position to.
• On Center – The tool center will be on the automatic contain area shape
• Upto – The full diameter of the tool will be contained within the shape of the automatic contain
area

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

• Past – The full diameter of the tool will be on the outside of the shape of the automatic contain
area

2
XY Offset – The XY offset value is an additional amount that is added to the tool condition.
10. Edit the operation to modify the Automatic contain area

02
a. Edit the operation parameters of Area Clearance1
b. Click on the Geometry tab
c. Change the method to Bounding box

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d. Click on Preview

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Notice the changes to the XY extents of the toolpath

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e. Click the X in the upper right corner of the Operation parameter to expand the
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operation parameters dialogue

f. Change the Automatic contain area Method to All Silhouettes
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

g. Click on Preview

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02
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Notice the changes to the XY extents of the toolpath

operation parameters dialogue

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h. Click the X in the upper right corner of the Operation parameter to expand the

i. Change the Automatic contain area Method to Outer Silhouettes

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j. Click on Preview
k. Notice the changes to the XY extents of the toolpath
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

2
02
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l. Click OK
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For this toolpath, we want to machine from the top of the defined stock down to the bottom of the
feature. As mentioned above, when we use the Method: Stock, the automatic contain area will be the
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bounding box of the stock if it is defined from anything other than a SOLIDWORKS sketch. In this case,
the automatic contain area doesn’t contain the toolpath as we would like based on the stock defined.
We can use the rest machining settings to get a better contain area. By using the rest machining
settings, the toolpath will be constrained to the stock and any operations in the tree above the
operation we are working with. In this example, we will only use the defined stock as the WIP model.
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First, we will reset the Z limits and Automatic Contain Area settings
11. Reset the Z Limits and Automatic Contain Area Settings
a. Right click on Area Clearance1 and select Edit definition
b. Click on the Goemetry tab
c. Set the Automatic Contain Area Method to Stock.
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d. Click on the Area Clearance tab

e. Set the Limits, First cut from to Top of Stock and Last cut at to Bottom of Feature

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Case Study: Limiting toolpaths with Limits and Automatic Contain Areas

2
02
f. Click Preview to Generate the Toolpath
12. Set the Rest Machining Setting

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a. Click on the Rest Tab
b. Change the Rest Machining Method to From WIP.

13. Generate toolpath

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

Exercise 6 – Insert Contains and Avoids

Constrain the X and Y constraint of 3 axis toolpaths using avoid and contain areas.

2
In this exercise, we will use avoid and contain areas to keep the tool from machining areas where the
part would be clamped to a table. A second Mill part setup will be used to machine away the material

02
leftover from the fixturing.
Setup 1 Setup 2

e2
This exercise reinforces the following skills from Lesson 3:
• How to create new avoid and contain areas
• Contain area options
Procedure:
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1. Open Part
a. Open P_01_08.SLDPRT from the \Lesson_03\Exercises folder
b. Click on the CAMWorks Feature tree
c. In this part the Machine, Stock, and Coordinate system have already been defined
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2. Define Mill Part Setup

a. Use the top flat face of the part as shown

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

b. Check on the Multi Surface feature check box and for Strategy, select Area Clearance,
Constant Stepover

2
02
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c. Click OK
3. Generate Operation Plan
4. Split the Mill Part Setup into two groups
e
a. Right click on Mill Part Setup1
b. Select Split Setup from the menu
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

5. Copy operations
a. CRTL+Drag and drop on Area Clearance1 to copy the operation

2
b. Then drag the copied operation to the Mill Part Setup1 [Group2]
c. Do the Same for Constant Stepover1

02
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6. Insert new avoid area for Area Clearance1
a. Right click on Area Clearance1 and select New avoid area, or edit the operation
parameters of Area Clearance1, click on the Geometry tab, and under User defined
avoid area, click on the create avoid are icon
e
b. Under the Shape section, select the Multiple icon
c. Select Avoid Sketch01 from the list of available sketches
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d. Set the Tool condition to Tool Upto Curve

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

2
02
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e. Click OK to insert the avoid area
7. Insert Avoid area
a. Right Click on Area Clearance1 and select New avoid area, or, or edit the operation
parameters of Area Clearance1, click on the Geometry tab, and under User defined
avoid area, click on the create avoid are icon

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b. Select the top edges of the hole

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c. Scroll to the bottom of the Avoid Area Property Manager dialog

d. Select the Machine over icon

8. Generate Toolpath
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

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02
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9. Simulate toolpath

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a. Click OK
10. Insert New Contain area for Constant Stepover1
a. Right Click on Constant Stepover1 and select New Contain Area…
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b. Select Contain Sketch01 under the allowed Sketches section

c. Set the Tool Condition to Tool Upto Curve

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

2
02
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d. Click OK
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11. Copy the Avoid area of the center hole from Area Clearance1 to the Constant Stepover1
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a. CRTL+Drag and drop Avoid Area2 from Area Clearance1 to Constant Stepover1
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12. Generate toolpath

a. Generate toolpath on Constant Stepover1
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

2
02
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13. Insert Contain area for Area Clearance1 – Copy
a. Right Click on Area Clearance1 – Copy and select New Contain Area
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b. Or, edit the operation Area Clearance1 – Copy, click on the Geometry tab and under
User defined contain area, click on the Create button
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c. In the Contain Area property manager, select the Multiple icon under the Shape section
d. From the Allowed Sketches list, select Contain Sketch02

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

e. Set the Tool Condition to Tool Upto Curve

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f. Click OK
14. Copy the Contain area to Constant Stepover1 – Copy
a. CRTL+Drag and drop the Contain Area2 under Area Clearance1 – Copy to Constant
Stepover1 – Copy
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15. Generate Toolpath for the operations under Mill Part Setup1 [Group2]
16. Simulate entire toolpath

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 6 – Insert Contains and Avoids

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 7—Insert Automatic Contain area and using Z Limits

Exercise 7—Insert Automatic Contain area and using Z Limits

Constrain the toolpath by using automatic contain area and Z limits

2
This exercise reinforces the following skills from Lesson 3:
• Control the extents of a toolpath using the Automatic contain area

02
• Control the XY and Z extents of a toolpath with Rest Machining settings
Procedure:
1. Open Part
a. Open Wheel Center.SLDPRT from the …\Lesson_03\Exercises folder

e2
b. Click on the CAMWorks Feature tree
c. In this part the Machine, Stock, and Coordinate system have already been defined
2. Define Multi Surface Feature
a. Under Mill Part Setup1, define new Multi Surface Feature
b. For Feature Type, select All Displayed
c. For Strategy, select Area Clearance, Constant Stepover

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d. Click OK
3. Generate Operation Plan
4. Edit Area Clearance1 and adjust Automatic Contain Area
a. Edit Area Clearance1
b. Click on the Pattern tab
e
c. Under Pattern type, set the Pattern to Pocket In – Core
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d. Click on the Geometry tab

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e. Under Automatic contain area set the Method to All Silhouettes

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f. Click Preview to generate the toolpath

g. Simulate the toolpath to examine what gets cut
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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 7—Insert Automatic Contain area and using Z Limits

2
02
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h. Expand the operation by clicking on the X in the upper right corner of the collapsed
operation parameter dialogue box
i. Under Automatic contain area, set the Method to Outer Silhouettes
e
j. Click on Preview to generate the toolpath
k. Simulate the toolpath to examine the results
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5. Edit Area Clearance1 and adjust Z Limits

a. Click on the Area Clearance tab
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b. Under Limits set the Last cut at to Bottom of Feature

c. Set the Offset to -5mm
d. Click Preview to generate the toolpath
e. Simulate the toolpath to examine the results

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 Lesson 3—Avoid and Contain Areas, toolpath limits, Exercise 7—Insert Automatic Contain area and using Z Limits

2
02
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a. Click on the Geometry tab

c. Click OK
7. Generate Toolpath
8. Simulate Toolpath
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6. Edit Area Clearance1 and set the automatic contain area to stock

b. Under Automatic contain area, set the Method to Stock

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 Lesson 4—Inserting operations, Common Operation Parameters

Lesson 4—Inserting operations, Common Operation Parameters

2
Upon successful completion of this lesson, you will be able to:
• Identify the CAMWorks options related to 3 Axis Toolpath Generation

02
• Interactively insert 3 axis operations
• Insert 3 axis operation from CRTL drag and drop
• Identify the operation parameters that are common among the different operation types
o Tool Tab
o F/S Tab

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o NC Tab
o Links Tab
o Entry/Retract Tab
o Advanced Tab
o Rest Tab

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o Statistics Tab
• Insert an avoid feature
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 Lesson 4—Inserting operations, Common Operation Parameters

In this lesson, we will take a closer look at some of the operation parameters that are common among
the 3 axis operation types. We will also examine ways to manually insert 3 axis operations into the

2
CAMWorks Operations tree from predefined multi surface features.
Types of 3-Axis operations

02
Before we start, we will review the types of 3-axis operations that are available in CAMWorks. Here are
the types of 3 axis operations that we can use in CAMWorks 3-Axis milling:
Area Clearance – The Area Clearance cycle
removes the material between the stock or
contain area and the selected feature at

e2
decreasing Z depth levels by making a series of
parallel cuts across the stock (Lace) or by
pocketing out toward the stock.

This operation type is discussed in greater detail

in Lesson 5

Pattern Project – The Pattern Project operation

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is a multi-surface finishing cycle that removes
material based on the selected pattern: Slice,
Flowline, Radial and Spiral.
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This operation type is discussed in greater detail
in Lesson 6
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 Lesson 4—Inserting operations, Common Operation Parameters

Z Level – The Z Level cycle is a finish contouring

cycle that removes material by making a series

2
of horizontal planar cuts. The cuts generally
follow the contour of the feature at decreasing Z
levels based on the Surface Finish you specify.

02
This operation type is discussed in greater detail
in Lesson 5

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Flat Area – The Flat Area cycle uses a pocket out

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pattern to remove material from feature faces
that are flat and parallel to the XY machining
plane. CAMWorks generates toolpaths only on
completely flat areas. e
This operation type is discussed in greater detail
in Lesson 5
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Curve Project – The Curve Project cycle removes

material by projecting selected 2.5 Axis Engrave
and/or Curve features onto the faces/surfaces of
a Multi Surface feature and generating toolpaths
along the projected entities.

This operation type is discussed in greater detail

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in Lesson 8
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 Lesson 4—Inserting operations, Common Operation Parameters

Constant Stepover – The Constant Stepover

operation removes material by maintaining a

2
constant user-defined stepover relative to the
surface.

02
This operation type is discussed in greater detail
in Lesson 7

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Pencil Mill – The Pencil Mill cycle generates
toolpaths to finish machine corner areas using a

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single pass or multiple constant stepover passes.

This operation type is discussed in greater detail

in Lesson 8
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

Case Study: Modifying common operation parameters

1. Open part

2
a. Open the part Controller_Core.SLDPRT in the …\Lesson_04\Case Study folder
b. Click on the CAMWorks Feature tab and CAMWorks CommandManager tool bar

02
2. Set the Facet deviation
a. Open the CAMWorks Options on the CAMWorks CommandManager Toolbar

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b. Go to the Mill features tab

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Look at the Faceting section. When generating 3 axis toolpaths, the multi surface feature is
approximated by triangles called facets. The Facet deviation refers to the maximum deviation between
the faceted model and the actual part. The smaller the deviation, the more triangles will be used to
generate the toolpath. As the deviation gets smaller, more time is required to generate toolpath.
Spline Deviation will control the accuracy of spliner profiles used in Rough Mill and Contour Mill
e
operations. It also controls the accuracy of the profiles used to created contain and avoid areas
Force facet regeneration will force the faceted model to be regenerated every time a 3-axis toolpath is
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generated. When unchecked, the faceted model will update only when the first 3 axis operation is
generated for a certain feature.
c. Keep the default values entered in for Facet deviation and Spline deviation
i. Facet deviation: 0.01mm
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ii. Spline deviation: 0.03mm

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3. Set the toolpath generation method

a. Go to the Update Tab.
b. Set Update 3 axis toolpaths when parameters change: to Prompt.
CAMWorks will ask us to regenerate the toolpath when editing operation parameters
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c. Set 3 axis toolpath generation method: to Advanced method

d. Click OK to the CAMWorks Options

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

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02
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The following options are helpful when working with 3-Axis operations
Update 3-Axis Toolpath When Parameter Change
Update 3 axis toolpath when parameter change is the option that controls how the toolpath is
e
generated when exiting the operation parameters dialogue box. It can be helpful to use this option to
control when an operation is generated
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• Always – When modifications are made to the operation parameters, the associated toolpaths
will be automatically regenerated to be in sync with the updated parameters.
Selecting the Always option eliminates the possibility that the toolpaths are not up to date.
• Prompt – When modifications are made to the operation parameters, a message will be
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displayed stating that Operation parameters have changed and that toolpaths need to be
recalculated; and whether you wish to regenerate toolpaths.
• Yes – The toolpaths will be regenerated to be in sync with the updated parameters.
• No – Then toolpaths will not be updated. The Generate Toolpath command can be used
later to regenerate the affected toolpaths
• Never – When modifications are made to the operation parameters, the toolpaths will not
regenerate automatically nor, will any warning message be displayed indicating the need to
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update toolpaths.
Toolpaths will need to be regenerated manually after making modifications to the parameters.
3-Axis Toolpath Generation Method
3 axis toolpath generation method is the option that determines which algorithm is used to calculate
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the 3-axis toolpaths.

• Advanced method – The new toolpath generation method for 3 axis operations.
• Previous Method – Legacy toolpath generation algorithm.

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

This training manual focuses on the Advanced method. The help documentation is available if you want
to use the Previous method.

2
Notice that the Machine, the stock, and the coordinate system have already been defined on the part.
Also, a mill part setup (Mill Part Setup1) has already been defined.

02
4. Create a new Multi Surface feature.
a. Insert a new multi surface feature by right clicking on Mill Part Setup1 and selecting
Multi Surface Feature... from the menu.

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We can also select the Multi Surface Feature icon from the CAMWorks Command Manager toolbar.
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b. For Feature Type, select All Displayed

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c. Click OK
For this Case Study, it doesn't matter which strategy we select. We are going to insert the operations
manually.
5. Insert Area Clearance Operation

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

a. Go to the CAMWorks Operations tree

b. Insert Area Clearance operation. This can be done by right clicking on Mill Part Setup1

2
and from the menu, selecting 3 Axis Mill Operations, Area Clearance.

02
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We can also select the 3 Axis Mill Operations icon from the CAMWorks CommandManager Toolbar
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The New Operation: Area Clearance property manager is now active. Here we have three tabs that we
can use to define some of the necessary parameters for inserting a 3-Axis operation.
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

Operation – option to select which type of operation. For example,

if we initially try to insert an Area Clearance operation but we decide

2
after initiating the command that we want to insert a Constant
stepover operation, we can change it here.
• Operation Parameters – allows us to select whether the

02
operation parameters are determined by the Default setting
in the Technology Database or copy it from an existing
operation

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Tool – Allows us to select a tool to use for the operation.
• Add New… – We can add a tool to the tool crib from the
Technology Database
• Pick from the tool crib – We can select a tool from the tool
crib
•
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From Operation Parameter – The tool is selected from the
operation parameters defined in the Technology Database
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Features – Select the feature we are applying the operation to.
•
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Selected Features – Shows the selected features for the

operation
• Parameters – this option allows us to pick a strategy and
adjust other parameters
• Create Features – this option allows us to create features on
the fly
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c. Go to the Tool tab and select T05 – 20 Flat End for the tool
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

2
02
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d. Go to the Features tab and select the check box next to Multi Surface Feature1. This
will add Multi Surface Feature1 to the Selected Features box

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e. Click OK
The Area Clearance operation has been successfully inserted. After clicking OK, the Operation
Parameters dialog box will open.
Here are the operation parameters for the area clearance operation. Here we have various tabs and
parameters that control the operation. Many of these tabs are common to all 3 axis operations. In this
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lesson, we will learn about these common parameters.

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

TOOL TAB – The Tool and F/S tabs are the same in
SOLIDWORKS CAM. In the Tool tab, Mill Tool tab

2
we can define the tool geometry and other cutting
parameters. The comment line is used to define
the tool name for post processing and setup sheet

02
definition.

e2
The Tool tab, Mill Holder tab sets up the tool
holder to be used to hold the tool to the machine.
We can define the tool with either a User Defined
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custom holder, or with parameterized number. For
now, we can leave it to User Defined
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The Tool Tab, Tool Crib tab gives us a list of tools in

our tool crib, or tool that are readily available to
use. Here we have options to select other tools in
the crib or define new tools.
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

The Tool Tab, Station tab lets us define the Tool

station number and station ID.

2
The Gage offset (XYZ) sets the attachment point of

02
the tool to the CAMWorks Virtual Machine model.
Typically, this is set to the back of the holder

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6. Edit the Operation Parameters
a. Click on the Tool tab
b. Click on the Mill Tool tab and examine the settings
c. Click on the Mill Holder tab and examine the settings
d. Click on the Tool Crib tab and examine the settings

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e. Click on the Station tab and examine the settings
F/S TAB
On the F/S tab we control the feeds and speed for operations. In CAMWorks this is defined three
different ways: By operation, by Tool, and by Library
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When the feeds and speeds are defined by the
Operation, the values for Surface Feet per Minute,
Spindle RPM, Feed per tooth and Feed rate can be
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entered in manually.
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If defined by Library is selected, CAMWorks will

use an external library and generate feeds and
speeds based on the material chosen in
CAMWorks.
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

Feeds and Speeds can also be defined by the Tool

selected. When this option is selected, CAMWorks

2
will use the data that is stored with the tool for
feed and speed calculation

02
For Sharp Corners, the Enable corner slowdown

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option allows us to override the Feedrate as the
tool approaches a sharp corner. The angle of the
corner and the radius can also be controlled here.

related to these tabs later in this course.

f.
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We will skip over the Pattern and Area Clearance tabs for now. We will be discussing the options
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Activate on the F/S tab and examine the options
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g. Activate the Pattern tab
h. Set the pattern to Pocket in – core.
i. Activate the Area Clearance tab.
j. Set the XY Allowance and Z allowance to 1mm respectively
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NC Tab
The Rapid plane is the plane from which the tool will approach from before an operation and retract to
after an operation. The NC tab controls the Rapid plane of the operation and offset in the Z direction by
the value entered into the Distance field.
Rapid plane is:
Top of Feature – The rapid Z plane will be at an
incremental Distance above the top of the feature.
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

Setup Origin – The rapid Z plane will be at an

incremental Distance above the Setup origin.

2
02
Clearance Plane – Specifies that the rapid Z plane
will be at an incremental Distance above the value
of the Skim clearance parameter on the Entry
Retract tab.

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Top of Stock – The distance value parameter is
calculated from the top of the stock. When selecting
this option, a preview of the stock is made visible in

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the graphics area.

It is important to note where this plane is coming from because it is possible to crash the tool if the
e
Rapid Plane is based off a part origin that is set at the bottom of the stock.
k. Activate the NC tab
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l. Set the Rapid plane is to Top of Stock
m. Set the Distance to 25mm
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Links tab
The Links tab defines how the toolpath connects
from the end of one cut to the start of the next
cut.
When Spline Curve is selected for the Type, a
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curve is applied to the link move

When Straight Curve is selected, a sharp corner
move is applied
The Max link distance will define a threshold as to
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when a link move is applied. If the distance

between the cuts falls below the threshold, then
the link move is applied

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

Entry/Retract tab
The Entry/Retract tab controls the Vertical and

2
Horizontal leadin/out and how the tool will ramp
into cuts.

02
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Preview

This button at the bottom of the Operation Parameters dialogue generates the toolpath

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based on the current operation parameters. The Simulate Toolpath and Stepthrough Toolpath icons
become active once the toolpath is generated from the preview. This allows us to easily visualize the
toolpath without having to exit out of the operation parameters dialog box
To exit out of the preview mode, click on the X in the corner of the minimized Operation Parameters box
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n. Activate the Entry Retract tab and click on the Preview button
o. Click on the X in the upper right corner of the operation parameters to view the
operation parameters again
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One of the important parameters to note is the Retract Method. Notice how this is set to Skim as a
default coming from the Technology Database.
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Important – Depending on the controller of the machine, this setting can cause a possible crash of the
tool into the part even though CAMWorks doesn't show the crash. This is because when the machine
controller reads a rapid move, the axis motors move at max speed simultaneously to the next position.
This results in an initial rapid move in 45deg until one of the axes has reached position. Then the other
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axis moves in a straight line until it reaches position. Because of this phenomenon, it is best to change
this setting to Full
p. Set the Retract Method to Full

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

2
02
q. Preview the toolpath. Notice the rapid moves now move to a higher plane.
Geometry Tab
The Features (Faces to cut) section defines the
Multi surface feature. We can create a new multi-

e2
surface feature, edit the existing multi-surface
feature, and add a new multi-surface feature
The Avoid feature (Faces to avoid) section, we
define Multi Surface features where toolpath will
not be generated
The User defined contain area section gives us as

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alternative place to define Contain areas
The User defined avoid area section gives us an
alternative place the define Avoid areas.
The Automatic contain area options control the
shape and size of the automatic contain area and
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which side of the automatic contain area the
toolpath will position to.
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Advanced Tab
The Arc fitting options control the output of lines
versus arcs. Arc fitting can reduce the size of the
posted G-code.
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The Holder avoidance options define whether 3

Axis toolpaths should consider the holder during
toolpath computation
The Mirror toolpath checkbox option defines
whether to apply the mirror transform to the
toolpath associated with the operation.
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Avoid small profiles sets the largest diameter that

can be generated
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

Rest Tab
The rest tab allows us to tell the machine to skip

2
over already-machined areas
When the Method is set to From WIP the toolpath

02
will only be generated in areas that haven’t been
machined from previous operations
Previous Tool lets us specify a Tool type (Flat End,
Ball End or Hog Nose) and Cut diameter to
determine the toolpath that is generated. Areas
that are generated are where the Previous tool

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couldn’t reach
From STL File lets us browse to an STL file to
determine where the rest machined toolpth is
generated from
Current part will generated the toolpath based on

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the Model offset value and the part geometry.

Posting Tab
Parameters on the posting tab vary with each
postprocessor, such as coolant type
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Statistics Tab
Information on the statistics tab includes toolpath
analysis, distance travelled, and machining time
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r. Click OK to accept the operation parameters

Operations can be copied in the tree by holding down CRTL, dragging and dropping in the tree to copy
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the operation.
In this part, we want to copy this operation and change the tool and some other parameters to get a
second rough cut on the part.
7. Copy the Area Clearance operation
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a. CRTL+drag and drop on Area Clearance1 operation to copy it.

b. Click and drag the new Area Clearance1 – Copy operation so that it is below Area
Clearance1 in the operation tree

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

c. Slow double-click on Area Clearance1 – Copy or right click on the operation and select
Rename. This allows us to change the name. Change the name to Area Clearance2

2
02
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8. Change the tool
a. Change the tool to T02 – 10 Flat End.
b. This can be done by editing the operation, Tool tab, Tool Crib and selecting it on this list,

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c. Or, by going to the Tool tree and dragging that operation from T05 – 20 Flat End to
T02 – 10 Flat End.
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9. Modify Operation parameters on Area Clearance2

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

a. Edit Area Clearance2 and go to the Area Clearance tab. Set the XY Allowance and Z
Allowance to 0.3mm respectively.

2
02
e2
b. Go to the Links tab and set the depth processing to To depth by region. This will keep
the tool path from jumping around.

0.1mm
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c. Go to the Rest tab and set the Method to From WIP. Set the Min. stock to remove to
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d. Click OK
10. Generate Toolpath
11. Simulate Toolpath
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a. Simulate the toolpath

b. Set the Mode to Tool mode
c. Set the Toolpath to Next Toolpath
d. Click Play
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

2
02
e2
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Now we are ready to insert some finish operations.
12. Create new Pattern Project operation
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We can see the operation Area Clearance2 cleaning up where the previous toolpath left off.
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a. Right click on Area Clearance2
b. Select 3 Axis Mill Operations, Pattern Project
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c. For the Tool, select T08 – 10 Ball Nose

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2
02
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d. Click on the Features tab and verify that Multi Surface Feature1 is the selected
feature.

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e. Click OK to insert the operation.

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Notice that the following tabs are also available in the Pattern Project operation parameters:
• Tool • Geometry
• F/S • Advanced
• Finish • Rest
• NC • Posting
• Links • Statistics
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• Entry/Retract
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13. Edit operation parameters

a. Go to the Entry/Retract tab
b. Set the Vertical lead in/out, Lead-in length and Lead-out length to 5mm.

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

2
02
This will change the length of the feed move in Z as it starts the cut

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c. Click on the Advanced tab, in the Arc fitting section, uncheck the Line moves only
checkbox.

d. Click OK
14. Generate toolpath
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This will force CAMWorks to generate G18/G19 arcs. This will result in less lines of code in the post G-
Code.
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This will work for the shut off surfaces of this mold. For the actual cavity surfaced, we want to use a
different toolpath. We can insert an Avoid area over the cavity, so the tool won’t cut the cavity.
An Avoid area can be inserted from selecting on part geometry in the graphics area. This would include
faces edge and even SOLIDWORKS sketches
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Avoid Area – An avoid area is a defined area where toolpath will not be generated. It can be defined by
selecting a 2D sketch or from the 2D footprint of selected surfaces.
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Avoid areas were discussed in greater detail in the previous lesson.

15. Insert Avoid Area
a. Right click on Pattern Project1 in the CAMWorks Operation tree and select New Avoid
area…

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02
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b. From the list of Allowed Sketches, select the sketch Area Sketch

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c. Click OK and allow the toolpath to generate
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We can now create a Constant Stepover operation to machine the cavity area of this part
16. Insert Constant Stepover Operation
a. Right Click on Pattern Project1 and select 3 Axis Mill Operations, Constant Stepover.

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

2
02
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b. For the tool select T08 – 10 Ball Nose
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c. Click on the Feature tab and make sure that Multi Surface Feature1 is selected.
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

2
02
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d. Click OK to insert the operation
17. Edit Operation
a. The Constant Stepover operation parameters dialog will pop up
b. Change the stepover amount. Click on the Constant Stepover tab, under Pass options,

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set the constant cut amt. to 1.5mm

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We want to contain the toolpath inside the area of the cavity of this part. We can do this in one of two
ways. We can insert a contain area using the Area Sketch sketch in the SOLIDWORKS feature tree or we
can use an Avoid feature.
Avoid Feature – An avoid feature is a multi-surface feature that will be avoided when the toolpath is
generated. It is defined from a multi-surface feature.
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We can create an avoid feature from the operation parameters on the Geometry tab. In the avoid
feature section we can do the following:
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• Create – by clicking on the Create button the Multi Surface Feature property manager will be
activated allowing us to select faces on the part as the avoid surface. When I click OK to the
property manager, a Multi surface feature is created and added to the Avoid features list in the
operation parameters

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

• Edit – the Edit button will only be active when an existing multi surface feature is selected.
When we select a Multi Surface feature and click on the edit button the Multi Surface Feature

2
property manager will be activated letting us edit the multi surface feature.
• Advanced – the Advanced button will launch the Avoid Features dialog box that allows us to add

02
new and existing Multi surface features to be avoid features

e2
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We can also access the avoid features from Avoid Features icon under the Operation node in the
CAMWorks operation tree. The Show Avoid Feature only check box will display only those features that
have been defined as Avoid Features. e
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18. Define an avoid feature

a. Click on the Geometry tab
b. Under the Avoid features (Faces to avoid) section, click on the Create button
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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

c. Select the outer faces in the graphics area as shown then click the green check to insert
the Feature

2
02
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d. Click OK
We can also use an avoid area to prevent the tool from going down into the hole in the model.
19. Insert avoid area

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a. Right Click on the Contour Mill operation and select New Avoid Area

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b. Select the top edge as the selected contour

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c. Select the option to Machine Over the avoid area

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 Lesson 4—Inserting operations, Common Operation Parameters, Case Study: Modifying common operation parameters

2
d. Click OK to insert the Avoid Area

02
20. Generate the toolpath
Once an avoid area is defined it can be copied to other operations.
21. Copy the Avoid area
a. CRTL drag and drop the Avoid area under Constant Stepover1 to Area Clearance2

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22. Generate toolpath
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a. Generate the toolpath for Area Clearance2
23. Simulate toolpath
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 Lesson 4—Inserting operations, Common Operation Parameters, Exercise 8 – Insert 3 Axis Operations and adjust common operation
parameters

Exercise 8 – Insert 3 Axis Operations and adjust common operation parameters

Create new Area Clearance and 3 axis finish

2
operations.
Modify common Operation parameters

02
This exercise will reinforce the following skills
from Lesson 3:
• Interactively insert 3 axis operations
(Area Clearance, Pattern Project)

e2
• Modify common parameters
Procedure
1. Open Part
a. Open PGS_01.SLDPRT from the …\Lesson_04\Exercises folder
b. In this part the Machine, Stock and Coordinate system have already been defined

ng
2. Create mill part setup
a. Create a new mill part setup normal to the selected face as shown

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b. Click OK
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3. Create Multi Surface Feature

a. Create Multi Surface Feature
b. Use Feature Type Method: All Displayed
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4. Insert Area Clearance Operation

a. Go to the CAMWorks Operation tree
b. Right click on Mill Part Setup1 and select 3 Axis Mill Operations, Area Clearance
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 Lesson 4—Inserting operations, Common Operation Parameters, Exercise 8 – Insert 3 Axis Operations and adjust common operation
parameters

2
02
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c. On the Tool tab in the New Operation: Area Clearance dialog, select T05 – 20 Flat End

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as the tool

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d. Select Multi Surface Feature1 as the Features for the Area Clearance
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e. Click OK
5. Edit Operation Parameters

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 Lesson 4—Inserting operations, Common Operation Parameters, Exercise 8 – Insert 3 Axis Operations and adjust common operation
parameters

a.
Tool tab – Go to the Tool tab, Mill Holder sub tab and set the Protrusion (L3): to 60mm
b.
F/S tab – Set the Defined by setting to Library

2
Pattern tab – Set the Pattern to Pocket in – Core
c.
d.
NC tab – Set the Rapid plane is to be the Top of the stock and set the Distance to

02
25mm
e. Entry Retract – Set the Vertical leadin/out, Lead in length and Leadout length to 3mm.
Also set the Retract Method to Full
f. Geometry tab – Set the Automatic contain area to Method: Stock and Tool Condition:
Past

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g. Click OK
6. Generate toolpath
a. Generate the toolpath for this Area Clearance operation

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7. Insert Pattern Project operation

a. Right click on Area Clearance1 and select 3 Axis Mill Operations, Pattern Project
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 Lesson 4—Inserting operations, Common Operation Parameters, Exercise 8 – Insert 3 Axis Operations and adjust common operation
parameters

2
02
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b. On the Tool tab, select T08 – 10 Ball Nose for the Tool

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c. On the Features tab, select Multi Surface Feature1 as the feature for the Pattern
Project
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d. Click OK
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8. Edit Operation Parameters

a. Tool tab – Go to the Tool tab, Mill Holder sub tab and set the Protrusion (L3): to 40mm
b. F/S tab – Set the Defined by setting to Library

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 Lesson 4—Inserting operations, Common Operation Parameters, Exercise 8 – Insert 3 Axis Operations and adjust common operation
parameters

c. Pattern tab – Under Pattern options, Set the Cut Angle to 45deg and under XY stepover
set the Cut amount to 1mm

2
d. NC tab – Set the Rapid plane is to be the Top of the stock and the Distance to 25mm
e. Links tab – Set the Type to Spline Curve and the Max link distance to 15mm

02
f. Entry Retract – Under Vertical leadin/out, set the Leadin radius, Leadout radius, Leadin
length and Leadout length to 3mm respectively. Also set the Retract Method to Full
g. Advanced tab – Set the Automatic contain area Method to All Silhouettes and Tool
Condition to On center. Set the XY offset to 4.5mm
h. Click OK

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9. Generate Toolpath
a. Generate the toolpath for the Pattern Project operation

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10. Simulation the toolpath for the setup
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11. Save
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 Lesson 4—Inserting operations, Common Operation Parameters, Exercise 9 – Insert Avoid Areas and Avoid Surfaces

Exercise 9 – Insert Avoid Areas and Avoid Surfaces

Control the extents of the toolpath using avoid areas and avoid surfaces. Copy avoid areas.

2
This exercise will reinforce the following skills from Lesson 3 and 4:
• Insert an avoid area

02
• Insert an avoid feature
• Copy an avoid area
Procedure
1. Open Part

e2
a. Open PGS_02.SLDPRT from the …\Lesson_04\Exercises folder
b. In this part the Machine, Stock and Coordinate system have already been defined
c. Also, the operations from the previous exercise have been applied to this part
2. Insert and new Avoid Area
a. Go to the CAMWorks Operations tree
b. Edit the operation Area Clearance1

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c. Click on the Geometry tab
d. Under the User defined avoid area section, click on the Create button
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e. Select Avoid Sketch from the list of allowed sketches

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f. Set the tool condition to Tool On Curve

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 Lesson 4—Inserting operations, Common Operation Parameters, Exercise 9 – Insert Avoid Areas and Avoid Surfaces

2
02
g. Click on the green check
h. Click OK and let the toolpath regenerate

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i. Select on Area Clearance1 in the CAMWorks Operation tree and note the updated
toolpath

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3. Copy Avoid area

a. CRTL+drag and drop Avoid Area1 from Area Clearance1 to Pattern Project1 in the
CAMWorks Operation tree
b. Regenerate the Pattern Project1 toolpath
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 Lesson 4—Inserting operations, Common Operation Parameters, Exercise 9 – Insert Avoid Areas and Avoid Surfaces

4. Insert and avoid feature

a. Edit Pattern Project1

2
b. Click on the Geometry tab
c. Under the Avoid feature (Faces to avoid) section, click on the Create button

02
e2
d. With the Multi Surface Feature property manager, select on the face shown below as
the selected face

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e. Click OK to the Multi Surface Feature property manager
f. Click OK and regenerate toolpath
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 Lesson 5—Area Clearance and Z Level Operation Parameters

Lesson 5—Area Clearance and Z Level Operation Parameters

2
Upon successful completion of this lesson, you will be able to:
• Insert and adjust the parameters of an Area clearance operation.

02
• Identify the area clearance pattern types
o Pocket out
o Pocket in – core
o Lace
o Adaptive

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o Volumill
• Use the Depth parameters: Constant vs scallop
• Insert and adjust the parameters of a Flat Area operation.
• Insert and adjust the parameters of a Z Level operation.
• Use the following depth parameters

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o Cut Type: Z level or Helical
o Method: Constant or Scallops
• Use Limits to control the toolpath
o By slope
o Contact areas only
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• Use the combination cycle option
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• Use the Links tab: Depth processing: Bottom up parameter
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

Case Study: Area Clearance and Flat Area operation parameters

We will now discuss in more detail the Area Clearance and Flat Area operation parameters. In a previous

2
lesson we went through the common operations shared among all the 3 axis operations we have
available to us in CAMWorks. We will now look at the operation specific parameters starting with Area

02
Clearance.
1. Open Part
a. Open the part ACFA_75_01.SLDPRT in the …\Lesson_05\Case Study folder
b. Click on the CAMWorks Feature Tree tab and the CAMWorks CommandManager tool bar
Review how the part is set up. Notice the stock definition is based off a SOLIDWORKS sketch called

e2
Stock.

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Also notice that there is a Mill Part Setup already defined in the tree.
2. Create new Multi-Surface feature
a. Under Mill Part Setup1, create a new Multi Surface feature
b. For the Method, use All Displayed.
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c. For the Strategy select Area Clearance, Z Level

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3. Generate operation plan

a. Generate Operation Plan for Multi Surface Feature1
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4. Edit the Area Clearance Operation

a. On the CAMWorks Operations Tree, edit Area Clearance1
There are two tabs in the Area Clearance Operation Parameters that are specific to the Area Clearance
operation type. The Pattern tab and the Area Clearance tab.

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

Pattern Tab
The Pattern tab defines the roughing pattern of the toolpath that will be generated. The following

2
pattern types are supported:
Pocket out – Starts in the middle of a cavity and

02
offsets outward to the defined feature faces

e2
Lace – Similar to a Zig Zag pattern, it creates a set

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of parallel toolpath passes along a line at a user-
defined angle

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Pocket in – Core – Starts on the outsides of a
cavity and offsets in a pattern toward the core
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shape
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In addition to these patterns, we have the following high-performance toolpath options:

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

Adaptive – Eliminates full width cuts using a

concept like trochoidal machining

2
02
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VoluMill – A strategy that enables much faster
and deeper cuts than with traditional toolpath
strategies. While avoiding sharp directional
changes, VoluMill controls material removal rates

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and can significantly extend tool life.

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The options below control how much the tool will step over with each pass. Different options will be
available as we select different pattern types, For Example, when Lace is selected, there is an option to
control the angle of the cut.
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When we select VoluMill an entirely different set of options become available.

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

2
02
Area Clearance Tab
The Area Clearance tab generally controls the how the part is roughed out.

e2
The Surface Finish options control how close the
toolpath will run to the finished part.

Direction Control controls the milling direction,

whether the cut will be climb or conventional
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Depth Parameters control the specifics of each

pass. When using the Pocket Out or Pocket In –
Core pattern types there are two methods
available. Constant will step the tool down based
on a specified cut amount. Scallop will try to
generate each Z level pass based on the size of the
Scallop material that is left. The smaller the scallop
setting is set, the more passes in Z there will be.
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

The Limits options control the starting and end

depth of the tool path

2
02
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5. Set the Pattern tab parameters
a. Click on the Pattern tab
b. Set the pattern Method to Pocket In – Core

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c. Set the Max stepover % to 50 and the Min Stepover % to 25
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6. Set the Area Clearance tab parameters
a. Click on the Area Clearance tab
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b. Under Depth parameters set the Method to Constant

c. Set the Cut amount to 5mm
d. Uncheck the Adaptive Stepdown checkbox
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7. Preview toolpath
a. Click the Preview button to preview the tool path.

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

b. Change the view in the graphics area to a front view. Notice the depth of each cut is the
same

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02
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8. Set the Method to Scallop
a. Under Depth parameters set the Method to Scallop
b. Set the Scallop step to 1.5mm

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c. Click on the Preview button. Notice that the depth of each cut varies according to the slope
of the feature
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The Adaptive stepdown option. When this option is checked the first cut depth will be equal to the Max
cut amount, where the area of the entire level is machined. Next, the levels above that first cut will be
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machined. Only the material that was not removed in the previous pass will be removed in these
subsequent passes.
The setting Adaptive stepdown will create a more efficient toolpath by generating Z-levels the constant
depth utilizing the tool’s flute length and then it will come back and add the Z depths based on the
Ro

Scallop height setting.

For example, if we want to take a Z depth of 15mm depth of cut on the Pocket in pattern, the adaptive
stepdown option will generate Z depths of 15mm each but then come back and machine the 1.5mm

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

scallops before moving on to the next Z depth

2
02
e2
9. Set the Adaptive step parameter
a. Click on the Adaptive stepdown option

ng
b. Set the Max cut amount to 15mm

e
all
Ch

c. Click on the Preview button to generate and preview the toolpath

bo

Hit Flats. When the Hit flats checkbox option is checked, the cut amount will be adjusted to add a pass
to machine the flat areas to maintain the Z allowance specified in the Surface Finish group box.
10. Click on the option to Hit flats
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

2
02
e2
11. Set the Limits
a. Under Limits, set the Last cut at to Bottom of Feature

12. Insert avoid area.

a. Click on the Geometry tab
e ng
b. Under User defined avoid area, click on the Create button
all
Ch

c. Insert avoid area for the four counter bored holes. We can program this geometry in
different operations.
d. Select the shown edges
bo
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

e. For Shape, select Multiple

2
02
f. Under Avoid Areas, select the option to Machine over

g. Click OK

e2
13. Generate Toolpath
14. Simulate the toolpath

e ng
all
To clean up the flat surfaces that are perpendicular to the machining direction, we can insert a Flat Area
operation. This will take the multi surface feature and create a 2axis pocket toolpath using a flat endmill
on the flat surfaces of the feature.
Ch

15. Insert a Flat Area operation.

a. Right click on Mill Part Setup1, and select 3 Axis Mill Operation, Flat area
bo
Ro

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

2
02
e2
e
b. Select T05 – 20 Flat End for the tool.
ng
c. Click on the Features tab and select Multi Surface Feature1 as the selected feature
all
Ch
bo

d. Click OK
Flat Area tab
In the Flat Area operation parameters, there is only one tab that is specific to the area clearance
operation.
Ro

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

The Surface Finish options control how close the

toolpath will run to the finished part.

2
02
Direction Control controls the milling direction,
whether the cut will be climb or conventional

e2
The XY parameters control the stepover for each
pass

Axial offsetting options control how many passed

the generated toolpaths will take in Z.
e ng
all
The Limits options control the starting and end
depth of the tool path
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16. Edit operation parameters on the Flat area operation

a. Click on the Flat Area tab
b. Under XY parameters, set the Max stepover % to 60
bo
Ro

c. Click OK
17. Insert Avoid Area
a. CRTL drag and drop the Avoid area from Area Clearance1 to Flat Area1
18. Generate toolpath

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Area Clearance and Flat Area operation parameters

19. Simulate toolpath

2
02
e2
ng
20. Save

e
all
Ch
bo
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

Case Study: Z Level Operation Parameters

Generally, the Z Level cycle is a finish contouring cycle that removes material by making a series of

2
horizontal planar cuts. The cuts follow the contour of the feature at decreasing Z levels based on the
Surface Finish you specify. In most cases, cutting starts from the highest location on the model and

02
works down.
1. Open Part
a. Open the part ZL_CS.SLDPRT in the …\Lesson_05\Case Study folder
b. Click on the CAMWorks Feature Tree tab and the CAMWorks CommandManager tool
bar

e2
Here we see the operations that were completed in the last case study. The Z Level operation is the only
operation in the tree that hasn’t been generated
2. Generate the toolpath
a. Generate toolpath for Z Level1.
Notice that the CAMWorks also generated toolpath in the counterbored holes. Also notice that the

ng
toolpath doesn’t extend all the way to the bottom of the part.

e
all
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We can copy the avoid area from Flat Area1

We will also need to adjust the automatic contain area settings to allow the toolpath to be generated to
bo

the bottom of the feature.

3. Insert Avoid area for the counterbored holes
a. Expand Flat Area1 and Z Level1.
b. CRTL drag and drop the Avoid Area from Flat Area1 to Z Level1 to copy the avoid
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area

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

2
02
e2
4. Adjust the Automatic contain area
a. Edit Z Level1 and go to the Geometry tab.
b. Under the Automatic contain area section, change Tool condition to be Past and click
Preview to preview the toolpath

e ng
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Ch
bo

Z Level tab
The Z level tab controls the Surface finish, Direction, depth parameters and Limits of the Z level
operation
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

The Surface Finish options control how close the

toolpath will run to the finished part.

2
02
e2
Direction Control controls the milling direction,
whether the cut will be climb or conventional

Depth parameters
There are two cut types available in Z Level, Z Level
and Helical.
e
The Cut type: Z Level gives us parallel passes at a
constant Z Depth. With Method set to Constant
each Z level pass will occur at the same Z depth.
ng
all
The Cut Type: Helical strategy is like Z Level
machining; however, the toolpath is constantly
descending in Z in a helical motion. The advantage
of this approach is that it minimizes the number of
lead-in moves required. It is most suited to parts
Ch

where the change in XY shape is regular as Z

changes.
bo
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Method. Like the setting in the Area Clearance operations, we have the option to set the Z level method
to Constant and Scallop. When set to Constant, the Z levels will be consistent with the Cut amount

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

parameter. If we set it to Scallop the depth of each Z level pass will vary based on the slope of the part
surface.

2
02
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

The Limits options control the starting and end

depth of the tool path

2
• By slope will limit the toolpath by the slope of
the feature
• Contact areas only will generate the toolpath

02
only where the tool touches the feature

e2
Constant stepover settings control whether a
Combination cycle is initiated. The combination

ng
cycle will generate a constant stepover toolpath
for the areas of the feature where the slope is
shallow based on the Min angle and Max angle
e
5. Adjust the Z Level parameters
all
a. Change the view in the graphics are to a front view of the part. Notice the Z depth is the
same for each pass
Ch
bo

b. Click on the Z Level tab

c. Under Depth parameters, change the Cut type to Helical
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

2
02
d. Click Preview

e2
e
Notice the toolpath moves down in Z with each depth
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6. Change the method to Scallop
a. Change the Method to Scallop
b. Set Scallop to 0.5mm
Ch
bo

c. Click Preview.
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

2
02
e2
Notice how the Z level changes where there are more passes when the slope of the part is more shallow
The Hit flats checkbox will force the toolpath to generate a Z level on flat faces. Since the flat face has
already been cut with previous operations, we will leave this option unchecked.

ng
Constant Stepover. The constant stepover option lets us create a combination cycle that creates a
constant stepover toolpath on those surfaces of the features that have a more shallow slope.
The Cut amount is the stepover for the constant stepover toolpath
e
The Min and Max angles define a range in which the toolpath will generate a constant stepover toolpath
all
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7. Enable the Constant Stepover

a. Change the Cut type to Z Level
b. Check on the Combination cycle check box
c. Set the Cut amount to 2mm
bo
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d. Click the Preview button to view the results

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

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02
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Limits. In the Area clearance parameters we have the ability to limit the depth of the toolpath using the
First cut from and Last cut at options. In the finishing operations, Z Level, Pattern Project, and Constant
Stepover, we can also limit the toolpath that gets generated by the slope of the features. We can also
e
limit the tool path to only cut those surfaces where the tool will come in contact.
all
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When the By slope parameter is checked the areas machined are limited by the Min and Max angle.
When the Contact areas only parameter is checked on, toolpaths will be generated only where the tool
bo

is in contact with the feature faces and surfaces.

8. Set the limits using By Slope
a. Uncheck the Combination Cycle check box
b. Check the By Slope
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c. Set the Min angle to 45deg and the Max angle to 80deg

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

2
02
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d. Click on Preview to generate the toolpath

e ng
e. Set the Min angle and Max angle back to 0deg and 90deg respectively
all
f. Click Preview to generate the toolpath
Links tab
One more setting that affects the Z level toolpath is found in the Links tab. By default, the Z level
toolpath starts at the top of the feature and moves to the bottom of the feature.
Ch

We can also have the toolpath generate from the bottom of the feature first and move up the feature
with each successive pass.
This parameter is found on the Links tab
bo

9. Set the tool path to start at the bottom

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a. Click on the Links Tab.

b. Check on the Bottom up check box
c. Click on the Preview button

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Case Study: Z Level Operation Parameters

10. Step through the toolpath to show the tool starting from the bottom

2
02
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11. Save part file

e ng
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 10 – Insert Area Clearance Operation (Part 1)

Exercise 10 – Insert Area Clearance Operation (Part 1)

Create a new Area Clearance operation and modify the operation parameters

2
This exercise will reinforce the following skills from Lesson 5:
• Area clearance operation parameters from the

02
pattern tab
o Pattern types—Pocket out
• Area clearance operation parameters from the Area
Clearance tab

e2
o Depth parameters
o Adaptive stepdown
• Automatic contain area
• Flat Area operation parameters
Procedure:
1. Open Part

ng
a. Open AC_EX.SLDPRT from the …\Lesson_05\Exercises folder
b. In this part the Machine, Stock and Coordinate system have already been defined
2. Insert a Mill Part Setup
a. Create a new Mill part setup on the underside of the part using the selected face
e
all
Ch

b. In the Mill Setup property manager, click on the Multi-Surface Feature check box. For
bo

the Strategy, select Area Clearance, Z Level

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 10 – Insert Area Clearance Operation (Part 1)

2
02
e2
c. Click OK

ng
3. Generate Operation Plan
4. Edit Area Clearance1 and set the following:
a. On the Tool, Tool Crib tab: select T02 10MM CRB 2FL 22 LOC as the tool to use for
this operation
e
all
Ch

b. On the Geometry tab, under Automatic contain area, set the Method to Outer
Silhouette
bo
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c. On the Entry/Retract tab, set the Ramping Method to Plunge

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 10 – Insert Area Clearance Operation (Part 1)

2
02
5. Edit the Pattern tab parameters

e2
a. Click on the Pattern tab
b. Set the Pattern to Pocket Out
c. Set the Max stepover % and Min stepover % to 50 and 25 respectively

e ng
all
6. Edit the Area Clearance tab operation parameters
a. Click on the Area Clearance tab
b. Under Depth parameters set the Method: to Scallop.
c. Set the Max cut amount: to 13mm
Ch

d. Set the Scallop step: to .25mm

e. Check Adaptive stepdown checkbox
f. Check Hit Flats checkbox
bo
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g. Under Limits, set the Last cut at to User Defined. Click on the Pick point icon .
Select a vertex point on the bottom face of the cavity as shown:

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 10 – Insert Area Clearance Operation (Part 1)

2
02
e2
h. Click OK
7. Generate toolpath

e ng
all
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8. Insert Flat Area operation

a. Insert Flat area operation
b. Select T02 – 10.00 Flat End as the tool
c. Select Multi Surface Feature1 as the feature
bo
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 10 – Insert Area Clearance Operation (Part 1)

9. Set the operation parameters

a. On the Flat Area tab set the following:

2
02
e2
b. Click OK
10. Generate toolpath
11. Simulate toolpath
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 11 – Insert Area Clearance Operation (Part 2)

Exercise 11 – Insert Area Clearance Operation (Part 2)

Create a new Area Clearance operation and modify the operation parameters

2
This exercise will reinforce the following skills from lesson 5:
• Area clearance operation parameters

02
from the pattern tab
o Pattern types— Pocket in
• Area clearance operation parameters
from the Area Clearance tab

e2
o Depth parameters
o Adaptive stepdown
• Automatic contain area
• Flat Area operation parameters
Procedure:
1. Open Part

ng
a. Open AC_EX_02.SLDPRT from the \Lesson_05\Exercises folder
b. In this part the Machine, Stock and Coordinate system have already been defined
c. Also, a mill part setup with operations have been setup to machine the other side of the
part
2. Insert a Mill Part Setup
e
a. Create a new Mill part setup on the top face of the part using the selected face as
all
shown
Ch
bo

b. In the Mill Setup property manager, click on the Multi-Surface Feature check box. For
the Strategy, select Area Clearance, Z Level
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 11 – Insert Area Clearance Operation (Part 2)

2
02
e2
ng
c. Click OK
3. Generate Operation Plan
4. Edit Area Clearance1 and set the following:
a. On the Geometry tab, under Automatic contain area, set the Method to Stock and the
Tool condition to Past
e
all
Ch

b. On the Entry/Retract tab, set the Ramping Method to Plunge

bo

5. Edit the Pattern tab parameters

a. Click on the Pattern tab
Ro

b. Set the Pattern to Pocket in - Core

c. Set the Max stepover % and Min stepover % to 50 and 25 respectively

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 11 – Insert Area Clearance Operation (Part 2)

2
02
e2
6. Edit the Area Clearance operation parameters
a. Click on the Area Clearance tab
b. Under Depth parameters set the Method: to Constant

ng
c. Set the Cut amount: to 1.25mm

e
all
d. Click on the Geometry tab and create a User defined avoid area on Area Clearance2
e. Select the shown edge:
Ch
bo
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f. Under Direction 1 set the end condition to Blind and the Distance to 3mm

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 11 – Insert Area Clearance Operation (Part 2)

2
02
g. Under Avoid Areas, select Machine Over

e2
h. Click OK
i. Click OK
7. Generate Toolpath
a. Generate the toolpath on Area Clearance2

ng
8. Simulate toolpath

e
all
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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 12 – Z Level operation

Exercise 12 – Z Level operation

Modify the operation parameter of a Z level operation

2
This exercise will reinforce the following skills from Lesson 5:
• Z Level operation parameters

02
• Depth parameters
o Cut Type: Z level or Helical
o Method: Constant or Scallop
• Limits

e2
o By slope
o Contact areas only
• Constant step over
• Links tab: Depth processing: Bottom up
Procedure:

ng
1. Open Part
a. Open ZL_EX.SLDPRT from the \Lesson_05\Exercises folder
b. Go to the CAMWorks Operations tree. Area Clearance and Flat Area operations have
already been defined for both sides of the part
c. Also, Multi-surface features have already been defined in the CAMWorks Feature tree
e
2. Insert Z level operation for the cavity side of the part
a. Under Mill Part Setup1, insert new Z-Level operation
all
b. For the tool use T07 – 4 Ball Nose
c. Select Multi Surface Feature1 as the feature
d. Click OK
Ch
bo

3. Edit Operation Parameters

Ro

a. On the Z Level tab, under Depth parameters, set the Cut type to Z level
b. Set the Method to Constant
c. Set the Cut amount to 0.5mm

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 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 12 – Z Level operation

2
02
e2
d. Under Constant stepover, check on the Combination cycle check box and set the Cut
amount to 1mm

ng
e. On the Links tab, under Links set the Max link distance to 15mm
e
all
Ch

f. Click OK
4. Generate toolpath
5. Insert Z Level operation for the core side of the part
a. Under Mill Part Setup2 insert a Z Level operation
b. For the tool, use T09 – 12 Ball Nose
c. Select Multi Surface Feature2 as the feature
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167 | P a g e
 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 12 – Z Level operation

2
02
e2
d. Click OK
6. Edit Operation Parameters

ng
a. On the Z Level tab, set the under Depth Parameters, set the Cut type to Helical
b. Set the Method to Scallop
c. Set the Scallop to 0.02mm
d. Check on the Hit flats checkbox
e
all
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e. Click on the Links tab, under Links set the Max link distance to 15mm
f. Check on the Bottom up option
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168 | P a g e
 Lesson 5—Area Clearance and Z Level Operation Parameters, Exercise 12 – Z Level operation

2
02
e2
g. Click on the Geometry tab, under Automatic contain area, set the Tool condition to
Past

h. Click OK
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7. Generate Toolpath
8. Simulate Toolpath
a. Simulate the toolpath of both Mill Part Setups
Ch
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 Lesson 6—Pattern Project

Lesson 6—Pattern Project

2
Upon Successful completion of this lesson, you will be able to:
• Insert and adjust the parameters of a Pattern Project operation

02
• How to program with the pattern types
o Slice
o Radial
o Spiral
o Flowline

e2
• Use a Contain area to contain a 3-axis toolpath
• Use the Curve wizard to define the curve geometry for Flowline curves

e ng
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 Lesson 6—Pattern Project

The Pattern Project operation is a 3-axis finishing operation type that removes material based on the
selected pattern: Slice, Flowline, Radial and Spiral. Generally, these patterns are projected onto the

2
model surfaces with the tool stepping over with a constant value in X and Y. These patterns have unique
characteristics that make them appropriate for semi-finishing and finishing selected areas or the entire

02
model.

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

Case Study: Working with the Pattern Project Operations—Slice pattern part 1
In this case study, we will insert a new pattern project operation that uses a slice pattern. A slice pattern

2
uses a series of linear parallel cuts that move across the part at a constant distance. This pattern can be
used for Semi finishing and finish machining of non-vertical areas of a part.

02
1. Open Part
a. Open the part PP_CS_SLICE.SLDPRT in the …\Lesson_06\Case Study folder.
b. Click on the CAMWorks Feature tab and CAMWorks CommandManager tool bar.
c. A coordinate system has been defined and a Mill Part Setup1 has been inserted.
2. Insert new Multi-Surface Feature

e2
a. Right Click on Mill Part Setup1 and select Multi Surface Feature or click on the
Feature\Multi Surface Feature icon on the CAMWorks CommandManager toolbar.

b. For the Feature Type, select All Displayed

e ng
c. For the Strategy select Area Clearance, Pattern Project
all
Ch

d. Click OK to insert the feature.

3. Generate operation plan
Two operations will be generated based on the selected strategy Area Clearance, Pattern Project.
There will be an Area Clearance and a Pattern Project operation.
bo
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We will need to constrain the Pattern project toolpath so that it doesn’t machine the top face of the
part.

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

4. Generate toolpath for both operations

2
02
e2
5. Insert Contain area

ng
a. Edit Pattern Project1 and click on the Geometry tab
b. Click on the Create button under User defined contain section
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all
c. For the Edge Selection, select Constant depth loop
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d. Select the top edge of the cavity and notice the closed loop is selected.
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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

e. Under Offset section, select the icon for Tool Upto Curve

2
02
f. Click OK to insert the contain area and the toolpath will regenerate.
g. Click Preview and notice the change in the toolpath.

e2
6. Edit the Pattern Project1 operation
e ng
all
a. Click on the Pattern tab.
b. Under Pattern type, set the Pattern to Slice
Ch

Pattern Type
Here is where we control the parameters related to the pattern project operation. The following
patterns are available to us and will be explained in depth in this lesion:
bo
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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

Slice – uses a series of parallel passes across the

part. The angle of the cut can be controlled

2
through the operation parameters. Typically, this
is used for machining non-vertical areas.

02
e2
Radial – typically used for round shapes, this
pattern will generate a toolpath in a radial
pattern into or out from a user-defined center

ng
point and can be limited to a defined angular
range.
e
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Spiral – also used for round shapes, the toolpath

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generated will spiral out from a user-defined

center point
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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

Flowline – produce toolpath based on two user-

specified curves. The generated toolpath can

2
either be parallel or perpendicular to these
curves

02
e2
ng
Since this case study we are dealing with the slice pattern we will talk about the options related to the
Slice pattern type. Later, we will talk about the Radial, Axial, and Flowline.
Pattern Options
The pattern options for the slice pattern type are:
• Cut angle
• Cross machining
e
• Extension
all
• Tangent extension
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Cut Angle – Cut angle is the angle that the slice pattern will take based off the X axis.
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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

Cross Machining – Cross machine is used to clean up those areas in the toolpath where the toolpath
could not reach in one direction. For example, since this toolpath is set for 90degs the walls will have

2
extra material and need to be cleaned up. Cross machining will clean this up.

02
e2
Here are the Cross-machining options:

ng
• None—this will generate only the toolpath at the specified angle
• Standard—generates a perpendicular tool path after the slice toolpath
• Before—a perpendicular toolpath is generated before the Slice toolpath
• Only—Only the perpendicular toolpath is generated
e
all
Ch

Extension – The Extension option is used to specify the length a pass extends past the edge of the
boundary to move into the cut at machining feedrate rather than rapid feedrate.
Tangent Extension – The Tangent Extension option will generate the toolpath tangent to the toolpath
bo

edge
c. Under Pattern options, set the Cut angle to 45deg.
d. Check on the Tangent extension checkbox and set the Extension to 5mm
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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

2
02
e2
XY Stepover
The XY stepover controls how the toolpath steps over. We can set it for a typed in distance, control by a
scallop height or the percent of the diameter of the tool.

Method
e ng
• Distance – sets the distance between cuts based on the cut amount parameter
all
• Scallop – Scallop refers to the material left on the theoretical surface between two successive
tool passes. The scallop is a theoretical scallop and will be computed based on the current tool
and a flat surface that is parallel to the XY plane. The stepover will be constant across the part.
The smaller the scallop, the greater the number of cuts or passes and the smoother the surface
finish.
Ch

• Percent – Sets the distance between the passes based on a percentage of the tool diameter

e. Under the XY stepover settings, set the Method to Distance and set the Cut amount to
1.5mm
bo

7. Preview toolpath
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a. Click on the Preview button

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

2
02
e2
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8. Simulate toolpath
a. Click on the Simulate toolpath in the upper corner on the minimized Operation
Parameters dialogue
Since there is a lot of toolpath to simulate with this operation is can take several minutes to simulate the
e
toolpath if the simulation mode is set to Tool mode. Setting the simulation to Turbo mode will allow us
to skip to the end of the program to see what material is removed from the operation.
all
b. Set the simulation to Turbo mode.
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c. Notice the toolpath in the corner of the pocket.

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179 | P a g e
 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

2
02
e2
d. Click OK to exit the simulation

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e. Click on the X in the corner of the minimized operation parameters dialog to maximize
it
9. Set the Cross-Machining parameters
a. Click on the Pattern tab, under Pattern options, set the Cross-machining to Standard
e
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b. Click OK
10. Generate toolpath
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11. Simulate the toolpath using Turbo mode

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

Case Study: Working with the Pattern Project Operations – Slice Pattern part 2
In this case study we with work with controlling how the tool stays in contact with a Surface feature

2
when it finishes a pass using the slice pattern. Take a look at the image below:

02
e2
e ng
all
To completely machine the top surface, the tool will flow over the edges. In some case this might not be
ideal.
Ch

If we try to use an Automatic contain area to constrain the toolpath it can leave the edges uncut
bo
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

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02
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1. Open Part
e ng
This case study shows how to control the tool to keep it tangent to the surface all the way out to the
edge of the feature

a. Open the part PP_CS_SLICE_01.SLDPRT in the …\Lesson_06\Case Study folder.

b. Click on the CAMWorks Operation Tree tab and CAMWorks CommandManager tool
all
bar.
c. Examine the 2.5 axis operations that have already been defined.
Ch
bo

2. Insert new Multi Surface Feature

a. Click on the CAMWORKS Feature Tree tab
Ro

b. Right Click on Mill Part Setup1 and select Multi Surface Feature or select on Mill Part
Setup1 in the CAMWorks Feature Tree tab, click on the Feature, Multi Surface Feature
icon on the CAMWorks CommandManager toolbar.

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c. For Feature Type, select All Displayed
d. For Strategy, select Area Clearance, Pattern Project

e ng
all
e. Click OK to insert the feature
3. Generate Operation Plan
a. Right Click on Multi Surface Feature1 and select Generate Operation Plan
Ch

This will generate two 3 axis operations in the CAMWorks Operation Tree. We will start by
modifying the Area Clearance operation to remove the material for the finishing pattern project
operation.
4. Edit Area Clearance1 operation parameters
a. Edit Area Clearance1 and change the following parameters:
b. On the Pattern tab, change the Pattern Type to Pocket in – Core
bo

c. On the Area Clearance tab, under Depth parameters, check on the Adaptive stepdown
check box
Ro

d. Set the Cut amount to 5mm

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

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02
e. On the Links tab, change the Depth processing to To depth by region

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f. On the Entry/Retract tab, set the Ramping Method to Plunge and the Retract Method
to Full

e ng
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g. Click on the Geometry tab
h. Under the User defined contain are section click on the Create button
Ch
bo

i. Under the Shape section of the Contain Area property manager, select Multiple
j. For the Selected Contours, select the two angles surfaces
k. Under the Offset section, set the Tool condition to Tool On Curve
Ro

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l. Click OK
m. Click OK to the operation parameters
5. Generate toolpath
e
a. Generate the toolpath for Area Clearance1
ng
all
Ch
bo

6. Insert Contain area on Pattern Project Operation

a. Copy Contain Area1 from Area Clearance1 to Pattern Project1 using CRTL+Drag and
Drop
Ro

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ng
7. Generate toolpath

e
all
Ch

8. Simulate toolpath
a. Right Click on Pattern Project1 and select Simulate toolpath…
bo
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

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b. Under Navigation, set the dropdown to Up to Current

c. Run Simulation
e
d. Click on the Show Difference icon
ng
all
Ch
bo

Notice the tool does not remove all of the material at the ends of the part. We can modify the contain
Ro

area to allow the tool to machine past the boundary of the contain area.

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

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9. Edit Contain Area
a. Edit Contain Area3 under Pattern Project1
b. Under the Offset section, change the Tool condition to Tool Past Curve

e ng
all
c. Click OK
d. Generate Toolpath
Ch
bo

Notice how the tool move past the boundary of the contain area but it moves over the edge of the
angled surface.
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

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Ideally, we want the toolpath to extend past the surface without machining over the edge. To do this we
will first modify the feature to be based off of the two selected surfaces instead of All Displayed.

ng
We will then uncheck the waterfall end parameter which will force the tool tangent to the feature at the
ends.
e
all
Ch

Since we used a contain area on the Area Clearance operation, we will not have to make any
bo

modifications to that operation after we edit the multi surface feature.

10. Edit Multi Surface feature
a. Click on the CAMWorks Feature tree
b. Edit Multi Surface Feature1
Ro

c. Change the Feature Type to Faces or Surfaces

d. Select the shown surfaces at the Selected Faces

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

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e. Click OK
f. Regenerate the toolpaths
11. Edit Pattern Project1
a. Click on the CAMWorks Operation Tree

ng
b. Edit Pattern Project1
c. On the Entry/Retract tab, set the Ramping Method to Plunge

e
all
d. On the Finish tab, under Limits, uncheck the Waterfall ends check box
Ch
bo

e. Click OK
f. Generate toolpath
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Slice pattern part 1

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ng
12. Simulate toolpath
a. Run Toolpath Simulation
b. Show the Difference
e
all
Ch
bo
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns

Case Study: Working with the Pattern Project Operations—Radial and Spiral
patterns

2
The Radial pattern has unique characteristics that make it appropriate for round shaped parts.
With the Radial pattern, the toolpath is created in a radial pattern into or out from a user-defined center

02
point and covers an angular defined range.
13. Open Part
a. Open the part PP_CS_RADIAL_SPIRAL.SLDPRT in the …\Lesson_06\Case Study
folder.

e2
b. Click on the CAMWorks Feature tab and CAMWorks CommandManager tool bar.
c. A coordinate system has been defined and a Mill Part Setup1 has been inserted.
14. Insert new Multi-Surface Feature
a. Right Click on Mill Part Setup1 and select Multi Surface Feature or select on Mill Part
Setup1 in the CAMWorks Feature Tree, click on the Feature, Multi Surface Feature
icon on the CAMWorks CommandManager toolbar.

e ng
all
Ch

b. For the Feature Type, select All Displayed

c. For the Strategy select Area Clearance, Pattern Project
bo

d. Click OK to insert the feature.

Ro

15. Generate operation plan

Once again, two operations will be generated based on the selected strategy Area Clearance. Pattern
Project. There will be an Area Clearance and a Pattern Project operation.

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns

We will start by editing the Area Clearance operation to set the pattern to pocket in. We will also insert
a Flat Area operation to rough out the material for the pattern project operation.

2
02
e2
We can then edit the pattern project operation and set the pattern type to radial.
16. Edit Area Clearance1
a. Edit Area Clearance1

ng
b. Click on the Pattern tab
c. Under Pattern type, set the Pattern to Pocket In – Core
e
d. Click OK
all
17. Generate toolpath on Area Clearance1
Ch
bo
Ro

18. Insert Flat Area Operation

a. Right Click on Area Clearance1 in the CAMWorks Operation Tree and select 3 Axis Mill
Operations, Flat Area

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b. For the Tool, use T05 – 20 Flat End

ng
c. For the Feature, select Multi Surface Feature1

e
all
Ch

d. Click OK
19. Generate toolpath on Flat Area1
20. Edit Pattern Project1
a. Edit Pattern Project1
b. Click on the Entry/Retract tab
c. Under Ramping, set the Method to Plunge
bo
Ro

d. Click on the Pattern tab

e. Change the Pattern type to Pattern: Radial

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns

2
02
Notice the change in the parameters that are available.
There is an option to pick the center of the radial toolpath. Also notice the different options that are
now available to us:

e2
e ng
all

Pattern type
Ch

Pick Point—allows us to select the center point of the radial tool path. This default to X0, Y0
The X and Y parameters allows us to specify the center point of the radial toolpath toolpath in X and Y
Pattern options
Minimum radius—sets the minimum radius around the center point that the toolpath will be generated
to
bo

Maximum radius—determines the outer size of the toolpath

The Start angle and End angle define the angular region to machine.
Reverse stepover changes the starting point of the toolpath
Here we will show how these options work
Ro

f. Under Pattern options, set the Minimum radius to 6mm

g. Set the Maximum radius to 42mm

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns

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02
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h. Click Preview to generate the toolpath

e ng
all
i. Click on the X in the corner of the minimized operation parameter window to maximize
Ch

the operation parameters

j. Leave the Start angle set to 0deg and set the End angle to 180deg
bo
Ro

k. Click Preview to generate the toolpath

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns

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02
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a. Click on the X in the corner of the minimized operation parameter window to maximize

ng
the operation parameters
b. Click on the Reverse stepover box
e
all
Ch

c. Click Preview to generate the toolpath

bo
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ng
Notice the start point has changed.
We will go back and edit the end angle so that the toolpath generates for the entire 360 degrees
a. Click on the X in the corner of the minimized operation parameter window to maximize
the operation parameters
e
b. Change the End angle to 360deg
all
Ch

c. Click OK
21. Generate the toolpath
bo
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns

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22. Simulate Mill Part Setup1

e ng
all

We can also insert an operation that uses a spiral pattern. We will do this by copying the existing Pattern
Ch

project operation so that the same general operation parameters are already set
23. Copy Pattern Project1
a. CRTL drag and drop Pattern Project1 in the CAMWorks Operation Tree to copy the
operation.
b. Rename the operation to Pattern Project2
bo
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns

24. Edit Pattern Project2

a. Edit Pattern Project2

2
b. Click on the Pattern tab
c. Under Pattern type, change the Pattern to Spiral

02
e2
d. Under XY stepover, change the Cut amount to 1mm

e ng
The controlling parameters for this pattern type are the Center point, Minimum radius and Maximum
radius settings. These were copied over from Pattern Project1 so we will leave these values as they are.
all
We can also use the Clockwise checkbox to control the machining direction.
e. Under Pattern options, check on the Clockwise checkbox
Ch
bo
Ro

f. Click OK
25. Generate Toolpath

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Radial and Spiral patterns

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02
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level generates the toolpath at a constant Z amount.
e ng
The pattern project toolpath generates the toolpath by offsetting in X and Y a constant amount.
The spiral pattern type in pattern project is different from the helical pattern type in Z level in that the Z

With steeper slope geometry, we would get less passes generated with Pattern project, spiral pattern
that with Z Level, Helical pattern.
all
26. Simulate Mill Part Setup1
Ch
bo
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

Case Study: Working with the Pattern Project Operations—Flowline patterns

In this case study, we will examine a pattern project operation that uses a Flowline pattern. The flowline

2
pattern produces toolpath based on two user-specified curves.
1. Open Part

02
a. Open the part PP_CS_FLOWLINE.SLDPRT in the …\Lesson_06\Case Study folder.
b. Click on the CAMWorks Feature tab and CAMWorks CommandManager tool bar.
c. A Coordinate System has been defined and a Mill Part Setup1 has been inserted.
2. Insert new Multi-Surface Feature
a. Right Click on Mill Part Setup1 and select Multi Surface Feature or click on the

e2
Feature, Multi Surface Feature icon on the CAMWorks CommandManager toolbar.

e
b. For the Feature Type, select All Displayed
ng
c. For the Strategy select Area Clearance, Pattern Project
all
Ch

d. Click OK to insert the feature.

3. Generate operation plan
CAMWorks will automatically create two operations, and area clearance and a pattern project. This is
bo

based on the strategy that was selected in the previous step that was preset in the Technology
Database.
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

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02
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We will start by editing Area Clearance1 to rough out the material for the Pattern Project finishing
operation.
4. Edit Area Clearance1
a. Click on the Pattern Tab
b. Under the Pattern type, set the Pattern to Pocket in – Core

ng
c. Click OK
d. Generate toolpath on Area Clearance1
e
all
Ch

5. Edit Pattern Project1

bo

a. Edit Pattern Project1

b. Click on the Pattern tab
c. Under Pattern type, set the Pattern to Flowline.
Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

The following options allow us to define the flow line pattern.

2
02
Curve 1 and Curve 2 buttons will launch the Curve wizard in the SOLIDWORKS property manager that
allow us to select curve geometry. This geometry can either be model edges or SOLIDWORKS sketches.
Curve Wizard Dialogue Box

e2
The following boxes are used to define the curve geometry for a flowline curve:
Selection Mode – Allows us to change the way we
select the geometry for the flowline curve. Face
selection option allow use to select a single face.
Window select multiple faces at a time or select
adjacent faces. Edge selection allows us to select

ng
single edges at a time, or a loop of edges that are
at a constant Z depth

Selected contours – list the edges, faces, or

sketches that have been selected to define the
flowline curve
e
all
Allowed sketches – will list the available sketches
that can be used to define the flowline.
Ch

Offset – allows us to offset the curve to either side

by a given amount
bo

Start Point – Allows us to flip the side of the curve

the toolpath will be fit to.
Ro

d. Click on the Curve 1 button

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

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02
e. Under the Selection Mode section, set Edge Selection Mode to Single Edge

e2
f. Select the top edge of the cavity in the graphics area

e ng
all
Ch

The white dot at the one end of the selected edges defines the start point of the curve. In the property
manage this can be changed under the start point options.
bo
Ro

g. Click OK to accept this as Curve 1. This will bring us back to the Operation Parameters
window

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

h. Click on the Curve 2 button

2
02
i. Click on the edge of the part below the fillet

e2
e ng
all
Notice the preview of the edge is projected onto a 2D plane.
Ch
bo
Ro

Also notice that the white dot at the end of that profile is at a different end than the previous curve.

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

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j. Change the Start Point to End of Curve

e ng
all
Ch

We can also offset the curve in either direction.

k. Offset the curve by 4mm
bo
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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

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ng
l. Click OK to accept this as Curve 2
We can control the direction of cut to be either along the two flow lines or across.
Along – will generate toolpath parallel to the
flowlines
e
all
Ch

Across – will generate toolpath perpendicular to

the flowlines
bo
Ro

m. Leave the cut option set to Along.

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

2
02
n. Click on the Geometry tab and set the Automatic contain area Method to Outer
Silhouette and the Tool condition to Past

e2
ng
o. Click on the Entry/Retract tab and under Ramping set the Method to Plunge

e
all

p. Click on the Links tab and under Links set the Max. link distance to 10mm
Ch
bo

q. Click on the Preview button

Ro

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

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02
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The pattern project toolpath produced a tool path that has a constant stepover in X and Y. we can see
that the generated tool path shows this but at the areas where the slope of the cavity surface is greater

ng
there are less toolpath generated which leaves extra material.

e
all
Ch

When we use the Flowline pattern in the Pattern Project toolpath we have an additional option to use a
3D step over which will produce a toolpath that steps over in constant X, Y and Z.
r. Click on the Pattern tab
s. Under XY stepover, check on the 3D Stepover check box
bo
Ro

t. Click OK

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 Lesson 6—Pattern Project, Case Study: Working with the Pattern Project Operations—Flowline patterns

6. Generate toolpath

2
02
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7. Simulate Mill Part Setup1
a. Simulate Mill Part Setup1
e ng
all
Ch
bo
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 Lesson 6—Pattern Project, Exercise 13 – Insert Pattern project operation using Slice pattern

Exercise 13 – Insert Pattern project operation using Slice pattern

Create a new pattern project operation using the Slice Pattern

2
This exercise will reinforce the following skills from Lesson 6:
• Using a Pattern project operation with the Slice Pattern

02
• Use a contain area to constrain the toolpath
• Utilize the pattern options of Cut angle
• Cross machining to optimize the toolpath
Procedure:

e2
1. Open Part
a. Open PP_EX_013.SLDPRT from the …\Lesson_06\Exercises folder
2. Define Machine
a. Use the following parameters:
i. Machine: Mill – Metric
ii. Tool Crib: Tool Crib 2 (Metric)

ng
iii. Post Processor: M3AXIS-TUTORIAL
3. Define Stock
a. Use the following parameter to define the stock type:
i. Stock Type: Extruded Sketch
e
ii. Select the SOLIDWORKS sketch, STOCK SKETCH as the sketch
iii. Set the End condition to Offset Face
all
iv. Select the opposite face of the part as shown
Ch
bo

v. Set the offset distance to 2mm

vi. Click OK
Ro

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 Lesson 6—Pattern Project, Exercise 13 – Insert Pattern project operation using Slice pattern

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02
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4. Define Coordinate System
a. Set the Method to User Defined
b. Use the Stock bounding box vertex option to define the origin
c. Select the Top Center point as the Coordinate system

ng
d. Define the Z direction as shown

e
all
Ch

e. Click OK
bo

5. Insert Mill Part Setup

a. Under Entity, select the Top Plane
b. Make sure the Z direction is set correctly
Ro

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 Lesson 6—Pattern Project, Exercise 13 – Insert Pattern project operation using Slice pattern

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ng
c. Check on the Multi Surface Feature check box
d. Set the Strategy to Area Clearance, Pattern Project
e
all
Ch
bo
Ro

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 Lesson 6—Pattern Project, Exercise 13 – Insert Pattern project operation using Slice pattern

6. Generate Operation Plan

a. Generate the Operation Plan

2
7. Edit Area Clearance1
a. Edit Area Clearance1 and set the following parameters
i. On the Pattern tab, Set the Pattern Type Pattern to Pocket In – Core

02
ii. On the Area Clearance tab, under Depth parameters, set the Cut amount to
1.5mm.
iii. Under Limits, set the Last cut at to User Defined
iv. Click on the Pick Point and select the shown point from the graphics area

e2
e ng
all
v. Under Offset set the Z value to -5mm
Ch

vi. On the Geometry tab, under Automatic contain area, set the Tool condition to
bo

Past
Ro

vii. Click OK to the operation parameters

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 Lesson 6—Pattern Project, Exercise 13 – Insert Pattern project operation using Slice pattern

8. Generate Toolpath
a. Generate toolpath for Area Clearance1

2
02
e2
9. Edit Pattern Project1

ng
a. On the Pattern tab, set the following parameters
i. Under Pattern type, set the Pattern to Slice
e
all
ii. Under Pattern options, set the Cut angle to 90deg
iii. Set Cross machining to Standard
iv. Set the Extension to 1mm
v. Check on the Tangent extension checkbox
Ch
bo

vi. Under XY stepover, set the Method to Scallop

vii. Set the Max scallop to 0.03mm
Ro

b. On the Geometry tab set the following parameters

i. Under Automatic contain area set the Tool condition to Past

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 Lesson 6—Pattern Project, Exercise 13 – Insert Pattern project operation using Slice pattern

2
02
c. Click OK
10. Generate toolpath

e2
e ng
all
11. Copy Pattern Project1
a. CRTL+drag and drop Pattern Project1 to copy it
Ch

b. Rename Pattern Project1 -Copy to Pattern Project2

bo

12. Edit Pattern Project2

a. Change the tool use for Pattern Project2 to T07 – 4.00 Ball Nose
b. Change the following parameters on the Pattern tab
Ro

i. Under Pattern Options, Set the Cut angle to 45deg

ii. Set Cross Machining to None
iii. Set Extension to 0mm

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 Lesson 6—Pattern Project, Exercise 13 – Insert Pattern project operation using Slice pattern

2
02
e2
iv. Under XY Stepover set the Method to Distance
v. Set the Cut amount to 0.5mm

c. Click on the Geometry tab

e ng
d. Under the User defined contain area section, click on the Create button
e. Insert a contain area using the shown edge as the contain area
all
Ch
bo

f. Under Offset, set the Tool condition to Tool Past Curve

Ro

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 Lesson 6—Pattern Project, Exercise 13 – Insert Pattern project operation using Slice pattern

g. Click OK
h. Click OK to the operation parameters

2
13. Generate Toolpath
a. Generate toolpath for Pattern Project2

02
14. Simulate Toolpath
a. Simulate Mill Part Setup1

e2
e ng
all
Ch
bo
Ro

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 Lesson 6—Pattern Project, Exercise 14 – Insert Pattern Project operation using Radial and Spiral Patterns

Exercise 14 – Insert Pattern Project operation using Radial and Spiral Patterns
In this exercise, we will insert pattern project operations that use the Radial and Spiral Patterns

2
This exercise will reinforce the following skills from lesson 6:
• How to program with the Radial and Spiral Pattern Types

02
Procedure
1. Open Part
a. Open PP_EX_014.SLDPRT from the …\Lesson_06\Exercises folder
b. Click on the CAMWorks Operation Tree. The Machine definition, stock, and coordinate

e2
system have already been defined. In addition to that, a mill part setup has with
operations have already been programmed.
c. Simulate the tool path

e ng
all
2. Insert Pattern Project operation
a. Insert new Pattern Project operation
b. Use T08 – 10 Ball Nose as the tool
Ch
bo

c. Use Multi Surface Feature1 as the feature for the Pattern Project operation
Ro

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 Lesson 6—Pattern Project, Exercise 14 – Insert Pattern Project operation using Radial and Spiral Patterns

2
02
e2
d. Click OK to insert the Feature
3. Edit Pattern Project1
a. Set the following parameters on the Pattern tab:
i. Under Pattern type, select the Pattern to Spiral
ii. Under Pattern Options, set the Minimum radius to 20mm

ng
iii. Set the Maximum radius to 65mm

e
all
Ch

iv. Under XY stepover, Set the Cut amount to 1mm

bo

b. Set the following parameter on the Geometry tab:

i. Under Automatic contain area, set the Method to All Silhouettes
ii. Set the Tool condition to On center
Ro

c. Click OK
4. Generate Toolpath for Pattern Project1

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 Lesson 6—Pattern Project, Exercise 14 – Insert Pattern Project operation using Radial and Spiral Patterns

2
02
e2
5. Copy Pattern Project1
a. Using CRTL+Drag and Drop, copy Pattern Project1
b. Rename Pattern Project1 – Copy to Pattern Project2

e ng
all
6. Edit Pattern Project2
Ch

a. On the Pattern tab, set the following parameters:

i. Under Pattern type, set the Pattern to Radial
ii. Under Pattern options, set the Minimum radius to 65mm
iii. Set the Maximum radius to 135mm
bo
Ro

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 Lesson 6—Pattern Project, Exercise 14 – Insert Pattern Project operation using Radial and Spiral Patterns

b. Click OK
7. Generate Toolpath for Pattern Project2

2
02
e2
8. Simulate toolpath
e ng
all
Ch
bo
Ro

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 Lesson 6—Pattern Project, Exercise 15 – Insert Pattern Project operation using Flowline pattern

Exercise 15 – Insert Pattern Project operation using Flowline pattern

In this exercise, we will create a pattern project operation that uses a flowline pattern between two

2
curves.
This exercise will reinforce the following skills from Lesson 6:

02
• Create a program using a flowline pattern
• Using the curve wizard to define flowline curves
Procedure
1. Open Part

e2
a. Open PP_EX_015.SLDPRT from the …\Lesson_06\Exercises folder
b. Click on the CAMWorks Operation Tree. The Machine definition, stock, and coordinate
system have already been defined. In addition to that, a mill part setup has with
operations have already been programmed. Among these operations in an Area
Clearance that uses a previously defined Multi-Surface Feature
c. Also notice that there in an un-generated operation in the CAMWorks Operation tree.

ng
d. Simulate the tool path

e
all
Ch

2. Edit Pattern Project1

a. On the Tool, Tool Crib tab, select T07 – 4mm Ball Nose
b. Set the following parameters on the Pattern Tab
i. Under Pattern type, set the Pattern to Flowline
bo
Ro

ii. Define Curve 1, In the Curve Wizard, select the top out edge of the cavity as
shown:

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 Lesson 6—Pattern Project, Exercise 15 – Insert Pattern Project operation using Flowline pattern

2
02
e2
iii. Click OK to insert Curve 1
iv. Define Curve 2, In the Curve Wizard for select the top inside edge of the cavity
as shown:

e ng
all
Ch

v. Click OK to insert Curve 2

vi. Under XY Stepover, set the Cut amount to 1mm
vii. Check on the 3D Stepover Checkbox
bo
Ro

c. On the Finish tab, set the following parameters:

i. Under Direction Control, select Zig

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 Lesson 6—Pattern Project, Exercise 15 – Insert Pattern Project operation using Flowline pattern

2
02
d. Click OK
3. Generate Toolpath
a. Generate toolpath for Pattern Project1

e2
e ng
all
4. Simulate toolpath
a. Simulate Mill Part Setup1
Ch
bo
Ro

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 Lesson 7—Constant Stepover

Lesson 7—Constant Stepover

2
Upon successful completion of this lesson, you will be able to:
• Define a Constant Stepover operation and adjust the operation parameters

02
• Understand Direction Control: Reverse priority
• Modify Pass options
o Offset curve: Contain Only vs Contain and avoid
o Number of Cuts
o Axial Offsetting

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

Case Study: Constant Stepover Operation parameters

In this case study, we will be inserting a new constant step over operation and adjusting it parameters.

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The Constant Stepover operation is a 3-axis finishing operation that removes material by maintaining a
constant user-defined stepover relative to the surface. This operation can be used for semi finishing and

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finish of surfaces and cavities.

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1. Open Part
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a. Open the part CS_CS_01.SLDPRT in the …\Lesson_07\Case Study folder.
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b. Click on the CAMWorks Feature tree tab and CAMWorks CommandManager tool bar.
c. Notice that the Machine, Stock and Coordinate System have already been defined
2. Insert Mill Part setup
a. Insert a Mill Part Setup on the top face of the part.
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b. Check on the Multi surface feature checkbox and for Strategy, select Area Clearance,
Constant Stepover.

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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c. Click OK
3. Generate Operation Plan
a. Generate the operation plan

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4. Edit Area Clearance operation
a. Change the tool for Area Clearance1 to T03 – 20 Flat End (Go the CAMWorks Tool
Tree tab, drag Area Clearance1 from T05 – 20 Flat End to T03 – 12 Flat End)
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5. Generate Toolpath
a. Generate the toolpath for Mill Part Setup1
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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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Notice that the toolpath for Constant Stepover1 is machining the top surface. We will want to constrain
the toolpath to the cavity. To do this, we can insert a Contain area and use the top edge of the cavity as

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the bounding area.
6. Insert contain area
a. Edit Constant Stepover1 and click on the Geometry tab
b. Under User defined contain area click on the Create button
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c. In the Contain Area property manager, under Edge selection, select Constant Depth
Loop

d. Select the top edge of the cavity as shown

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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e. Under Offset, set the Tool condition to Tool on curve

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f. Click the OK to finish inserting the contain area.
g. Click Preview
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Examine the resulting toolpath. Notice the stepover of the toolpath is based on the perimeter of the
cavity, or the contain area that was inserted.
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Notice the shape of the toolpath follows the outside of shape of the cavity with each successive pass.
We can also influence how the tool path converges to its center with each pass.
In the Contour Mill Operation Parameters, there are the Pass options controls Constant Stepover tab.

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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Contain Only – the toolpath machines continuously from the Contain Area to the Avoid area following
the Contain Area shape

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Contain and Avoid – The toolpath will machine continuously from the Contain Area to Avoid Area based
on both areas.
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7. Insert an avoid area.

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a. Click on the “X” to expand the operation parameters

b. Under User defined avoid area, click on the Create button

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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c. In the Avoid area property manager, under Selected Contours, select the middle
surface as shown

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d. Under Offset, set the Tool condition to Tool On Curve
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e. Click the OK to finish inserting the avoid area.

f. Click Preview
Examine the resulting toolpath. Notice the pattern of the toolpath still conforms to the geometry of the
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contain area. We can constrain the toolpath to conform to both the contain area and the avoid area.
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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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g. Click on the Constant Stepover tab.
h. Under Pass options, set the Offset curve to Contain and Avoid.
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i. Click on the Preview button to generate the toolpath
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Examine the generated toolpath. It now conforms to the geometry of the contain area and the avoid
area.

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

Number of cuts
We can control the number of passes the tool make by clicking on the Number of cuts check box and

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entering a number. If the Offset curve method is set to Contain Only then the number of cuts will only
be applied to the contain area contour.

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If the Offset curve setting is set to Contain and Avoid then the number of cuts that are generated will
be for each offset curve. For example, if we enter in 5 for the Number of cuts, there will be five passes
offset from the Contain geometry and an additional 5 passes offset from the Avoid area geometry.
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The direction of cut is controlled by the Reverse Priority and Reverse order checkboxes
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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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We can make copies of the operation Contour Mill1 to finish the remainder of the cavity.
j. Click on the X in the upper right corner of the collapsed Operation Parameters window
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k. Under Pass options, set the Constant cut amt to 1mm and click Preview to generate the
toolpath.
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l. Click OK to the operation parameters

8. Generate toolpath
a. Generate toolpath for Constant Stepover1
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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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9. Copy Contour Mill1
a. CRTL+Drag and Drop Constant Stepover1 in the CAMWorks Operation Tree to Copy the

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operation

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10. Edit Contain area

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a. Edit the contain area under Constant Stepover1 - Copy

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b. Remove the Loop selected under the Selected Contours selection and replace it with the
shown selection
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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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c. Click OK to the Contain Area Property Manager

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d. Delete the Avoid area under Constant Stepover1 - Copy
11. Generate toolpath
a. Generate toolpath for Constant Stepover1 - Copy
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12. Simulate toolpath

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a. Simulate tool path for Mill Part Setup1

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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cleanup these areas.
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Since we used a 10mm Ball endmill additional operations will be required to clean up the areas where
the 10mm Ball endmill was too big. In the next lesson, we will learn how to use a Pencil mill operation to

We can also use some of the settings in a constant stepover operation to clean up these toolpaths
13. Insert Constant Step over operation
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a. Insert new Constant Stepover operation
b. Select T07 – Ball Nose as the tool
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c. For the Feature, use Multi Surface Feature1

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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d. Click OK to insert the operation
14. Edit the Operation Parameters
a. Click on the Constant Stepover tab
b. Under Pass Options, set the Constant cut amt to 0.5mm

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c. Click on the Number of cuts checkbox
d. Set the Number of cuts to 12
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e. Click OK
15. Insert Contain Area
a. Insert Contain area on Constant Stepover2
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b. Set the Edge selection to Single edge

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c. Select the shown entity in the graphics area as the Selected Contour
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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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d. Under Offset, set the Tool condition to Tool on Curve
e. Set the Offset distance to 1.5mm
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f. Click OK to insert the new contain area
16. Generate toolpath
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a. Generate toolpath for Constant Stepover2

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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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17. Simulate Toolpath

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a. Simulate the toolpath for Mill Part Setup1
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The same techniques from constant stepover2 can be used in cleaning up the other areas of the cavity
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 Lesson 7—Constant Stepover, Case Study: Constant Stepover Operation parameters

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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

Exercise 16 – Insert Constant Stepover Operation

This exercise will reinforce the following skills from Lesson 7:

2
• Defining a Constant Stepover Operation and adjusting the operation Parameters
• Modifying pass option

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Procedure:
1. Open Part
a. Open CS_EX_016.SLDPRT from the …\Lesson_07\Exercises folder
2. Define Machine

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a. Use the following parameters:
i. Machine: Mill – Metric
ii. Tool Crib: Tool Crib 2 (Metric)
iii. Post Processor: M3AXIS-TUTORIAL
3. Define Coordinate System
a. Edit the Coordinate system

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b. Set Method to User Defined
c. Set Origin to Stock bounding box vertex
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d. Select the top center node as the coordinate system

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e. Orient the coordinate system axis as shown

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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

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f. Click OK

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4. Insert Mill Part Setup
a. Insert Mill Part Setup using the top face of the part
b. Check on the Multi Surface Feature checkbox and set the Strategy to Area Clearance,
Constant Stepover
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c. Click OK to finish inserting the new mill part setup

5. Generate Operation Plan
a. Generate the operation plan
6. Generate Toolpath for Area Clearance1
a. Generate Tool path for Area Clearance1
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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

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7. Insert Contain Area

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a. Edit Constant Stepover1
b. On the Geometry tab, add a Contain area
c. Select the highlighted faces below for the selected contours
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d. Under Offset, set the Tool Condition to Tool on Curve

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e. Click Preview
8. Insert Avoid Area
a. Add a User defined avoid area for Constant Stepover1
b. Select the highlighted face for the Selected Contour
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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

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c. Under Offset, set the Tool Condition to Tool on Curve

d. Click OK
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9. Edit the Operation Parameters for Constant Stepover1
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a. Click on the Constant Stepover tab, under Pass Options, set the Offset curve to Contain
and Avoid
b. Set the Constant cut amt to 1mm
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c. Click OK
10. Generate toolpath for Constant Stepover1
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a. Generate the toolpath for Constant Stepover1

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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

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11. Insert Pattern Project operation

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a. Insert new Pattern Project operation
b. For the Tool, select T08 – 10 Ball Nose
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c. For the Feature, select Multi Surface Feature1

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d. Click OK
12. Edit Pattern Project Operation
a. Edit the new Pattern Project operation

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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

b. Click on the Pattern tab, under XY stepover set the Cut Amount to 1mm

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c. Click on the Geometry tab
d. Under User defined contain area, create a new contain area

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e. Select the highlighted face for the Selected Contour

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f. Under Offset, set the Tool Condition to Tool on Curve
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g. Click OK
h. Click OK
13. Generate Toolpath
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a. Generate Toolpath for Pattern Project1

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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

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14. Insert Constant Stepover operation

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a. For the Tool, select T07 – 4 Ball Nose

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b. For the Feature, select the existing Multi Surface Feature1

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c. Click OK
15. Edit Constant Stepover2
a. Click on the Constant Stepover tab

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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

b. Under Pass Options click on the Number of cuts checkbox

c. Set the Number of cuts to 15

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d. Set the Constant cut amt to 0.75mm

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e. Click on the Geometry tab
f. Under User defined contain area, create a new contain area
g. Select the four edges around as shown below:

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h. Under Offset, change the offset value to 1.5mm
i. Set the Tool Condition to Tool Past Curve
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j. Click OK
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k. Click OK
16. Generate Toolpath
a. Generate Toolpath for Constant Stepover2
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 Lesson 7—Constant Stepover, Exercise 16 – Insert Constant Stepover Operation

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17. Simulate Toolpath

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a. Simulate Toolpath for Mill Part Setup1

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 Lesson 8—Pencil Mill

Lesson 8—Pencil Mill

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Upon successful completion of this lesson, you will be able to:
• Insert a Pencil Mill Operation and modify its parameters

02
• Understand the following Pencil mill Pattern types
o Trace
o Parallel Lace
o Mixed

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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

Case Study: Working with a Pencil Mill Operation

The Pencil Mill operation is used to create a finishing toolpath that finishes areas of a multi surface

2
feature that have radii of curvature less than the radius of the tool. This can be done in one pass or
multiple passes depending on the pattern parameters selected in the operation parameters.

02
In the last lesson, we used a Constant Stepover operation to clean up a corner on the cavity by
manipulating the number of passes. The Pencil Mill operation does this automatically

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1. Open Part
a. Open the part P_01_01.SLDPRT in the …\Lesson_08\Case Study folder.
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b. Click on the CAMWorks Feature tab and CAMWorks CommandManager tool bar.
c. Notice that the Machine, Stock and Coordinate System have already been defined
2. Insert Mill Part setup
a. Insert a Mill Part Setup on the Front Plane as the reference entity.
b. Click on the Reverse Selected Entity button to ensure that the setup direction is
correctly oriented
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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

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c. Under Features, check on the Multi surface feature check box
d. Set the Strategy to Area Clearance, Constant Stepover
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e. Click OK
3. Generate Operation Plan
a. Generate the Operation Plan for Multi-Surface Feature1
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4. Edit operation parameters

a. Edit the operation Area Clearance1
b. On the Pattern tab, under Pattern type, set the Pattern to Pocket in – Core

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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

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c. Click OK

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d. Edit Constant Stepover1
e. On the Constant Stepover tab, under Pass Option, set the Constant cut amt to 1mm

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f. Click OK
5. Generate Toolpath

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a. Generate Toolpath for Mill Part Setup1
6. Simulate toolpath
a. Simulate the toolpath for Mill Part Setup1
b. Use Turbo mode
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There are areas of the part where the 10mm Ball Endmill cannot reach. The Pencil Mill operations can
be used to clean up these areas.

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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

By default, a pencil mill operation is not automatically generated from the Generate Operation Plan
command. This is because the strategy Area Clearance, Constant Stepover does not have a pencil mill

2
operation set up in the default Technology Database for that strategy.
We can insert a Pencil Mill interactively.

02
7. Insert Pencil Mill operation
a. Insert a Pencil Mill operation

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b. For the Tool, select T07 – 4 Ball Nose
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c. For the Feature, select Multi-Surface Feature 1

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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

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d. Click OK to insert the operation
8. Edit Pencil Mill operation parameters
a. Edit Pencil Mill1

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In the Pencil Mill operation, we have the following pattern types:
Trace – The Trace pattern will generate a
single pass toolpath that runs parallel to the
corner area.
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The toolpath will be generated at locations
where the radius of curvature of the Multi-
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Surface feature is greater that the tool
radius
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Parallel Lace – The Parallel lace pattern will

generate multiple passes parallel to the
corner area.

The toolpath will be generated at locations

where the radius of curvature of the Multi-
Surface feature is greater that the tool
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radius
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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

Mixed – The Mixed pattern will generate a

toolpath that will machine the steep and

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shallow areas using a reference tool to
determine where to cut

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Trace Pattern
The following options are used when using the Trace pattern:
Overthickness – This option sets an additional temporary radius to the tool when generating toolpath.
This will allow for toolpath to be generated in areas where the radius of curvature is greater than the

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tool radius. As an example, if the tool is 4mm and the feature include a fillet with a radius of 5mm, you
would specify an Overthickness of 1mm or more.
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Bitangency angle – This option allows you to set an angular tolerance that controls how CAMWorks
calculates the areas to be machined. When the angle formed between two adjacent faces becomes very
large, it may not be necessary to generate a pencil mill toolpath. The Bitangency angle defines the
minimum angle required between the two contact point normals for the cutter position to be
considered and a pencil milling toolpath generated. The figure below defines the Bitangency angle.
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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

As the angle formed between two adjacent faces gets larger, the bitangency angle becomes less.

2
Therefore, to machine further into corner areas where the angle formed by adjacent faces is large, you
must decrease the value of the bitangency angle. Typically, the default setting of 20 degrees produces

02
good results; however, the value depends on the part being machined.

Parallel Lace
The following options are available when using the Parallel Lace pattern:
Overthickness – This option sets an additional temporary radius to the tool when generating toolpath.

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This will allow for toolpath to be generated in areas where the radius of curvature is greater than the
tool radius. As an example, if the tool is 4mm and the feature include a fillet with a radius of 5mm, you
would specify an Overthickness of 1mm or more

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Bitangency angle – The Parallel lace pattern also uses the Bitangency angle parameter as explained
above.

Number of cuts – This option sets the number of passes generated with this toolpath. When checked
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the number of cuts is applied to the toolpath. If the check is not selected, the parallel cuts will be
generated across the entire Multi-Surface feature.
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Cut Amount – Defines the distance between each pass.

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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

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Mixed
The following options are available when the Mixed pattern is selected:
Steep Threshold – this option defines the angle used to identify the split between steep and shallow

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areas. In the steep areas, the cuts will be horizontal.
In Figure 1 below, the Steep threshold is set to 90deg. This results in the toolpath running parallel to the
corner areas. If we set the Steep Threshold angle to a lesser value, the vertical corner areas that are at
an angle greater than that angle will produce horizontal cuts. We can see this in Figure 2. If I go to an
even lesser Steep Threshold angle the entire vertical area is now machined with horizontal cuts as show
in Figure 3.

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Figure 1 - Steep Threshold angle set to 90deg

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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

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Figure 2 - Steep Threshold Angle set to 75deg. This results in parallel and horizontal cuts

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Figure 3 - Steep Threshold angle set to 60deg results in horizontal cuts

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Horizontal cut amt – This parameter defines the distance between each non-vertical pass
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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

Vertical cut amt – This parameter defines the distance between each vertical parallel pass

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part model.
b. Click on the Pattern tab
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c. Under Pencil mill type set the Pattern to Trace
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Mixed reference tool, Cut diameter – This parameter defines the reference tool diameter. This value
represents the hypothetical previous tool that CAMWorks will use to recognize the uncut areas on the
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d. Click on the Entry/Retract tab
e. Under Retract, set the Method to Full
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f. Click OK
9. Generate Toolpath
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a. Generate the toolpath for Pencil Mill1

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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

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10. Simulate Toolpath
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Simulating Area Clearance1 and Constant Stepover will take time to simulate. For the purposes of
this lesson, we will define the stock using an STL file that has the same geometry the machined part
would have after Area Clearance1 and Constant Stepover1
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a. Edit Stock Manager
b. Set the Stock Type to STL file
c. Click on the Browse button and select P_01_01.stl in the Lesson_08\Case Study folder
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d. Click OK
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e. Click Yes to the Stock update warning box dialogue box

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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

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f. Simulate Pencil Mill1

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11. Edit the operation

a. Edit Pencil Mill1
b. Click on the Pattern tab
c. Under the Pencil mill type change the Pattern to Parallel Lace
d. Check on Number of Cuts checkbox
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e. Set the Number of cuts to 10

f. Set the Cut amount to 0.3mm
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 Lesson 8—Pencil Mill, Case Study: Working with a Pencil Mill Operation

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g. Click OK
12. Generate Toolpath
a. Generate toolpath for Pencil Mill1

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13. Simulate Toolpath

a. Simulate toolpath for Pencil Mill1
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 Lesson 8—Pencil Mill, Exercise 17 – Pencil Mill Operation

Exercise 17 – Pencil Mill Operation

This exercise will reinforce the following skills from Lesson 8:

2
• Defining a Pencil Mill Operation and adjusting the operation Parameters
• Change the pattern to Mixed

02
Procedure:
1. Open Part
a. Open P_01_EX.SLDPRT from the …\Lesson_08\Exercises folder
2. Click on the CAMWorks Operation tree

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a. Click on the CAMWorks Operation Tree
b. Examine the existing operations
c. Simulate the toolpath

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3. Insert Pencil mill operation

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a. Under Mill Part Setup1 insert a new Pencil Mill operation

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b. For the Tool, select T08 – 10 Ball Nose

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 Lesson 8—Pencil Mill, Exercise 17 – Pencil Mill Operation

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c. For the Feature, select the existing Multi Surface Feature1

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d. Click OK to finish inserting the Pencil Mill Operation
4. Edit Pencil Mill operation
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a. Edit Pencil Mill1

b. Click on the Pattern tab, under the Pencil mill type, set the Pattern to Parallel Lace
c. Uncheck the Number of cuts checkbox
d. Set the Cut amount to 0.75mm
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e. Click on the Links tab

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 Lesson 8—Pencil Mill, Exercise 17 – Pencil Mill Operation

f. Set the Max. link distance to 5mm

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g. Click on the Entry Retract tab

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h. Under Vertical leadin/out, set the Leadin radius to 0mm
i. Set the Leadout radius to 0mm
j. Set the Leadin Length to 0mm
k. Set the Leadout length to 0mm

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l. Click on the Geometry tab
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m. Create a New Contain Area for the cavity as shown
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n. Under Offset, set the Tool condition to Tool on Curve

o. Click OK
p. Click OK
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5. Generate Toolpath
a. Generate Toolpath for Pencil Mill1

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 Lesson 8—Pencil Mill, Exercise 17 – Pencil Mill Operation

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6. Insert Pencil mill operation
a. Under Mill Part Setup1 insert a new Pencil Mill operation

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b. For the Tool, select T07 – 4 Ball Nose
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c. For the Feature, select the existing Multi Surface Feature1

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 Lesson 8—Pencil Mill, Exercise 17 – Pencil Mill Operation

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7. Edit Pencil Mill operation
a. Edit Pencil Mill2
b. Click on the Pattern tab, under Pencil mill type set the Pattern to Mixed

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c. Set the Steep Threshold to 60deg
d. Under Pass options, set the Horizontal cut amt to 0.5mm
e. Set the Vertical cut amt to 0.5mm
f. Under Mixed reference tool, set the Cut diameter to 10mm
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g. Click on the Entry Retract tab

h. Under Vertical leadin/out, set the Leadin radius to 0mm
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i. Set the Leadout radius to 0mm

j. Set the Leadin length to 0mm
k. Set the Leadout length to 0mm
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 Lesson 8—Pencil Mill, Exercise 17 – Pencil Mill Operation

l. Under Retract, set the Method to Skim

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m. Click OK
8. Insert contain area
a. Expand Pencil Mill1

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b. CRTL+Drag and drop Contain Area8 from Pencil Mill1 into Pencil Mill2

9. Generate Toolpath
a. Generate toolpath for Pencil Mill2
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b. Examine the corners

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 Lesson 8—Pencil Mill, Exercise 17 – Pencil Mill Operation

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10. Edit Pencil Mill operation
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a. Edit Pencil Mill2 and click on the Pattern tab
b. Under Pencil mill type, change the Steep threshold to 90deg
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c. Click OK
11. Generate Toolpath
a. Generate toolpath for Pencil Mill2
b. Examine the corners
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 Lesson 8—Pencil Mill, Exercise 17 – Pencil Mill Operation

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12. Simulate Toolpath
a. Simulate the toolpath for all setups
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 Lesson 9—Curve Project

Lesson 9—Curve Project

2
Upon successful completion of this lesson, you will be able to:
• Define a Curve Project operation and modify its parameters

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 Lesson 8—Pencil Mill, Case Study: Working with a Curve Project operation

Case Study: Working with a Curve Project operation

The Curve Project operation removes material by projecting a selected 2.5 Axis Engrave and/or Curve

2
features onto the surface of a Multi Surface feature and generating toolpaths along the projected
entities.

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1. Open Part
a. Open CP_01_01.SLDPRT from the …\Lesson_09\Case Study folder.
b. Click on the CAMWorks Operation tree tab and CAMWorks 2021 CommandManager
tool bar.
c. Notice that the Machine, Stock and Coordinate System have already been defined.
2. Simulate toolpath
a. Click on the CAMWorks Operations Tree Tab
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b. An Area Clearance operation and a Pattern Project operation has been already defined.
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 Lesson 9—Curve Project, Case Study: Working with a Curve Project operation

c. Simulate the toolpath to see what is already there

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d. Click OK

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e. Click on the CAMWorks Feature Tree tab
A Curve project operation requires either a 2.5 axis Engrave Feature or a Curve feature to project onto
the multi surface feature. Before we get started, we will need to define one of these features.
The Engrave/Curve feature needs to meet the following criteria to be used for a curve project operation
•
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The Engrave/Curve feature needs to be on the same setup as the Multi Surface feature used in
the curve project operation.
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• The depth of the Engrave/Curve feature does not matter.
• When defining an Engrave feature from a 2D sketch, the allowable sketch entities include lines,
arcs, splines, and Text objects. Text must be in a sketch without the other entity types unless it
has been exploded.
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3. Insert Engrave Feature

a. Under Mill Part Setup1, create a new Engrave feature
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 Lesson 8—Pencil Mill, Case Study: Working with a Curve Project operation

b. Select Sketch5 from the Available Sketches for this feature

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4. Insert a Curve Project operation
a. Click on the CAMWorks Operation tree
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b. Insert a new Curve Project operation
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c. Click on the End Condition button (The end condition does not matter)
d. Click OK to insert the engrave feature
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The tool we will use for this operation isn’t set up in the tool crib for this part. We will need to add a
1mm Ball endmill to the toolcrib
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 Lesson 9—Curve Project, Case Study: Working with a Curve Project operation

c. Click on the Add new button to add a new tool to the tool crib
d. In the Tool Select Filter, set the Tool type to Ball Nose

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e. Select a 1mm Ball endmill

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f. Click OK to insert the tool
g. Select on the inserted tool
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h. For the feature, select Multi Surface Feature1

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 Lesson 8—Pencil Mill, Case Study: Working with a Curve Project operation

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i. Click OK to insert the Operation

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5. Edit operation parameters
a. Edit Curve Project1 and click on the Curve Project tab.
b. Under Curve features to project, click Add.
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c. In the Add Engrave/Curve Feature box, select the feature Engrave Feature1 from the
list of Available features and click Add ->
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d. Click OK to the Add Engrave/Curve Feature box

e. Under Surface finish, set the Z Allowance to -0.5mm
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 Lesson 9—Curve Project, Case Study: Working with a Curve Project operation

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f. Click on the Entry/Retract tab
g. Under Ramping, set the Method to Plunge

h. Click OK
6. Generate Toolpath
a. Generate Toolpath
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b. Hide Sketch5 from in the SOLIDWORKS Feature Tree
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7. Simulate toolpath
a. Hold down SHIFT, Right Click and select Simulate toolpath
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 Lesson 8—Pencil Mill, Case Study: Working with a Curve Project operation

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b. Simulate toolpath

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 Lesson 9—Curve Project, Exercise 18 – Curve Project Operation

Exercise 18 – Curve Project Operation

This exercise will reinforce the following skills from Lesson:

2
• Defining a Curve Project Operation and adjusting the operation Parameters
• Define an Engrave Feature

02
• Set the Engrave Feature as the projection curve
Procedure:
1. Open Part
a. Open CP_01_EX.SLDPRT from the …\Lesson_09\Exercises folder

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2. Insert New Mill Part Setup
a. Use the Front Plane as shown

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b. Check on the Multi surface feature checkbox and set the Strategy to Area Clearance,
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Pattern Project
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c. Click OK to insert the feature

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 Lesson 8—Pencil Mill, Exercise 18 – Curve Project Operation

3. Insert a new Engrave Feature

a. Under Mill Part Setup1, insert a new engrave feature

2
b. Under Available Sketches, use Sketch24

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c. Click on the End Condition button
d. The end condition does not matter. Leave this distance at the default
e. Click OK
4. Insert new Curve project feature
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a. Click on the CAMWorks Operation Tree
b. Under Mill Part Setup1, insert new curve project operation
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c. For the Tool, add a new 1mm Ball Endmill from the library
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 Lesson 9—Curve Project, Exercise 18 – Curve Project Operation

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d. Select Multi Surface Feature1 as the feature

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 Lesson 8—Pencil Mill, Exercise 18 – Curve Project Operation

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e. Click OK
5. Edit operation parameters
a. Click on the Entry/Retract tab
b. Under Ramping, set the Method to Plunge

c. Click on the Curve Project tab

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d. Under Curve features to project, click Add to add the engrave feature
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e. In the Add Engrave/Curve Feature dialogue box, under the Available features list,
select Engrave Feature1 and then click on Add -> to add it to the Feature list
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f. Click OK
g. Under Surface finish, set the Z allowance to -0.5mm

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 Lesson 9—Curve Project, Exercise 18 – Curve Project Operation

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h. Click OK
6. Generate Toolpath

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7. Simulate Toolpath
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 Lesson 10—3 Axis Undercut

Lesson 10—3 Axis Undercut

2
Upon successful completion of this lesson, you will be able to:
• Use a Z-Level operation to cut an undercut on a multi-surface feature

02
• Use a Multi-Axis operation to cut undercut on a multi-surface feature

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 Lesson 10—3 Axis Undercut

In this lesson, we will examine the methods of programming for 3-axis undercut. In CAMWorks, this can
be done with one of two different operation types, Z-Level and Multi-axis.

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Multi Axis operation.
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We will start by showing programing an undercut with a Z-Level operation. Next, we will introduce the
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This section can also serve as an introduction to multi-axis programming.
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 Lesson 10—3 Axis Undercut, Case Study: 3-Axis Undercutting using a Z-Level Operation

Case Study: 3-Axis Undercutting using a Z-Level Operation

In this case study, we will define a Z-level operation to program geometry that has an undercut. We will

2
be using a keyway or a lollipop cutter to cut the undercut geometry.
1. Open part

02
a. Open the part UC_EX_01.SLDPRT in the \Lesson_10\Case Study folder
b. Click on the CAMWorks Operation tree and CAMWorks CommandManager tool bar.
c. An Area Clearance and Constant Stepover operation have already been defined on this
part.
d. Notice the geometry of that part has some undercut geometry

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2. Simulate the toolpath
a. Run toolpath simulation to show the existing operations
b. Notice the existing operations aren’t able to cut the entire geometry because of the
undercut geometry

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3. Insert Z-Level Operation

a. Insert new Z Level operation
For the Z Level operation, the ability to cut undercut geometry is enabled through the selection of a
Lollipop or Keyway cutter.
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One of these tool types has been added to the tool crib.
b. For the Tool, select T14 – 14 Lollipop
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 Lesson 10—3 Axis Undercut, Case Study: 3-Axis Undercutting using a Z-Level Operation

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c. On the Feature tab, select Multi-Surface Feature1

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d. Click OK to insert the operation

4. Edit Operation Parameters
a. Click on the Z Level tab
b. Under Depth parameters, set the Cut amount to 1.0mm
c. Under Limits, set Last cut at to User Defined
d. Set the shown point for the User Defined point
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 Lesson 10—3 Axis Undercut, Case Study: 3-Axis Undercutting using a Z-Level Operation

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e. Click OK
f. Generate Toolpath e ng
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5. Simulate toolpath

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 Lesson 10—3 Axis Undercut, Case Study: 3-Axis Undercutting using a Z-Level Operation

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

Case Study: 3 Axis Undercutting using a Multi Axis Operation

This case study can serve as an introduction to the Multi-Axis operation. Typically, the Multi-Axis

2
operation is used for four and five axis simultaneous operations. The Multi-Axis operation can also be
used for three axis toolpaths including undercuts.

02
For this case study, we will start with generating 3 axis toolpath on a simple surface followed by
generating a 3 axis undercut toolpath.

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1. Open Part
a. Open UC_EX_02.SLDPRT from the \Lesson_10\Case Study folder
b. Click on the CAMWorks Feature Tree
c. A Coordinate System has been defined and a Mill Part Setup1 has been inserted.
When defining a new Multi Surface feature there are 5 different feature types available. These were
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discussed in greater detail in Lesson 2.

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While all these feature types can be used in three axis programming it is most common to use the All
Displayed and defining contain and avoid areas to constrain the toolpath for the 3 Axis operations
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discussed so far.

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

When using the Multi-Axis operation however, we exclusively use the Faces or Surfaces feature type.
The resulting toolpath will be constrained to only the surfaces selected as part of the Multi-Surface

2
feature.
2. Insert a new Multi Surface Feature

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a. Insert a new Multi Surface Feature

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b. For the Feature Type select Faces or Surfaces
c. Set the Strategy to 3 Axis Under Cut
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d. For the Selected Faces select the shown surfaces in the graphics area
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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

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e. Click on the Show normal checkbox

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The selected surfaces in the graphics area will now show a green arrow. This arrow shows which side of
the face the surface normal is.
When selecting surfaces from any solid body geometry or surfaces that have been offset from a solid
body, the surface normal is established and this step is not necessary.
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This option can be used when defining a multi surface feature from a revolved or extruded surface. The
normal direction can be reversed by selecting the surface in the Selected Faces box and toggling on the
Reverse Direction button .
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By reversing the direction of the surface normal, we can tell CAMWorks which side of the Multi-Surface
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feature we want to machine.

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

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f. Click OK to insert the Multi Surface Feature

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

3. Generate Operation Plan

a. Generate the operation plan for Multi Surface1

2
4. Change Tool for the operation
a. Click on the CAMWorks Tool Tree
b. Drag the Multi Axis Mill1 from T14 – 19.5 Keyway to T08 – 10 Ball Nose

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5. Edit the Operation Parameters Axis Control tab
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a. Click on the CAMWorks Operations tree
b. Edit Multi Axis Mill1
c. Click on the Axis Control tab
When programming for 4 and 5 axes, the Axis Control tab controls the tilt of the tool relative to the
Multi Surface feature.
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For this example, the Number of axis is set to 3 Axis. This parameter is set to this by the 3 Axis Under
Cut strategy in the Technology Database. If the CAMWorks license doesn’t include 4 or 5 axis milling, this
will be the only option on the list
6. Edit Operation Parameters
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a. Click on the Pattern tab

In the Multi axis operation there are seven types of patterns we can use. When selecting on any of these
pattern types the associated parameters are made available. For example, if we select the pattern type
called Offset from curve, a curve button appears that allows us to define the offset curve.

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

The following is a list of the seven pattern types. More detail on each of these patterns is discussed in
the 5-axis training or the help documentation

2
Slice – Creates toolpaths that are parallel to each
other. The direction of the cuts is defined by the

02
two angles

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Cuts Across Curve – Generates a toolpath
orthogonal to a selected curve

Flowline Between Curves – Generates toolpath

that morphs between two selected curves
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Offset from Curve – Creates toolpath segments

parallel to a selected curve
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Curve Projection – Generates a single toolpath

along a curve
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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

Flowline Between Surfaces – Generates toolpath

that morphs between two surfaces

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Offset from Surfaces – Generates cuts on the
surface that are parallel to a surface

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b. Under Pattern, set the Pattern to Flowline Between Curves

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c. Click on the Upper… button to define the upper flowline curve
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d. Select the shown model edge for the upper flowline curve
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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

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02
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e. Click on the Lower… button to define the lower flowline curve

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Select the shown model edge for the lower flowline curve
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g. Under Limits set the Method to Avoid Cuts At Exact Edges

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

This parameter will generate toolpath that avoids the feature surface edges. This can be useful to set
this way when the surface boundaries are not entirely smooth

2
h. Click on the Entry/Retract tab
The Entry/Retract Tab will control how the toolpath will begin and end. The following settings will let us

02
set up this toolpath
i. Under Clearance, set the Type to Plane in Z and set the Z Distance to 25mm

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j. Under Distances, set the Rapid length to 15mm and the Feed length to 5mm

k. Click on the Finish tab

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l. Under Options section, check on the Extend/Trim button
m. Click on the Extend/Trim options
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n. In the Extend/Trim dialogue box, under Tangent Extensions, set the Start and End
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values to 5mm respectively

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o. Click OK
13. Generate Toolpath
a. Generate toolpath
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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

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We will now use the same method to define a 3-axis undercut toolpath for the groove around the side
of the part

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14. Insert New Multi Surface Feature
a. Click on the CAMWorks Feature tab
b. Under Mill Part Setup1, create a new Multi Surface Feature
c. In the Multi Surface Feature property manager, set the Feature Type to Faces or
Surfaces
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d. Set the Strategy to 3 Axis Under Cut
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e. Select the shown faces of the groove around the sides of the part
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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

f. Click OK to insert the new Multi Surface feature

15. Generate Operation Plan

2
a. Generate Operation Plan
16. Change the tool type

02
a. Click on the CAMWorks tool tree
b. Drag Multiaxis Mill2 from T15 – 19.5 Keyway to T14 – 20 Lollipop

17. Edit Multiaxis Mill2 operation parameters

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a. Edit Multiaxis Mill2
Since the strategy for Multi Surface Feature was set to 3 Axis Undercut the parameters of the Multi Axis
Mill operations will be set based on this strategy from the technology database.
Therefore, the Number of Axis setting on the Axis Control tab will already be set to 3 Axis

b. Click on the Pattern Tab

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c. Under Pattern, set the Pattern to Flowline Between Curves
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d. For the Upper… curve select these edges as shown

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

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02
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e. For the Lower… curve select these edges as shown

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f. Under the Direction, set the Pattern to Zig

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g. Under Limits set the Method to Avoid Cuts At Exact Edges

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h. Click on the Entry/Retract tab

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

The Entry/Retract tab

The parameters for Leadin move and Leadout move allow us to approach the cut horizontally. The

2
Leadin and Leadout tabs let us set the distance and type of leadin and leadout cuts.

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i. Under Clearance, set the Type to Plane in Z

j. Set the Z distance to 25mm
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k. Under Distances, set the Rapid length to 15mm and set the Feed length to 5mm
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l. On the Leadin and Leadout tabs, under Parameters, select the Arc radial button and set
the Tool diameter % to 65%

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 Lesson 10—3 Axis Undercut, Case Study: 3 Axis Undercutting using a Multi Axis Operation

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m. Click OK in the operation parameters

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18. Generate toolpath
a. Generate toolpath for Multiaxis Mill2
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19. Simulate toolpath

a. Simulate Mill Part Setup1
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 Lesson 8—Pencil Mill

Exercise 19 – 3 Axis Undercutting

This exercise will reinforce the following skills from Lesson:

2
• Define a 3 Axis undercut toolpath using a multi-axis milling operation
Procedure:

02
1. Open Part
a. Open UC_01.SLDPRT from the \Lesson_10\Exercises folder
b. Click on the CAMWorks feature tree
2. Insert a Multi Surface Feature

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a. Under Mill Part Setup1 create a new multi surface feature
b. Set the Strategy to 3 Axis Undercut
c. For Select Faces, select the shown face

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d. Click OK to insert the new feature

3. Generate Operation Plan
a. Generate Operation Plan
4. Change tool
a. Change the tool from T15 – 19.5 Keyway to T14 – 20 Lollipop
b. This can be done either through the CAMWorks Tool tree or by editing the operation
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5. Edit operation parameters: Axis Control Tab

a. Edit Multiaxis Mill1
b. Click on the Axis Control Tab
c. Under Number of axis, make sure that the Number of Axis is set to 3 Axis
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 Lesson 10—3 Axis Undercut, Exercise 19 – 3 Axis Undercutting

6. Edit operation parameters: Pattern tab

a. Click on the Pattern tab

2
b. Under Pattern, set the Pattern to Flowline between curves

02
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c. For Upper… curve select the shown curve from the graphics area

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d. For Lower… curve select the shown curve from the graphics area
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 Index

e. Under Direction, set the Pattern to Zig

f. Under Limits, set the Method to Avoid Cuts At Exact Edges

2
g. Under Surface Finish, set the Max. stepover to 0.5mm

02
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7. Edit the operation parameters: Entry/Retract tab
a. Under Clearance, set the Type to Plane in X
b. Set the X distance to 50mm
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c. Click OK
8. Generate Toolpath
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9. Simulate Toolpath
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 Lesson 10—3 Axis Undercut, Exercise 19 – 3 Axis Undercutting

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 Lesson 8—Pencil Mill

Index

2
Multi Axis operation, 296
3 Multi Surface Feature
Face or Surface method, 40, 296

02
3 axis operations types, 8, 99 Multi Surface Features, 34
3D step over, 211
O
A
Operation Parameters
Area Clearance operation, 135 F/S Tab, 109

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Pattern types, 136 Tool Tab, 108
Automatic Contain Areas, 73 Operation Paramters
Automatic Feature Recognition (AFR), 16 Advanced Tab, 113
Avoid Areas, 65 Entry/Retract Tab, 112
Links Tab, 111
C NC Tab, 110
Posting Tab, 114

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CAMWorks NC Editor, 25 Rest Tab, 114
CAMWorks Workflow, 10 Statistics Tab, 114
Configuration Manager, 12
Options, 103
Constant Stepover operation, 228
Contain Areas, 22, 65
Coordinate System, 16 P
Copy Avoid Area, 147
ePattern Project operation, 170, 171
Copy Operations, 114
Flowline pattern, 203
Curve Project operation, 277
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Radial and Spiral pattern, 193
Curve Wizard Dialogue Box, 205
Slice Pattern, 172
Pencil Mill operation, 254
E Post process, 24
Post processor selection, 35
Engrave/Curve feature, 279
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F R
Rest Machining, 44, 84
Facet deviation, 102
Flat Area operation, 135
Force facet regeneration, 102 S
Simulate Toolpath, 19
G Spline Deviation, 102
Stock Manager, 12
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Generate Operation Plan, 18

Generate operations manually, 104
Generate Toolpath, 19 T
Tool
I Change the tool in the operation, 21, 115
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Interactive Feature Recognition (IFR)., 16

U
M User Interface, 8
Mill Part Setup, 36

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 Index

Z Z-Level operation
Undercutting, 292
Z Level operation, 147

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