A thousand words could be used to describe CAD. Entire books and educational curriculums have been created around it. In its simplicity, CAD is a word used to describe the “design” aspect of what our industry does. It stands for:

“Computer Aided Design.” Our software systems offer CAD functionality that allows the customer to design or draw their parts from start to finish. Primarily it is drawing software that allows the customer to create blueprints with dimensions that they can then priout and use for the manufacturing stage of making the part as well as models that can be viewed as if you were looking at the actual finished part for inspection and evaluationis also a part of the man

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In the end, CAD offers all of the necessary drawing and design functions to get the part laid out in order for the manufacturer to their job. This is probably the first most fundamental term that you must know. BobCAD-CAM software includes CAD design capabilities that are simple and that are easy to learn and use. This is another reason why our software is an effective product for manufacturers to use. Below you can see a 3 dimensional design and a solid render view of the same part.

3 dimensional design/drawing Rendered Model

A wireframe is a 2 or 3 dimensional frame of a part or drawing that represents the part and can also be used to create toolpath for machining. Here is a 3D wireframe drawing of a guitar:

Basically a wireframe is the lines and arc or drawn geometry segments that make up a model or part. You could literally relate it to an outline or skeleton of something. A wireframe can be used to create surfaces that toolpath can be applied to for 3D/3 Axis machining. Once again, a wireframe can be constructed in 2D or 3D. Not all parts are 3D. Below you can see a image of a model that is actually a 2D part that only contains hole types in it.

In CAD, a “Solid” is a standard series of shapes that are used to design something. They are: Sphere: Cube: Cone:

Cylinder: Torus:

These are the 5 basic solids. They are also referred to as “Primitives.” These shapes have depth, area and used together in conjunction with Solid Editing operations are used to create models. Here is an example part below that was created using some of these primitive solids along with special editing operations.

This is a word that is used in CAD-CAM software to generally describe the outer face or exterior of an object. CAD-CAM software is used to create the toolpath that will make the finished surface of a part. Surface toolpath usually has some sort of peak or valley type finish to it and is sometimes very complex. The example below shows the actual surfaces of the guitar used in the wireframe example.

Everything around you has a surface to it. Surfaces do not have to be flat. In fact, surfaces that are not flat like the bottom area of this guitar and the edges of the top and bottom are referred to as contours or contoured surfaces. In manufacturing, the last step of completing a part is to machine “Finish Surface Toolpath.” This usually produces a nice smooth surface finish when the finish machining is done. BobCAD-CAM not only allows you to design surfaces but you can also create finishing toolpath for surfacing and the g-code program. BobCAD-CAM software offers a complete series of surface features for constructing and working with various surface types.

Here are other surface-creation features that BobCAD-CAM software offers:

As you can see, there are many types of surfaces. BobCAD-CAM software also allows the customer to import various types of files that contain surfaces in them. Other CAD design software systems such as Solid Works or AutoCAD or PRO Engineer are all CAD design systems that can create surfaces as well. You can draw or construct a surface in another CAD system, save it as an IGES or STEP or STL file and bring it into BobCAD. You will learn more about other CAD systems and their native file types as well as which ones we support and which ones we do not support later in this training book.

BobCAD-CAM software offers advanced design and manufacturing capabilities and to this point we have discussed toolpath, types of machines and some CAD basics in terms of what a wireframe is and what a surface is. This leads us to, “Solid Modeling.” Solid Modeling is possibly the most revolutionary approach to modern engineering and manufacturing that has ever existed. This is the designing and creation of a part using wireframe design, surface creation and/or primitive solids to create a model. Solid Modeling is the term used to describe this activity. A solid model itself is the designed part when it is finished. There are many benefits to solid modeling. Some are:

The ability to visually see the product as you would see it when it is done. The ability to check and verify aspects of the part before spending machine time and money on

material. You can inspect the product before manufacturing takes place. The manufacturer can present the product to a customer for approval before manufacturing

has taken place. You can use advanced CAM systems to create toolpath directly from a solid model to machine

the part itself. This saves a lot of time. These are just a few good reasons why solid modeling is important. Here are some solid models of manufactured parts:

This is a solid model of a rubber dog bone that you would buy at the local pet store for your dog. It was designed in a CAD system as a solid model and consists of many surfaces that were created and stitched together to form a solid model.

Molds are designed as solid models for machining. Here are the negative and positive mold plates. Negative Mold Plate: Positive Mold Plate:

Once the solid model is created, the CNC programmer can generate the right toolpath directly from the model. Then the G-Code program is generated by a CAM system like BobCAD-CAM software.

In order to make an accurate mold for the part, a solid model is first created to represent the actual part itself along with its physical size, area and volume. Then the solid model is used to construct a mold. Solid modeling is typically used for more complex parts that require 3D design, 3-axis toolpath and corresponding g-code programs to be written. 2D wireframe drawings are typically used for flat 2D part programming with a CAD-CAM system. Here, you can see that 3D toolpath was created for the inside of the mold cavity.

BobCAD-CAM software is a complete solid modeling CAD-CAM system capable of solids based design, toolpath and g-code creation for both 2D and 3D models. This is advanced technology that over the last several years has become more common and more desirable for the manufacturer because of how fast new products can be created and manufactured for the market place. What used to take months of engineering, design and manufacturing can now take a matter of hours. There are higher levels of CAD and CAM functionality that have to do with solid modeling. However, this is the basics and is actually a prime example of how technology drives the economy.

The word “Hybrid” in CAD software is used to describe a system that has two kinds of methods that when used or put together produce the same result. This being said, we can discuss the use of both wireframe and surface creation functions to make a solid model. Have a look at the chart below.

As a hybrid system you can work with Wireframe, Surfaces or Solids in any order. For example, if you had a solid model and needed to extract edge geometry in order to create pocket toolpath, you could. See the example below.

There is more to this. In some cases the engineer may want to extract or get the wireframe geometry from a model. The reason for this is because the extracted wireframe geometry can be used in containing the toolpath that is created. Have a look at the example image below.

The wireframe geometry was extracted from this model for the purpose of toolpath containment. Here you can see an example of generating 3D toolpath inside of geometric boundaries. This is called toolpath containment or Boundary Machining and is a special feature that our BobCAD-CAM software provides.

This adds a new term: Toolpath Containment or Boundary Machining. This is important because some complex parts require different toolpath strategies to get the job done. This is another reason why BobCAD-CAM software fits the bill. We can do it. In the end, Hybrid Modeling is the ability to work with wireframe, surfaces and solids in any order necessary to accomplish the program.

Here is another concept that is important to CAD Design. To “Extrude” something means to force out or to force through a die. A die is a tool used for stamping or shaping something. An example of this would be the childrens toy where the child loads the clay and turns the crank to make what looks like spaghetti. Well, the piece that has the little holes that the spaghetti goes through would be the die and the process would be called, Extrusion. Get it? It’s literally that simple. Now, in CAD you can perform extrusions that are slightly different but still fall under the same concept. Have a look at the example image below.

Here you can see a flat surface and then the result of extruding the surface with a tapered angle. This would be called a “Tapered Extrusion” and is a function that BobCAD-CAM software offers. This is an important concept because you will talk to engineers that make extrusion dies and need functionality for both designing them and then machining them.

Here is a solid tapered extrusion with finishing toolpath on the inside tapered wall.

“2D” is a shortened term for two dimensions or a two dimensional drawing or part. 2D is described in the American Heritage dictionary as something that has no range or depth to it. Basically something that is flat. The term “2D” is used in our industry to refer to flat type work or machining flat parts that do not have complex curves to them. They are mostly flat. This requires simple machining and is something that BobCAD-CAM software can handle. Examples of how this term would be used:

“The machinist cuts mainly 2D parts.” “We do a lot of 2D type work.” “We are looking for a CAD-CAM system for making 2D parts.” “Our machine can only handle 2D jobs.” “We are looking to get out of just 2D and into more complex machining.” “BobCAD-CAM software allows you to design 2D parts and machine them easily.”

Examples 1: This would be considered a 2D part because it is basically flat and has no complex curves to it.

Example 2: Here is another part that is flat. This is a 2D part. Making this part would require flat 2D machining.

“3D” is a shortened term for three dimensions or a three dimensional drawing or part. Three dimensional is described in the American Heritage dictionary as having or appearing to have an extension in depth. The term “3D” is used in our industry to describe parts or anything having to do with parts that has extended depths involved. The images below are perfect examples of a 3D part.

You can see that there are curved areas that are not flat, even though there are also flat 2D areas of this part. Because this part has those curved depths, you would consider this to be a “3D Part.” Machining 3D parts is a more complicated task than machining a 2D part and requires that a CAD-CAM system have functions allowing a programmer or machinist to create 3D toolpath. Here are some examples of how this term would be used:

“I am looking at a few different 3D CAD-CAM systems.” “Right now all we do is 2D but would like to get into 3D.” “Do you offer any sort of 3D machining capabilities?” “We don’t do any 3D at all.” “BobCAD-CAM offers both 2D & 3D design and machining capabilities.” “I need something to take my 3D drawings and machine them.”

There is more to the concept of 2D & 3D. Aside from the toolpath aspect, you have a viewing aspect. You can have a 2D part being viewed in a 3D view or a 3D part being viewed in a 2D view. When you look at something in life you are seeing it in 3 dimensions. It has height, length, width and depth. This is 3D. In engineering and design, when you are drawing something in a CAD system, you want to be able to see it as closely defined as if the real thing was right there in front of you. This has a great benefit in the design process. In present times, most of the CAD-Design systems on the market allow you to draw and create as well as view the part as a model in 3D on the screen. BobCAD-CAM software offers these capabilities.

It is important to understand what types of CAD Files that BobCAD-CAM can open and work with. The following is a list of file types that we can read into our software. File names will appear with the name of the file, then a “.” and the file extension. Here is a list of extensions. Dxf files: We can read and write/save this file type. Iges files: We can read and write/save this file type. Step files: We can read and write/save this file type. Sat files (also known as ACIS). We can read and write/save this file type. AutoCAD .dwg files; Wireframe, Surfaces & Solids (native file format). We can read and

write/save this file type. SolidWorks .sldprt files (native file format). Read only. Parasolids X_T & X_B files. Read only. RhinoCAD .3dm (native file format). We can read and write/save this file type. Stl files: We can read and write/save this file type. Bbcd files (native to BobCAD). We can read and write/save this file type. These files can contain CAD geometry such as points, lines, circles, solids, surfaces and other entity types. Refer to this section as needed when you are asked about these files. The idea is that a customer who buys BobCAD-CAM software can use it with their existing CAD software. This is a BIG added value to their entire operation. If they have a CNC Machine they can open and machine the file directly without having to send the work out to another shop with a CAM system. Therefore, once again, some customers will receive a CAD file from one of their customers and will need to import one of these file types into BobCAD-CAM just for the machining capabilities that we offer. BobCAD-CAM is a recognized SolidWorks Solution Partner. Therefore we have permission to use the logo below on our website and our promotional materials.

This also is a word that has been written about, discussed a taught. Millions of dollars have been thrown at it for development and use! In its simplicity, CAM is a word used to describe the “manufacturing” aspect of what our industry does. It stands for:

“Computer Aided Manufacturing.” Our software systems offer CAM functionality that allows the customer to machine their parts from start to finish. Primarily it is manufacturing software and is the aspect of our software that allows the customer to determine how the part will be machined and finished. CAM software also creates a numeric language that is sent to the machine from the computer that basically tells the machine how to cut the part with a cutting tool. In the end, CAM offers all of the necessary machining and communication functions to get the part machined and delivered to the end

customer on time. This is the second most fundamental term that you must know. BobCAD-CAM software includes CAM functionality in it that will allow the manufacturer to create the part with the machine.

First of all, “Toolpath” is the path in which a cutting tool takes whether it is simple or complex, while cutting, to remove material from a block. Thus, you end up with a flat finished part.

Here you can see the tool is traveling along the flat 2D toolpath. The toolpath is only flat and has no curves that would make the tool travel up or down while moving in a direction. When you hear the term, “2D Toolpath” you now know that the toolpath is simple. It is flat. Here are some examples of how this term would be used:

“The machinist needs to be able to create 2D toolpath.”

“I’m looking for a software system to help me with 2D toolpath.”

“I would like to generate my 2D toolpath faster with a CAD-CAM system.”

“Right now I do all my 2D toolpath by hand.” “BobCAD-CAM software allows you to

generate your 2D toolpath easily and quickly.”

An example of 2D Toolpath:

Here you can see the tool is moving back and forth across an area without going up or down while traveling along the path. This is also known as 2D cutting. Just about every CAD-CAM system on the market today offers the ability to create 2D toolpath for machining. In many cases, you can expect that if the manufacturer that you are talking to says he already has a CAD-CAM system, this means that he can already create 2D toolpath and may be looking for a faster and easier way to do it. Or, They may be looking for something more advanced. It is important for you to know that 2D toolpath is also referred to as 2-Axis toolpath (X and Y).

The 3D Toolpath offers tool movements that include going up or down while traveling along a path. Here is an example of 3D toolpath shown in a 3D view.

You can clearly see that the toolpath is not flat. It actually follows along a 3D contour that has depths that the tool travels along while cutting. In the next image below, you can see the same model from a side view. The tool travels along the contour of the part going in a specific direction. The contour defines what the part will look like when it is finished and the toolpath goes up and down while the tool travels along it in what is called the “Z-Axis.”

Whereas 2D toolpath is only X and Y, 3D toolpath incorporates the Z axis while the tool is traveling along its path (toolpath). Thus, we get what is called, “3D Toolpath.” BobCAD-CAM software has the ability to create 3D toolpath for machining. There are other CAD-CAM systems on the market that offer 3D toolpath capabilities. This is the basics regarding this type of toolpath. Therefore, now you know that, if asked, we do offer 3D design and machining capabilities. It is important for you to know that 3D toolpath is also referred to as 3-Axis Toolpath because it has to do with the Z-Axis.

Here are some examples of how the term “3D Toolpath” would be used:

“I’m looking for something to help me with creating 3D toolpath.” “Does your software offer 3D Toolpath capabilities?” “I need to create 3D toolpath from my models.” “What sort of 3D toolpath options does BobCAD-CAM offer?” “BobCAD-CAM offers 3D toolpath generation directly off of a solid model.”

Here are some examples of 3D/3 Axis toolpath:

In each of the 4 example images you can see that the toolpath in them has Z-Axis movements along the contour that the toolpath follows. Once again, this is 3D or 3-Axis toolpath.

In the end, this is how a machinist or CAM programmer decides the best way to machine a part. It includes what toolpaths will be used and in what order depending on the part. It would be the best, most efficient way to cut away the material to get the final finished part. Certain parts would require certain toolpaths to be used. Generally, you would have a “Roughing” toolpath cycle first. Then a “Semi-Finish” type toolpath and lastly, a “Finishing” type toolpath. Sometimes you would want to use more than just 1 type of finishing toolpath. Here are the various 2D & 3D toolpath strategies that BobCAD-CAM software has to offer: 2D/2.5 Axis Strategies: Profile Milling

Single Cut Side Rough / Spring Passes

Pocket Milling Lace/Horizontal Parallel Offset In / Out High Speed

Face Milling Plunge Roughing Thread Milling Chamfer Milling Engraving 3D/3 Axis Strategies: Slice Planar Slice Spiral Slice Radial Z-Level Roughing Z-Level Finishing/Semi-Finish Plunge Roughing Equi-Distant Offset 3D Engraving V-Carving (BobART) 4 Axis Strategies: 4th Axis Indexing 4th Axis Wrapping In our software they are known as Machining Features but they are all direct strategies that the machinist can use to machine a completed part.

G-Code is simply the language that communicated to the machine so that the machine can cut the part. G-Code is also known as “NC Code.” NC stands for Numeric Code. Here are some basics:

“Numeric” means having to do with numbers. The “G” in G-Code stands for Geometric (having to do with geometry). The word “Code” has to do with systematic collection of numbers or symbols that are put

together as a language to give an instruction. In manufacturing with CNC machines, Numeric Code and G-Code are the same thing. You will hear the term “G-Code” used far more often. This is a basic term that you absolutely need to know. You don’t need to know what the code means when looking at it, but you need to know that G-Code is the language produced by a CAM system that is sent to the machine to make the machine cut the part. G-Code is basically an instruction that the machine reads and adheres to. It doesn’t make the machine run, nor does it drive the machines motors. It is simply instruction to tell the machines controller where to go and what to do. Here is an example of G-Code with the sequence being shown:

The G-Code tells the controller what to do with the tool, the speed in which the tool travels and spins, when to change to a different tool etc. Once again, G-Code does not drive the machines motors, it is simply instructions for the machines controller that consists of X, Y and Z locations, depth of the tool and other commands all pertinent to machining the part. G-Code is based primarily off of the toolpath. CAM software automatically writes the G-Code program which is then sent to the machine.

The big reason that CAD-CAM software companies develop their systems is because of this thing called, “CNC.” CNC Stands for:

“Computer Numeric Control”

This is the term used to describe a machine that is computer driven. CNC machines have what is called a “Controller.” The controller is what our software communicates with to make the machine cut the part or program that the CAD/CAM software created. There are two types of machines. There are Manual machines and then there are “CNC machines.” BobCAD-CAM software and all other CAD-CAM software systems are used for programming “CNC” machines ONLY. The picture of a machine to the left is a manual machine with hand cranks. The bottom picture on this page is what is called a “CNC Machine.” Next to the machine itself is a CNC Controller that reads in the NC (numeric code) program from the CAD/CAM software and allows the machinist to go ahead and cut the part without having to do it

manually with hand cranks etc. There are many different brands of CNC machine and CNC controllers. In the end, CNC machines have changed the way the world used to manufacture parts. Now, parts can be made much faster than when there were only manual machines that didn’t have CNC controllers.

You can have both 2 and 3-Axis CNC Machines.

You have already learned what CNC is. Let’s take this a step further here. A milling machine is a standard piece of equipment that is used for cutting material. Milling machines are used for a wide variety of machining actions. For example:

Hole drilling, Pocket Milling and Profile Milling. Prototyping or other custom manufacturing. A wide range of 3D/3 Axis milling. General CNC Machining in 2-4 Axis and even higher (5th Axis etc).

The 3 axis mill is common in job shops and any manufacturing facility that makes parts. Just about every manufacturer that you talk to will have a machine like the one you see here. There are varying sizes of this machine. The smaller images show the tool cutting out of material. Usually coolant is used when cutting metal so that the tool and material do not over heat while the cutting/machining process is done. The table that the material sits on, moves in the X and Y directions. The tool and “head” move in the Z axis (up and down) directions. All 3 axes’ can be moving at the same time while the tool is cutting. This is really the basics of this type of machine. Now let’s take a look at what BobCAD-CAM software systems would work best with this machine and what functions would benefit a manufacturer that has a machine like this. This machine is also referred to as a “Tool Room Mill.”

A CNC Milling machine has a CONTROLLER attached to it.

A CNC Machining Center is basically a milling machine that is enclosed and has doors that are opened and closed to access the material/finished part or tools or to do repairs to the machine itself.

In the image above you can see the milling area as well as the CNC Controller on the left. The doors to the machine are closed during the milling process so that chips/material waste and coolant are contained and easy to clean up and coolant is easy to collect and recycle.

CNC Grinding Systems are widely used to produce parts for aerospace, medical, automotive, and other industries. Extremely hard and exotic materials are generally no problem for today's grinding systems and the multi-axis machines are capable of generating quite complex parts.

There are limited CAM systems on the market today that can program CNC Grinders. BobCAD-CAM software is not one of them at this time.

There is a difference in a tool room mill or machining center and a mini-mill or table top milling machine. Have a look at one of these mini-mills/table top mills below. They are also called “Micro-Mills”, Table Top Mills or “Desk-Top Mills.”

Here is a prime example of one. They stand about 3-4 feet tall and are small enough to sit on a table top or bench. Some are CNC and some are manual which means that the manual mills do not have controllers or motors. BobCAD-CAM software will allow someone with this CNC mill to make small parts. They will be able to design their parts in BobCAD and then generate the toolpath and numeric program to machine the part. For example, this is used in making jewelry or small prototypes. They can be full 3 axis or even set up with a 4th axis allowing the part to turn as the other 3 axes’ move as well. An example of this would be making rings or engraving and machining on a pool stick. You will also find that this type of mill is used by the hobbyist. Because they are small you can only make small parts on them.

A Knee mill or knee-and-column mill refers to any milling machine whose x-y table rides up and down the column on a vertically adjustable knee. This includes Bridgeports. This is considered a 3 Axis machine.

The term Bed mill refers to any milling machine where the spindle is on a pendant that moves up and down to move the cutter into the work. These are generally more rigid than a knee mill. This is considered a 3 Axis machine.

CNC Routers are different than a mill yet still have the same basic concept in mind. CNC Routers still have X, Y and Z movement. With a mill, the table moves in the X and Y direction and the tool moves up and down in the z-axis direction. With a CNC Router, the table doesn’t move. The tool head moves up and down and is on what is called an “Overhead Gantry.” This moves the length of the table and the head/tool part moves across the width of the table. Have a look below.

Routers are used by manufacturers that do a good amount of flat work. In other words, 2D type work that includes cutting out patterns, doors, fixtures and that do a lot of what is known as “production” machining. Industries that would have a CNC router:

Any type of Sign Making Custom Cabinet Makers Guitar Makers Surfboard Makers Furniture Makers Any manufacturer that does 2D programming

BobCAD-CAM software is a great match for programming parts with a CNC Router because the software provides a lot of 2D functions as well as 3D for those manufacturers generating 3D programs with this type of machine.

A Water Jet is a machine that combines water and an abrasive material (similar to fine sand) and shoots it from a nozzle at high enough pressure to cut metals. Have a look at the example image below.

A Water Jet is used for flat 2D cutting only. The machine itself is setup just like a CNC Router where the head moves along the overhead gantry that travels the length of the table itself and the table remains stationary. This is good for pattern cutting in volume.

Plasma cutting is a process that is used to cut steel and other metals (or sometimes other materials) using a plasma torch. In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. Plasma can also be used for plasma arc welding and other applications.

BobCAD-CAM works with most CNC Plasma machines. It is best to ask if the machine accepts standard G-Code to machine parts. Some of these machines will take a 2D DXF file and machine them directly. The BobART add-on may be an acceptable solution for creating these from pictures but may not be able to create a g-code file for some controllers. Check first.

This is a Wire Electrical Discharge Machine. It is a specific type of CNC machine that uses a wire with electricity running through it to cut material.

The upper and lower guides are called such because they hold the wire in place. Electricity is then put through the wire, enough so that the wire heats up to the appropriate temperature to cut the metal. The entire process takes place under water. If the upper and lower guides stay fixed, this is called 2 Axis wire programming. Because there is no Z movement up or down, the upper and lower guides move together while the wire is cutting in the X and Y axis only. This is also known as 2D Wire Programming.

If the upper and lower guides become independent of each other, meaning that they move separately, you get what is called a taper angle and it becomes 4 Axis wire programming. Have a look at the example image below.

An example of 4 Axis wire programming would be a square on the bottom and a circle on the top. Have a look at the example image below of a nozzle.

This type of part required a 4 axis wire EDM to cut it as it has a taper radius around the outside and the inside. This is a perfect example of why a wire EDM is important to manufacturing. With this type of machine you can get a near perfectly smooth part with precision accuracy. Not all wire machines are 4 Axis. Some are 2 and most are 2 & 4 Axis type EDM machines. BobCAD-CAM offers the “BobWIRE” software that will accommodate both 2 &4 Axis types for a manufacturer that needs to program this type of machine.

Sinker EDM consists of an electrode and workpiece that are submerged in an insulating liquid such as oil or dielectric fluid. The electrode and workpiece are connected to a suitable power supply. The power supply generates electricity between the two parts. As the electrode approaches the workpiece, dielectric breakdown occurs in the fluid forming an ionization channel, and a small spark jumps. The resulting heat and cavitation vaporize the base material, and to some extent, the electrode. These sparks strike one at a time in huge numbers at seemingly random locations between the electrode and the workpiece. As the base metal is eroded, and the spark gap subsequently increased, the electrode

is lowered automatically by the machine so that the process can continue uninterrupted. Several hundred thousand sparks occur per second in this process, with the actual duty cycle being carefully controlled by the setup parameters. These controlling cycles are sometimes known as "on time" and "off time". The on time setting determines the length or duration of the spark. Hence, a longer on time produces a deeper cavity for that spark and all subsequent sparks for that cycle creating a rougher finish on the workpiece. The reverse is true for a shorter on time. Off time is the period of time that one spark is replaced by another. A longer off time for example, allows the flushing of dielectric fluid through a nozzle to clean out the eroded debris, thereby avoiding a short circuit. These settings are maintained in micro seconds.

A CNC Punch Press is a machine for processing sheet material (usually metal) that performs the operation of stamping / forming. The punch enters the material, and pushes it through the die, obtaining the required shape of the punch and die set. This will form a piece of material that is ejected through the die and bolster plate and collected underneath the machine in a scrap container. At this time, BobCAD-CAM software is not developed to work with CNC punch press machines. There are 2 types of punch machines: Turret Punch and Hydraulic Punch machines. As a metal forming process, the punch press is used for the highest volume production.

A CNC Lathe is the most common piece of equipment in a job shop. It has been reported that CNC lathe sales are 3 to 1 over milling machines in the manufacturing industry. A lathe is a type of machine that is different from the milling machine. The primary axis that are used with a lathe are X and Z. A lathe is also sometimes called a “turning center” because it turns or rotates the material while the tool comes in from the side (Z axis) to cut the material away. Hold er Material Tool CNC Lathes can be very large or they can be small enough to sit on a table top as well. This example is a mid sized lathe. Some are inside of a complete casing with doors and can be called “Turning Centers.”

BobCAD-CAM software also includes 2 axis lathe programming capabilities for roughing, finishing, grooving, slotting and facing. These are just different types of toolpath. We offer a built-in tool library for the customer and can help the programmer complete their G-Code programs.

4th Axis is a method of machining parts around a fixed axis. The BobCAD-CAM software offers 2 types of 4th axis machining features. They are: 4th Axis Indexing 4th Axis Wrapping

This picture shows 4th Axis Indexing where the part will rotate and then stop so that the tool can machine. Then the part rotates again to another position and stops so the tool can come in and machine again. This is not full simultaneous 4th axis machining. It is indexing. The picture to the left shows 4th Axis Wrapping. This is where something is drawn flat in the software and then the CAM wraps it for machining around the diameter of the part for machining. BobCAD-CAM software works for both wrapping and indexing but is not full simultaneous 4 axis machining.

5 Axis machining is necessary for very complex part making. Generally you have 2, 3 and 4 axis milling which are all capabilities with the BobCAD-CAM software. However 5 axis requires X, Y, Z, A and B axis to be in motion at once.

In this picture you can see the cutting tool is machining at an angle. 5 Axis Precision Machining allows machining of all 5 sides in one Set up. While this can certainly be a cost saving factor, 5 Axis machining is used more often for complex contour work, which may need simultaneous movement of all 5 Axes. Current generation 5 Axis machines offer excellent tolerances.

The benefits of five-axis machining is the machines ability to machine complex shapes in a single set-up. This reduces the machinist setup time and increases production rates . By eliminating multiple set-ups, time and errors are reduced. Additionally, the feature-to-features accuracy is improved because the same zero or datum reference frame is used throughout the manufacturing process. Other advantages of five axis machining is the since simultaneous movement is allowed along the X and Y axis, shorter and more rigid tools may be used. Also, higher spindle/cutting tool speeds may be achieved while reducing the load on the cutting tool. Shorter and thicker cutters also reduce vibration when machining deep pockets or contoured features with three-axis machines. Example applications for five axis CNC machining are complex three dimensional profiles. These geometric are common for impellers, turbine blades, and plastic mold tools. BobCAD-CAM software is not set up for 5 axis machining at this time.

The job tree allows the operator to keep all of their machining strategies organized. It also allows the user to make edits to machining parameters fast and easy.

The Job Tree lists all of the machining features/strategies as you load them into the tree for use. Each machining strategy has special parameters that define how the toolpath will be created. The machining feature is then associated with CAD geometry. This means that if the CAD geometry needs to be changed, it can and then simply be reselected and assigned to the same cutting feature so that the toolpath is updated. It works the other way as well. For example, if you make a change to the parameters of the cutting feature then the toolpath can automatically be updated as well. You can blank and un-blank toolpath that is displayed on the screen through the job tree. You can rearrange the machining order as well as other things. This is where you define stock/material as well as tools. Basically, all CAM related operations are performed through the tree, including the generating of the G-Code. This is a very big feature in BobCAD-CAM software as it keeps things so simple and organized and allows us to just keep adding cutting features to the software.

Roughing is the standard machining process for removing layers of material, stepping down in the Z-Axis while cutting until all the material except for the part is removed. Have a look at the image below.

There is also what is called, “Z-Level Roughing.” This is another term for roughing that is typically used for roughing type toolpath. The goal with roughing is to remove the most amount of material in the most efficient amount of time. Typically, a larger tool is used when roughing to remove more material than the size tool that is used for finishing toolpath. This term is not to be confused with “Z-Level or Waterline” toolpath. Below is an example of Z-Level or Water-line toolpath.

Z-Level/Water-line toolpath is used for roughing and finishing as well. However, basic roughing should not be confused with Z-Level or Water-line path. Remember, roughing toolpath is used for removing the most amount of material before finishing toolpath is used to make the part contour as perfect as possible.

Finishing is the process of cutting toolpath that will produce a smooth or polished final part. Finishing toolpath is usually used with a smaller tool than you would use for roughing. Have a look at the two example images below. One of them is a representation of a surface after roughing and the other is the same surface after finishing. After Roughing:

As you can see, this block has a rough surface that has high ridges. These ridges are also known as “scallops.” In order to smooth out the scallops you have to create and machine finishing toolpath.

After Finishing: You can see that after finishing, the scallops are almost gone providing the machinist with a much smoother finish. You could take this a step further by creating toolpath for an even finer finish. This is called polishing and is common in the mold industry because there has to be an almost mirror-like finish.

The result of a toolpath has mostly to do with the size of the tool used and the toolpath that is created to cut the part. One important aspect of this is what is called “Tool Compensation” or “Step Over” for the tool itself.

A semi finishing toolpath is generally going to be after roughing and before a final finishing toolpath. This is used as a machining strategy when needed for complex 3D/3 Axis type machining. For example, in the image below you can see the first stage of the machining process was accomplished using plunge roughing, the second was Z-Level Finish and the last was the equi-distant offset contour toolpath.

The Z-Level Finish toolpath was used as a semi finish to remove the remainder of the material before a super fine finishing toolpath was used.

BobCAD-CAM software has many 3D machining features/strategies available in the PRO version that gives the machinist/user freedom to machine their parts the way they want to.

Profiling is a standard 2D machining strategy that is very commonly used in machining whereas the toolpath that is created simply follows around the outside or inside of a part profile and the tool cuts in a counter clockwise or clockwise direction. Have a look at the example below.

The toolpath simply follows along the profile of the part. Generally the tool cuts along the center of this profile path.

Profile milling toolpath sometimes requires a lead-in and lead-out for the tool so that when the tool comes into contact with the material it doesn’t leave a mark or gouge. This is a standard type functions that should always be a feature for profile milling in CAM systems. BobCAD-CAM offers automatic profile milling with lead-in and lead-out options.

This is the method by which a programmed toolpath can be altered to allow for the difference between the actual path and the tool that will be used to cut the part. In BobCAD-CAM software, compensation variables are available for the operator to pick and choose from. If the programmer is using a half inch tool, the cutter compensation offset will need to be a quarter inch around the outside of the toolpath just as an example. We allow the user to step his tool over a percentage of the size of the tool being used. This way the tool will not cut more than the desired amount of material. See the example below.

In the picture, you can see that there was a .25 offset created around the outside of the original profile. This is because the tool that was being used was a .5 tool. You can see that the tool simulation did not cut any farther than the original path. This is cutter compensation.

In the picture above you can see the tool compensation options that we have in the Profile machining.

of a part. Sometimes pocket toolpath is created around a piece of geometry on the screen to leave that geometry standing after the other material has been moved. If that is done, the item that was pocketed around is called an “island.” Have a look at the example image below.

Here is what is happening in the image above:

1. The tool does a rapid approach along the dashed line. 2. When the tool meets the Tool Lead-In line the tool will begin cutting along the first level pocket

toolpath. 3. When the tool has cut the first level of the pocket toolpath it will plunge down into the material

and begin cutting the first level roughing toolpath and so on. 4. When the tool is finished with the last roughing level toolpath it will retract from the pocket and

rapid back to its starting position away and above the pocket altogether.

This is also known as a 2.5 or 2 ½ axis program because the toolpath is mostly 2D/2 Axis toolpath but the tool does movement down in the Z axis, but NOT while traveling in the X or Y Axis at the same time. 3 Axis would be X, Y and Z simultaneously.

In the machining process there may be areas of a part that still have left over material after a finish that still needs to be cleaned out. Therefore, the machinist has to go in and machine the REST of the part that needs it with a smaller tool. This is an automatic CAM machining strategy that is popular. There can be both rest roughing and also rest finishing type toolpaths. In the future, BobCAD-CAM software will offer REST Machining capabilities. At this time it does not.

You will see in the image to the left that there is both green and red toolpath on the model. These are both pencil milling type paths. The red in a single pencil machining path that goes around the joints/intersection areas of the model and drives the tool around these areas to provide a very clean and smooth transition finish from one surface to another joining surface. The green paths are called parallel offset pencil toolpaths that further accomplish the goal of pencil milling and making sure these surface areas are clean and smooth. This is a finishing type toolpath operation.

This type of toolpath cycle allows users to define curves that will guide the tool to produce a smooth, consistent finish. This type of toolpath cycle uses a 3D projection algorithm to create a finish on any number of surfaces or solids.

Here is another example below of a flow line or Flow style machine toolpath. You will see in the picture below that the tool paths flow along the general contour of the shape that they are being applied to. This type of toolpath can be roughing or a finishing type of strategy.

It is important to understand that the cutting action of a Milling tool varies depending upon the direction of feed or motion. Have a look at the example diagram below.

Notice how the top image shows the tool sort of scooping the material with the tool edge. This is the conventional cutting method of a tool. Now notice the bottom part where the cutting edge sort of climbs into the material and cuts. This is climb milling. Sometimes you can remove more material at a faster rate by using the climb milling method. However, by doing this method you will produce more tool wear and it isn’t recommended except for very light finishing cuts. You may be asked from time to time if our software supports climb milling. The answer is yes.

system or manual programming operation. BobCAD-CAM software supports tools where the operator selects the tool in some cases from a list, but in all cases, enters in basic tool information when creating the toolpath. They are:

Ball End Mill tool Flat End tool Bull Nose tool V Carving tool

These are the 4 primary tools supported in our software to the Version 20 level. Have a look at each of the example pictures of these tools below.

The Ball End Mill: In this picture you can see that the bottom of the tool is basically round like a ball. The “L” in the picture represents the “Length” and the “D” represents the “Diameter.”

The Flat End: In this image you can see that the bottom of the tool is basically flat. Once again, the “L” in the picture represents the “Length” and the “D” represents the “Diameter.”

The Bull Nose End Mill: In this example picture you can see that the bottom is flat while the bottom edge is rounded. This tool is defined by the “L” which represents the “Length” and the “D” which represents the “Diameter” and the “R” that represents the corner “Radius.”

The V Carving Tool: You can see that this tool has a tapered end down to a point and is used for carving and engraving.

When the operator is creating toolpath, the tools diameter is always entered as well as how much that tool will be stepped over to compensate for the tool. There are many different types of tools for producing different cuts. It is not important at this point for you to know every type of cutting tool or their attributes. This is to give you an idea of what BobCAD software supports at this time. There are many tools for machining. These are just a few of the basic ones we support in BobCAD-CAM software.

DNC stands for Direct Numeric Control. This is a system used to send G-Code program from the CAD-CAM system to the machine controller or to receive G-Code from the machine to the CAM end of the software. Basically it is sending and receiving. A machine controller is like a computer and can, in most cases, store existing g-code programs in it. When the controller is full and cannot store any more systems, DNC functionality is used to transfer those programs to a CAM system on a PC that can store them. Controller memory isn’t like a normal computer, where the PC/computer has a lot more room for these programs. 2D part programs are typically smaller in size. 3D programs have a lot more code and can be very large. Therefore it is a benefit to have a CAM system with DNC capabilities like BobCAD-CAM. In BobCAD-CAM software we have added a feature called ARC FIT that turns the tiny line segments into arc segments. This reduces the amount of G-Code in a 3 axis program and can even allow the machinist to end up with a better smoother finish.

RS 232 Communications is what we use to send the G-Code program to the machine controller through a cable. This cable is called an RS 232 cable and can be purchased at any Radio Shack type store. This cable is plugged in to the back of the PC and the other end is plugged in to the machine controller. BobCAD-CAM software has built-in RS 232 Communications settings for sending the g-code program through the RS 232 cable to the machine controller. This is really all you need to know about RS 232. You simply need to know what it means as it will come up.

Now that you know what G-Code is, what a CNC Machine is and what a CNC Controller is we can discuss what a “Post Processor” is. A Post Processor is like a built-in translator that creates the special style of G-Code that communicates the same type of numeric language that a specific machine controller reads in and understands. It is a configuration setup where the operator opens the CAM side of our software by selecting this configuration first. When the CAM opens, everything in the menus and the code generator is configured to communicate that required language. This Post Processor configuration is what is set up in the software before the actual G-Code is written. Some CAD-CAM systems allow you to customize your own and some CAD-CAM companies charge money for them. Never the less, you must have the correct post processor created to meet the specifications of the CNC controller before making the g-code program. Otherwise the G-Code will not match the machine. The controller will not read it. We call these post processor configurations the same name as its corresponding machine controllers name. Known machine types that will work with BobCAD-CAM:

2,3and 4-Axis Mills 2 axis Lathes 2 Axis Water-jet 2-Axis Plasma/Laser

NOTE: If you are asked about a post processor and do not know if we have one that is available to support the customers machine, you can visit our website at www.bobcad.com to see the list of posts on the technical support page. There are many different CNC controllers in the industry today. You will here the following: We have a conversational type controller. “Conversational” means that the NC code is proprietary to that machine control. ALWAYS check this. There are only a few controllers that we can work with that have conversational type controls. Our software CAM side will output G-CODE. Not HPGL language or conversational type language to cut toolpath created in BobCAD-CAM. Always ask to make sure that we can work with the machine unless you know before hand. If the customer says he works with “G-CODE” then we are most likely good to go. The ultimate question to ask a customer….Does your machine accept a standard G-Code? If yes, you are fine. If not, get help from a technician or your manager to make sure that we can support the machine.

In the world of manufacturing software, some providers offer a “core” system and then modules that can be added on to that core system. An example of this would be a core CAD system that has an available Mill module, Lathe module, Punch Press module, ART module etc. This is the way BobCAD-CAM software works. We offer a standard 2D & 3D solid modeling CAD Design package that allows a customer to design their parts in 2D or 3D or construct simple or complex 3D solid models. This is technically our core system. From there the customer can add mill, lathe, art and wire EDM. Each of these will be explained to you in this training document. It is important to understand the most basic fundamentals first. This way you understand the various modules that we have to offer.

A hard lock is a device used for software security that plugs into the USB port of a computer. This is designed to activate the software so it can be used. BobCAD-CAM software is designed so that a password can be typed in and activate the software as well as the use of a hard lock for protection.

Together with your trainer or sales manager point out which one of the three parts below has 2D toolpath.

CHALLENGE 2 Together with your trainer or sales manager point out which of these 3 parts below has 3D toolpath.

CHALLENGE 3 Together with your trainer or sales manager point out which of these 3 parts below shows both 2D & 3D toolpath on the same part.

CHALLENGE 4 Together with your trainer or sales manager point out which of these parts below shows a 2–Axis toolpath and which one shows 3-Axis toolpath.