m 3 axis pro cam tutorial - bobcad support v30.pdfnext we use the second advanced rough operation to...

BobCAD-CAM Version 30 Training Workbook Mill 3 Axis Pro CAM Tutorial

Real CNC Programming Solutions for Global manufacturing | Copyright (c) BobCAD-CAM, Inc. 2017 1

MILL 3 AXIS PRO CAM TUTORIAL

This topic explains how to create the machining program for the Mill 3 Axis Pro demonstration file. The process includes first roughing the cavity and then simulating the roughing operations. Next the finishing operations are applied and simulated. This process is continued until the part is machined. This tutorial explains the general process while teaching you how to quickly and accurately create machining programs in BobCAD-CAM.

This tutorial highlights the following functionality of the BobCAD-CAM software:

Creating a milling job, stock, and defining the machining origin Selecting a stock material to determine automatic speeds and feeds calculations Using CAM Wizards to guide you through creating machining features Utilizing a 3 Axis feature to rough and finish the part with operations from the 3 Axis Pro

module Creating an Advanced Rough operation to rough the cavity Using a second Advanced Rough operation for Rest Roughing Tips for easier viewing of computed toolpath

Simulating the roughing operations Editing a feature and adding finishing operations to the Machining Strategy

Assigning tools from the Tool Library and Tool Crib Simulating the finishing operations

Performing Deviation Analysis Creating Mill Drill features and defining operation parameters Simulating the finished program



Part 1) Open the Example File and Save As

The first step is to open the finished Mill 3 Axis Pro CAD model from the Demo Files folder, and then use Save As to rename the file. It is good practice to properly name your files and save them often.

1 In the File menu, Click Open.

2 Navigate to C:\BobCAD-CAM Data\BobCAD-CAM V29\Examples\Demo Files, and select Mill 3 Axis Pro CAD.bbcd.

3 Click Open.

4 In the File menu, Click Save As.

Select or create a new folder to save to, or just use the Demo Files folder.

5 Change the File Name to Mill 3 Axis Pro CAM, and Click Save.

Part 2) Create a CAM Job

The process of creating a CAM Job in BobCAD-CAM includes selecting the type of job and machine. You can then go directly to defining the stock geometry.

1 To create a new CAM Job, do one of the following:

In the Modules menu, Click New CAM Job.

In the CAM Tree, Right-Click CAM Defaults, and Click New Job.

2 Under Job Type, select Milling.

3 Under Machine, select BC_3X_Mill.

4 Click Stock Wizard.



Part 3) Assign the Workpiece and Create Stock

Assign the Workpiece for Simulation

When you start the stock wizard from the Machining Job dialog box, the Workpiece dialog box displays before the stock wizard. This is used to assign the geometry that we want to use as the workpiece when we simulate the program.

1 Under Define Workpiece, Click Pick Solid Model.

2 Click to select the model in the Workspace.

3 Click to confirm the selection.

4 Click to go to the Stock Wizard.



Create Stock Geometry

The Stock Wizard is a powerful stock creation tool which can automatically detect geometry in the Workspace to speed up stock creation.

1 Under Stock Type, select Rectangular.

2 Click .

The default setting, Auto from Workspace, automatically creates stock geometry based on the CAD model.

3 Click .



Part 4) Select the Machining Origin

The Machine Setup is an important part of creating CAM Jobs in BobCAD-CAM. This includes setting the work offset number, clearance plane, and machining origin for each setup that you need on the physical machine.

1 In the Machine Setup under Origin, Click Origin.

Select the machining origin location at the top corner of the stock.

NOTE: This step defines the machining origin (work offset) location for the machining features that you create. The machining origin is independent of the CAD origin, and should be placed in the same location as the work offset location on the physical machine.

2 Click Work Offset. We use the default Work Offset #1 (G54).

Notice the XYZ values. These are important to create proper simulation when using Machine Simulation Pro. These values shift the part location on the virtual machine (distance from virtual machine zero, which is the center of the top face of the table, to the Machine Setup location).

Update the values:

X = -3.250 Y = 2.250 Z = 4.000

Click OK.



3 Use the default Clearance Plane value of 1.000, and Click OK.

The Milling Job is created with the defined stock and machine setup information.

4 In the File menu, Click Save.

Part 5) Select the Stock Material

Selecting the appropriate stock material for the job defines the values used for automatic speeds and feeds calculations in the Milling Wizard. This information can be customized using the Stock Material Library.

1 In the CAM Tree, Right-Click the current Stock Material, and Click Edit.



2 Under Material Group, select Aluminum.

3 In the Material List, Click Material Type to sort the list, and select Wrought Alum 6061-0, and Click OK.



Part 6) Add a 3 Axis Feature

We are now ready to create a machining feature. Dynamic Machining Strategies (DMS) allow us do all of our 3-axis machining for this part using a single feature. The next few parts show you how to use the Milling Wizard to guide you through the process.

IMPORTANT: In this tutorial, we use many of the default settings and only update them as needed. If you want more information about particular settings, view the BobCAD-CAM Help System.

Select Geometry

The first step of creating any machining feature is to select geometry (the feature) to which you apply all machining operations.

1 In the CAM Tree, Right-Click Machine Setup, and Click Mill 3 Axis.

2 Click Select Geometry.

Drag a window to select the entire model, and Click .

TIP: Generally, for 3-axis features, you should select the entire model. You can assign a boundary when you need to contain the toolpath to a specific area of the model.

Click Next>>.



Set the Feature, Machining Strategy, and Posting Settings

1 Under Material Approach, change the Rapid Plane value to 0.350.

Change the Feed Plane value to 0.250.

Click Next>>.

2 In the Machining Strategy under Pro, select Advanced Rough.

Under Available Operations, select Advanced Rough, and Click .

The Current Operations list now contains two Advanced Rough operations.

Click Next>>.

3 Notice Work Offset #1 (G54) is automatically set from the Machine Setup.

Click Next>>.

Part 7) Define the Advanced Rough Operation

The next step of the wizard is to define the operation parameters. In this part we set the parameters for our main roughing operation.



Select a Tool from the Tool Library

1 Click Tool Crib.

Under Tool Category, Click Endmill Rough.

Click Add from Tool Library.

2 Click the column label Diameter to sort the tool list.

Select the 0.750 diameter flat endmill with the 1.625 flute length (Tool Label: 3/4 Flat Rough Endmill - Standard).

Click OK.

3 Click OK in the Tool Crib.

Notice that the Tool Holder is automatically assigned using the information from the Tool Library.

4 Click Next>>.



Define the Operation Parameters

1 Use the default settings for the Patterns, and Click Next>>.

2 Update the Parameters as follows:

Depth of Cut = 0.375 Stepover = 0.200

Number of Intermediate Steps = 2 Machining Tolerance = 0.005

Allowance XYZ = 0.040

Click Next>>.

3 Under Entry, select Ramp.

Click Next>>.

4 Use the default settings for Options, and Click Next>>.

5 Under Within Groups, select S-Link.

Select the Rapid Retract for Large Gaps check box.

Click Next>>.



Part 8) Define the Rest Rough Operation

Next we use the second Advanced Rough operation to perform rest roughing. We use a smaller tool to rough only the areas that couldn't be cut by the larger tool used in the first rough operation.


1 Click Tool Crib.

Under Tool Category, Click Endmill Rough.



Select the 0.500 diameter flat endmill with the 1.125 flute length (Tool Label: 1/2 Flat Rough Endmill - Standard).

Click OK.


4 Under Tool Data, change the Protrusion Length to 1.500.

This sets the distance from the tool tip to the bottom of the tool holder.

5 Click Next>>.


1 Use the default settings for Patterns, and Click Next>>.

2 Set the Allowance XYZ to 0.0400.

Click Next>>.

3 Select Ramp.

Update the Ramp Length to 0.200.

Click Next>>.



4 Select Rest Roughing.

Notice that because Use Previous Operation is selected, the tool values from the previous operation are automatically set.

Click Next>>.

5 Select the Rapid Retract for Large Gaps check box.

6 Click Compute.

Viewing the Computed Toolpath

In this part, we hide job items and use the CAM Tree to highlight the toolpath in the Workspace to make it easier to view each toolpath.

1 In the CAM Tree, Right-Click Stock, and Click Blank.

2 Right-Click Feature 3 Axis, and Click Blank/Unblank Toolpath.

3 Click anywhere in the Workspace, to give it key focus, and press T to turn on the transparent view. (Alternatively, in the View menu, Click Transparent.)

4 Click the first Advanced Rough operation in the CAM Tree to highlight the toolpath in the Workspace.



5 Click the Advanced Rough 1 operation in the CAM Tree.

You can rotate the view or zoom in and out to better view each toolpath.

6 Press Ctrl+S to save the file.

Part 9) Simulate the Roughing Operations

We now simulate both of the roughing operations to confirm the desired results before moving on to create finishing operations.

1 Right-Click Milling Job, and Click Simulation.

2 In the Simulation group on the Simulation tab, Click the Machine button so that it

changes to Workpiece/Stock focus.

3 In the Visibility group, Click the Toolpath button to hide the toolpath.



4 Click to run the simulation, and adjust the speed slider as needed.

Notice how the intermediate slices of the roughing operation apply extra cuts to reduce the size of each step.

5 On the Modules toolbar, Click to close simulation.

Part 10) Edit the Feature and Add Finishing Operations

Use Two Operations to Define Steep and Shallow Cutting

The next step is to edit the 3 Axis feature and add two finishing operations to our machining strategy. We then use the Angle Range parameters to essentially split the model between the two operations: one for cutting the steep areas and one for cutting the shallow areas. This allows us to optimize the operations for the areas in which they excel.

Note that we also start to use the tree to navigate the wizard as well as using Next>>.



Update the Machining Strategy

1 In the CAM Tree, Right-Click Feature 3 Axis, and Click Edit.

2 In the tree on the left, Click Machining Strategy.

Under Current Operations, Click Advanced Rough 1 to set the insert location for the next operation.

Under Available Operations, Click Advanced Z Level Finish, and Click to add the operation to the Current Operations list.

Under Available Operations, Click Advanced Planar, and Click to add the operation.

3 Click Next>> to update the tree with the new operations.

Part 11) Define the Advanced Z Level Finish Operation


1 Under Advanced Z Level Finish, Click Rough to go to the tool settings.

2 Click Tool Crib.

Under Tool Category, Click Endmill Finish.



Select the 0.500 diameter ball endmill with the 0.250 corner radius and 1.125 flute length (Tool Label: 1/2 Ball Endmill - Standard).

Click OK.


5 Click Next>>.




1 Use the default settings for Patterns, and Click Next>>.

2 Change the Depth of Cut to 0.040.

Click Next>>.

3 Under Lead-in, Click Parallel.

Update the Length to 0.300.

Notice that the Lead-out automatically uses the same settings because Same as Lead-in is selected.

Click Next>>.

4 Select the Angle Range check box.

Update the Slope Angles:

Angle Start = 45.000 Angle End = 90.000

This sets the operation to perform only steep cutting, between the specified slope angles.

Part 12) Define the Advanced Planar Finishing Operation

Select a Tool from the Tool Crib

1 Go to the Advanced Planar operation tool settings.

2 Click Tool Crib.


3 Select the 0.500 diameter ball endmill to use the same tool as the previous operation.

Click OK.

4 Click Next>>.




1 Under Cut Pattern, select Zig.

Click Next>>.

2 Update the Stepover to 0.040.

Under Depth Options, select Top of Job, and set the value to -0.500.

This removes the toolpath from the top face of the part.

Click Next>>.

3 Under Lead-in, select Vertical Tangent.

Update the Radius to 0.100.

Update the Angle to 45.000.

Click Next>>.

4 Select the Angle Range check box.

Update the Slope Angles:

Angle Start = 0.000 Angle End = 45.000

This sets the operation to perform only shallow cutting, between the specified slope angles.

5 At the bottom of the wizard, Click Finish.

6 Save the file.



Part 13) Compute the Finish Operations

Reduce Calculation Time

Clicking Compute from the wizard calculates all operations in the feature. The next steps show how to calculate individual operations using the CAM Tree, which helps to eliminate unnecessary calculation time (the rough operations are already computed and their parameters have not changed).

1 In the CAM Tree, Right-Click Advanced Z Level Finish, and Click Compute Toolpath.

Notice how the Angle Range limits the toolpath to the steep areas of the model.

2 Right-Click Advanced Z Level Finish, and Click Blank.

3 Right-Click Advanced Planar, and Click Compute Toolpath.

Notice how the Angle Range limits the toolpath to the shallow areas of the model.

4 Right-Click Advanced Planar, and Click Blank.



Part 14) Simulate the Finishing Operations

Now we simulate the finishing operations to see if the machining of the cavity is complete. This part shows you some tips on speeding up the simulation process for the operations you are analyzing.

1 In the Modules menu, Click Simulation.

2 In the Move List tab on the right side of the simulation window, Click Op. 3: Advanced Z Level Finish.

Notice that the simulation completes the first two operations and is now at the beginning of operation 3.

3 Click to run simulation, or you can also Click Next Op to quickly run the simulation through each operation to the end.



Perform Deviation Analysis

After running simulation, you can use deviation analysis to help visualize the rest material or the difference between the cut stock material and the workpiece (target geometry).

1 In the Analysis tab in the lower-right corner, Click the down arrow and select Deviation.

2 Update the Gradient Minimum to -0.030.

3 Update the Gradient Maximum to 0.030.

4 Click Refresh.

The deviation analysis shows the rest (excess) material for the part in blue. We can see that the holes need drilled and the radii of the part require another finishing operation.

5 In the Modules menu, Click Exit Simulation.



Part 15) Add the Final Finishing Operation

Now we add a Pencil operation to clean up the radii of the main cavity.

Edit the Feature and Update the Machining Strategy

1 Right-Click Feature 3 Axis, and Click Edit.

2 Click Machining Strategy.

Under Current Operations, Click Advanced Planar.

Under Available Operations, Click Pencil, and Click to add the operation.

3 Click Next>> to update the tree with the Pencil operation.


1 Go to the Pencil tool settings.

2 Click Tool Crib.



3 Select the 0.375 diameter ball endmill with the 0.1875 corner radius (Tool Label: 3/8 Ball Endmill - Standard).

Click OK.




Define the Operation Parameters and Compute

1 Under Pencil, Click Parameters.

Click to select Ignore Holes.

2 Click Next>> to go to the Leads settings.

3 Under Lead-in, select Parallel.

4 At the bottom of the wizard, Click Finish.

5 Right-Click Pencil, and Click Compute Toolpath.

6 Hide the Pencil toolpath using Blank.

7 Save the file.

The 3-axis machining for the part is now complete. Next we create drill hole features.



Part 16) Add a Drill Hole Feature

In this part you learn how to create multiple drill hole features by selecting more than one diameter in the Hole Wizard. The software then automatically separates the features so you can define each feature within the wizard.

Add the Feature and Select Geometry

1 Right-Click Machine Setup, and Click Mill Drill Hole.

2 Click Select Geometry.

3 In the Layers Manager, hide the CAD layer, and show the Wireframe layer.

4 In the Edit menu, point to Select Entities, and Click Pick+Match Radius (it may still be selected).

Click any one of the larger circles.

Click any one of the smaller circles.



5 In the Data Entry Manager under Point and Arc Usage, select Use as Top.

This allow the software to automatically set the Top of Feature based on our geometry selection.

6 Click OK.

Define Parameters for Each Hole Feature

After selecting geometry, each hole diameter displays in the hole list in the wizard. The hole list is provided so you can define more than one drill hole feature in the wizard.

1 Notice the hole list is populated with the selected hole diameters.

Confirm that the 0.375 hole size is selected, and Click Pick Bottom.

Show the CAD layer, and Click the bottom edge of the hole.

TIP: Notice how you can select a surface edge through the transparent face of the model. Utilizing the Transparent and Shaded views greatly assist in geometry selection when working with solid models.

Clear the Through Hole check box.



2 In the hole list, select the 0.1875 hole size, and clear the Through Hole check box.

The Depth of 0.500 is correct for this hole size.

Click Next>>.

One hole feature is created for each hole size (in the tree on the left).

3 Notice the Feature settings are using the previously defined values (Top of Feature, Feature Depth, and Blind Hole).

Click Next>>.

4 In the Machining Strategy, select the Hole operation template.

This adds the center drill and drill operations to the feature under Current Operations.

5 Click Apply to All Features.

This applies the selected machining strategy to all features.

Click Next>> twice to go to the Center Drill tool settings.


1 Notice that the tool data is automatically selected from the Tool Library when using System Tool. (The software first checks the Tool Crib for the appropriate tool and then checks the Tool Library if one is not found.)

Click Next>>.

2 Update the Depth to 0.200.

Click Apply to All Operations.

Click Next>>.

3 System Tool is used again for the drill tool data.

Click Next>>.



4 Notice that Use Cutting Conditions is selected and automatically sets the Overall Depth using the Feature information and the Cutting Conditions database.

5 Under Cycle Type, select Peck.

6 You should always confirm the appropriate settings are made in each page of the wizard, but for this example, go to the Drill Parameters of the second feature.

Under Cycle Type, select Peck.

7 Click Compute.

Save the file.

Part 17) Final Simulation

Now that all of the required machining operations and toolpath are properly defined for the part, simulate the program again to confirm that everything is correct. View the next topic to learn more about simulation in BobCAD-CAM.

m 3 axis pro cam tutorial - bobcad support v30.pdfnext we use the second advanced rough operation to...

Documents