Home

PCadCam2000 Software User Manual

1. Create Hepar Compact E Io Mone f i Database 3 petem Datanase Options LAABAN S a E EE AA S a BA a Ma M a a a a oU E Ty T E ei a pen i Figure 6 4 Data source input display 5 The system will then ask user to select the database file via a dialog box as shown on Figure 6 5 Select database name frcad mdb then click on OK button Select Database Database Mame Directores Ok fread mdb c X program files pcadcam Cancel Ez c3 EN Sft mdb 7 Program Files f PCadCam 3 FILES Support Help Read Only Exclusive List Files of Type l Drives o Access Databases m Sc Network Figure 6 5 Database file selection 6 Upon completion of step 1 to 5 the display will return to the first display with an additional frcad added in the User Data Sources as shown on Figure 6 6 User should confirm that FRCAD exists on the list Click on OK then exit Control Panel PCadCam Software NODBO Data Source Administrator User DSN System DSN File DSN ODBC Drivers Tracing About User Data Sources Add Microsoft Access Driver mdb Remove dBASE Files Microsoft dbase Driver db Excel Files Microsoft Excel Driver x13 Configure FoxPro Files Microsoft FoxPro Driver db tread Microsoft Access Driver mdb MS Access O Database Microsoft Access Dri
2. ee Data in the above is for a Horizontal MC attached with A axis index devise PCadCam Software 5 1 3 Tool Pod Database 2adCam Database Toolpod Poadlam Database Toolpod Add Db Add coy 150 1 amp 1 1502 6 ies matt es 185 912 262 3 ioe 88 Tool Pod Database lists up all tools that may be used on a machine for each individual machine not machine brand Frequency value in the right most column indicates number of times when the tool has been selected by the CAM system The number is counted up every time the tool 1s selected When two or more candidate tools are found for an operation CAM system looks up this column and selects the tool having the largest number reflecting the past history that the tool has been used more frequently than other candidate tools Using this capability if user manually assigns a large value in this column the tool has less chance to be removed from the tool pod data Therefore the tool is eventually managed as the permanent resident tool of the machine PCadCam Software 5 1 4 Controller Database Poadlam Database Controller Controller ID li Controller Name 310 Lenath LIP M92 Format 310 Diameter LLZP M99 Format 310 Value E 352 Format Min Address ID 1 Sub Repeat format Max Address ID Al 352 Reverse Metric Inch Format Gel Macro format T Fo
3. B5 Tap Escape 10 Maximum Report 10 Generate Offset G41 842 Gunmen TUT Mo Cie Default values Ae n Close Tool Radius Offset Tool Wear Offset Default values database is the collection of typical data in the plant it does not require Figure 4 17 Default values dialog box further editing and it consists of the following as shown in Figure 4 17 e Raw Material X Y Z The most used raw material dimension e Product dimension X Y Z The most used product size after machining e Drill Escape The height R point height where the drilling tool once stops above the surface after traveling in rapid traverse to approach the workpiece e Tap Escape The height R point height where the tapping tool once stops above the surface after traveling in rapid traverse to approach the workpiece e Initial Point The height where a tool drill and tap included once stops above the surface after traveling in rapid traverse to approach the workpiece it is equivalent to initial point height in canned cycle e Maximum Report Input the maximum number of operator sheets that could be saved for NC programs generated in the immediate past e Generate Offset G41 G42 For CAM process to decide whether tool path compensation offset code G41 G42 is going to be applied or not in finish machining when generating the NC Program o No G41 or G42 is not applied o Tool Radius Offset Tool radius value is set in D code of the machine cont
4. PCadCam Software Follow the steps below to input a drawing file into FR 2 7 2 1 Start PCadCam software 2 7 2 2 Open the file using OPEN function of AutoCAD if the drawing is prepared in DWG format User has to import the drawing in DXF format by clicking the DXF Input icon in the fr toolbar as shown in Figure 2 14 A dialog box to locate the file will be shown in Figure 2 15 then click OPEN An example of imported design drawing is shown in Figure 2 16 Ig To 5 DXF Input FR Database fr Import PDrata Figure 2 14 Feature Recognition Toolbar PEZ BAR Look in 2000M anual File name Files of type DF deh Cancel aBn Open as read only Shore 39 te ae CF eae aah eee m se Figure 2 15 DXF file import dialog box P N P255 iR x x e ii C e Bll 6 6 PCadCam Software Ss EBEN g LEER m Hut Bini To 3 ntl T rm IL TL al l sti Figure 2 16 Example drawing imported from DWG or DXF file User needs to do further preparation on the projection drawing for the system to recognize the machining feature design Click on fr icon to bring up a dialog box as shown in Figure 2 17 ETE E Xj Drawing options CBS Bic kz Some e BEES xHES fn C 2 Ob peg Eleni RE i Cancel Figure 2 17 FRCAD frame for selection of projection PCadCam Software
5. There are two methods to input the position of workpiece origin point achieved on the machine table the point in NC program X 0 Y 0 Z 0 is similar to NCPR to the NC controller of the machine 1 Fully external setup CAM software will calculate the workpiece origin point then input the value into local coordinate sub program 056 057 058 etc automatically The explanation chapter describes the utilization of this method 2 Measured on machine then input manually User will measure the coordinate of workpiece origin point on the machine then input the value into the machine NC controller manually 3 11 2 Alternative Switch between Two Methods 1 To change into fully external setup 1 1 Assign YES to Machine Database ACS 1 2 Inthe local coordinate format of the controller database 1 2 1 When using G56 The controller of FANUC and YASNUC use common variable for NCPR sub program therefore the coordinate value of the NCPR is loaded into G56 G57 G58 or G59 In this case make sure that the symbol 1s given in the macro format of the controller database Also in this case input the following sub program example to call for FXO fixture origin point that is registered as a PCadCam Software resident sub program in the machine CNC controller O55 111 5241 1 12 5242 113 5243 G40G49G80G90G17 G9I1G30Z0 G90 G55 M99 1 2 2 When using G52 for FANUC controller When using G52Q2 for YASNUC c
6. Fixture ID Be Fixture Name Vise H Datum X 0 Datum Y 178 235 Datum Z 172 08 Orientation Back Index Angle 0 Application D 3 Surfaces H MC M Add Delete search Close gg Fixture Record 13 of 16 gg Grid Wier Figure 4 23 Type 3 Fixture data for three surface machining Example ViseO H In such a case when machining operation on three surfaces next to each other is going to be conducted on a horizontal machining center a vise type fixture is prepared to accommodate a square type workpiece as shown in Figure 4 24 Three surface machining is performed by rotation of the index table around B axis of the machine It is important to fix the Fixture Origin point FXO right on the center line of B axis rotation of the horizontal MC PCadCam Software aM is P E i s pT p A a a aol a ama a NCPR NC 71125 gt a oto Ls 7K RR Y Ww s Brie HFS ER G3 4 f TB ath Figure 4 24 Three surface machining on horizontal MC The example data shown in Figure 4 23 specifies a set of data for a fixture named Vise 0 H which is set at zero 0 B axis angle orientation as specified in the Index Angle data space When a work piece is clamped on the fixture it is set in symmetry around the center axis oriented in the direction of the specified Index Angle and passing through a point X 0 The Work Piece Origin point WPO will be at the mid point of the edge formed between
7. 16mm square end mill Product Spindle speed 600rpm Axial depth of cut 24mm Feed rate 150mm min Up cut Coolant Operation 3 Tool Tool 16mm corner end mill Product Spindle speed 2500rpm Axial depth of cut 2 4mm Feed rate 125mm min Down cut Airblow 0 1 y t Material SS41 Figure 2 8 Example of machining operation sequence for cut off with machining method of Medium 0 1mm from bottom product fixed Parameter dl will be used for the offset of depth of cut of the excess material in rough or medium finish machining The value of parameter dl is not a design variable therefore the value should not be given in CAD process For example dl d1 0 2 is set as a default in the operation database so that the rough machining process will leave 0 2mm of excess material on the boundary of cut off line PCadCam Software 2 5 User to Define Inclined Design Surface Although the BASE material is a rectangular shape user can define an inclined surface on the BASE with an optional angle other than 90 as explained herewith There will be two methods that utilizes the AutoCAD function of UCS Universal Coordinate System and it will be explained in following two sections 2 5 1 Three point Method 271 ER i 17 m i a S a I d i nd i I 1 I pe j j l STANDARD ORIGIN Figure 2 9 Three point origin shift method It is a method convenient to set an inclined surface ro
8. 2 7 2 4 There are three drawing options that user can choose to retrieve machining feature on the design drawing into FR as shown in Figure 2 17 The first one is The third angle projection method to select three projection views on the design drawing Figure 2 18 describes the projection layout on the third angle projection method however FR system can only handle the layout number 1 The second one is used only there is only one projection drawing to be processed by FR User has to input the thickness of the raw material then press OK to execute The third is to select from more than two projections PCadCam Software FRONT RIGHT BACK Bii Ti CR f amp tfi BOTTOM TOP CF if CEH Y 6 Both side and front back view are placed on the side X TOP BOTTOM Erf CF Y o When Top and Bottom view exist LEFT RIGHT BACK CE m f amp tfi X TOP Y 3 When the side view is placed When Vis side view is placed at the upper right at the upper left TOP Em FRONT LEFT FRONT BHE E A HiT ed the side view is placed When the DT view is placed at the bottom right at the bottom right Figure 2 16 Layout and name of view on Third Angle Projection Method PCadCam Software 2 7 3 Design Origin and Two Corner Selection on the Base Material User has to select three points on one projection drawing that represents the whole view area for the FR system to recognize the desig
9. Invert Design Surface TOP to BOTTOM is to specify whether TOP and BOTTOM design surfaces are witched around X axis TOP to BOTTON or around Y axis LEFT to RIGHT during CAD operations Projections will be switched during CAD operation in the manner specified here 2 5 Click on OK button to close Utility dialog box 4 2 PCadCam Database Management System 4 2 1 Tool Database The tool database is built based on the cutting tool and cutting condition data The dialog box of Tool Database is shown in Figure 4 3 PCadCam Software PCadCam Database Cutting Tool Add Tool Add CCondition Search Tool Close T Categor Drill Cutting Condition Dia 10 E ea 100 e select Material select Machine Brand 100 Common Common Axial Edge Length 40 Under Chuck L 100 Tool ID 4115 T Code bb Tool ID Axial FR mr tooth 0 14 Material Radial FR mm tooth Symbol Machine Brand Axial DOC mrn T Category E a Seo 30 Axial FDOC mm T Diameter MO Ma of Tooth 2 Radial DOC mm T sb Coolant Coolant MRR mm3 rev Drill Mode 0 Symbol Ramping Mode Ho Figure 4 3 Cutting tool dialog box 4 2 1 1 Cutting Tool Left Part of Figure 4 3 Cutting tool database consists of the following e Tool number an ID number given to a cutting tool e Try to set a unified ID number for tools used in the shop PCadCam software assigns four digit ID number as a default e Anezample customer applies nine digit
10. Ls BxesFHRUC oo FE Met fanuc La Data in the above is for FANUC controller of a Vertical MC attached with A axis index PCadCam Software PCadCam Database Controller Controller ID 5 Controller Name 310 Lenath Yn M98 Format 310 Diameter n M39 Format 310 Value Yn 352 Format Min Address ID Sub Repeat format Max Address ID el 352 Reverse Metric Inch Format Gel Macro format T Format I M57 Airblow NC No format Di Initial Return TL Offset GAS R Return No cycle LO TChanae Prep Code M16 Rigid Tap Code n ConmalelD Mame amp Gl Lenath G10Diameter 310 value IS dno 83 n fn Yaznuc 5 n Mes F M L T 8 Mior fanue Fn ER 2 Data in the above is for FANUC controller of a 5 axes MC 5 1 5 Index Table Database Horizontal MC Vertical MC with Index and 5 Axes Machining Index Table Data base 1s necessary for rotational index of A B or C Axis angle Three data items have to be prepared for each of A B and C angle endexing Index Table Data base below is for a Horizontal MC that has only B axis Therefore three data are entered only for B PCadCam Software PCadCam Database Index Table Machine A Index Address A Index sub Program Number A Min Angle of Rotation B Index Address B Index Sub Program Number B Min Angle of Rotation G Index Address C Index Sub Program Numbe
11. Q value will be automatically entered for the axial depth of cut In case of G86 Boring and others P value will be automatically entered in the dwell time in 0 001 second of Fig 18 G84 2 Rigid tapping data 1s not used currently but do not delete this value PCadCam Software PCadCam Database Canned Cycle Canned Gycle operan Command Canned Cycle opersion Parameter a G81 F UJL Gb CANNED CH NONE Bat wo a fo GEB FRE UL CANNED 03 S GSA Ey CANNEDO4 NONE Jee es owes Nae o k Hg Canned Cycle Record 1 of nn 4 2 6 Figure 4 16 Canned cycle dialog box Operator Instruction An operation sheet that lists the workpiece drawing file NC file or the machine and tool used data will be generated in this database It also generates a list of the NC program sequence number N number that corresponds to machining operation Click on Report to display the operation sheet and select the NC program file name The list of cutting tool operation and product data will be displayed as shown in Figure 4 19 Click on Print on the upper left of the display to print the list Note l 2 Operation sheet is created every time an NC program is generated and it is saved as many as specified in the Default Value Database Operation sheet older than the maximum number to save is however lost User can make a hard copy or save the old database file in a different director
12. User will key in three sets of XYZ values in sequence 1 Specify XYZ values of one of two points lying on the surface normal having smaller or more negative Z value on the new coordinate system 2 Specify XYZ values of the other point lying on the surface normal having greater or less negative Z value on the new coordinate system 3 Specify distance from the point in the above to the new design surface The intersection of the surface normal specified by 1 and 2 in the above with the new design surface will be the origin of the new coordinate system X axis of the new coordinate system will be parallel to the XY plane BOTTOM surface of the global coordinate system The area of the part having positive value of Z axis from the origin point belongs outside the part and therefore it is sliced and deleted from the display When the Z value is minus the range will be inside the work piece When the external geometry BASE of the part 1s already designed as a rectangular parallel hexahedral the procedure is as follows Click on the design surface icon and select ALL 2 Key in UCS in command line and press ENTER Key in N and press Enter key and key in ZA followed by pressing ENTER key 3 Key in the XYZ values of the point 1 in the above separated by a comma and PCadCam Software press ENTER key 4 Key in the XYZ values of the point 2 in the above separated by a comma and pre
13. accordingly click OK to complete This command can also be applied for data reconfirmation on machining features that have been designed previously Delete a machining Type in e or erase in the command input and push feature ENTER to erase a machining feature The erase icon in the MODIFY toolbar of AutoCAD can also be used to run the same command A message select object will appear Move the cursor to select any line of the feature to selected and push ENTER to complete the delete Multiple features could be selected at the same time To recover the deleted feature type in UNDO or click EDIT menu of AutoCAD and choose UNDO This command will cancel the last command executed frlegture engin IM PCadCam Software 11 Blind bore design Click the icon as shown on the right to display the following gi dialog box and supply the necessary data Create 3 4E Fen mre Mame E E SIC ri catat ioa Surface Ton Nick Home Feature Parmmeter di 30 000 di d d4 dE Chanter 000 Anale DU fochining Trai Hae Operation Date Repent Cancel Click on REPEAT to add another blind bore or OK to complete the design 12 Rectangular Array Click the icon as shown on the right OO Move the cursor to select the object to be copied in array and push ENTER Choose R for rectangular or P for circular array followed by ENTER Input the number of raws Y axis and columns
14. pg d 30 000 Duy d 10400 uri ubi dd 35 000 db Chanfer i 000 Angle Kachining Btandard tmp with canfer peration Data E pa rnt 0E Cancel Figure 2 6 Change the type of tap Click OK button to finish the selection User can also type in p to display the list of Pt type and u to display the unify type threads available in the database 22 Mirror Copying s Click on Mirror Feature icon and follow instructions displayed on the command line to specify one or more machining features and then mirror copy the feature around a line parallel either to X or Y axis If the mirror copying is performed after CAM processing of the original drawing is finished user does not have to do CAM process again but may proceed to NC program generation so that machining methods already defined for the original feature will be applied automatic to the feature after the mirror copying 23 Add Feature Design Before continuing to the next process try to revise or add some machining features on the design surface LEFT FRONT etc so that the part will include more features as shown in Figure 2 7 PCadCam Software E Es ae ee E Tit qa 4 P i a ey ea al a a d mn ik 5 a fm i waa 0 ay x Hn is a a ai ley E r i m ncs Tees he 4 _ 3 or E z M Lp gp E ue e SU 1 a A LL m o rd uu y f Te o E T a eon E e BOR usw UD 0077 09
15. 4 CAM processing will be started 3 14 5 When Operation Sequence table is opened the results of the CAM processing will be found added to the tail end of the table User may change sequence of operations and then proceed to NC generation 3 15 Deleting a machining feature after CAM If one or more machining feature is found not necessary and have to be removed from a drawing that has already finished CAM processing user may delete those features by using ERASE command from the drawing and do CAM processing again But in this case the results of previous CAM processing are all lost and user have to repeat checking on all tools and cutting conditions again that incurs substantial loss of time In such a situation by using Deleting Machining Feature icon one machining feature can be removed at a time together with all operations planned for machining the feature Click on Delete Machining Feature icon S 3 15 1 Following instruction displayed on the command line user will select one machining feature and press ENTER key The feature will be deleted from drawing 3 15 2 When Operation Sequence table is opened operations planned for machining the deleted feature are found deleted as well 3 16 Editing Machining Features after CAM If machining features are found needing some design change after CAM processing has been finished they can be additionally edited by following procedures 3 16 1 3 16 2 3 16 3 3 16 4 3 16 5
16. Database included in the software installed 1 4 2 Change over to Database specific for User Following step leads user to apply a database prepared specific for the user First of all click the PDatabase icon Click the utilities pull down menu from the dialog box Select Setting Options to bring another dialog box Browse on the Database Name mdb box to find the database file specific to the user and click Open Set the Owner and Language Click OK to close the dialog box Those are the steps to change the database PCadCam Software 1 5 Connection to the frcad mdb Database Follow the steps explained in Section 6 1 of Feature Recognition System in Chapter 6 to establish connection to frcad mdb database I 6 Changing the AutoCAD Display Background Color The background color of AutoCAD display is white by default User can change the background color when needed Type in preferences in command line and press ENTER Select Display in the dialog box and color C Change the color accordingly PCadCam Software Il PCadCam2000 Software CAD User Manual 2 1 Outline The utilization of PCadCam2000 to perform machining operation on plate or square like raw material on machining center will be explained in this chapter It is important to have AutoCAD2000 or higher version of AutoCAD running for this cad cam software to be operational Some functions of AutoCAD are al
17. Delete Search close TIE gt ni Figure 4 7 Dialog box of machine database Note PCadCam Software e The upper part of Figure 4 7 is similar to Figure 4 6 in which the machine ID 1 has a value of COMMON NEVER DELETE nor EDIT this COMMON data User can register or create other data by giving a machine ID of 2 etc as shown in the lower figure e Common Variable Create sub programs by using common variable when YES is selected in the next column of generate sub program Input a common variable in which the sub program number will start with e Generate Sub When YES is selected an example of sub program will be generated as shown in Figure 4 8 There are two sub programs in the figure the first one 1s a sub program to repeat under hole for tap chamfer and tap machining at the same position The second sub program is to divide the depth of cut based on cutting condition in pocket machining T52 8 5 Crill MOgerma MOSPs2 cagx1oao aaay41aa aagast1123 MOs64 32 50 000HS2 fe cate Co ea 90G812 27 454R5 000F 2021 0 MIBSP 102 S60 T139 25 0 Lead drill Masma MOSPSz G gx1aog aaagv1200 00081250 MO3G4azsn anoaH 139 Ra nes i GaogcGesrz 5 750Fe5 nn r2000 MIOGEP 102 GBSn T115 10 0 Tap Mosr4 MBBSP52 Goox 00 oo00v1 00 0003320 MOSGA43z50 000H445 ME MOsP102 Gen JMS Gone s ann 59 OGe42 20 000R10 000F4SoLo Main program JO 4 s pocket rough T
18. Do not erase nor edit any data with common value These data are crucial for automatic operation of data management User should register machine brand ID started with 2 to create a different data PCadCam Software PCadCam Database Machine Brand Machine Brand ID Bo Mame Enzhu Machine Type vertical M C Feed Rate Max mmimin Y Controller lfasno Feed Rate Min immimin Z T e E ToclPodIb TCod e Feed Rate Max mrn min Z Spindle Sp Min rpm Feed Rate Min degimin A Feed Rate Max deg mini A Feed Rate Min degimin B a00 Feed Rate Max degimin B X X x 0000 Rapid Traverse degimin A ji F Feed Rate Min immimin T apindle Sp Max rpm Feed Rate Min imrm min Feed Rate Max mmirnin Rapid Traverse deg min sooo Rapid Traverse degmin B 80000 Rapid Traverse deqimin Rapid Traverse deg min Grid View aa Delete seren cose M 4 Record 2 of 5 gt rt Figure 5 2 Dialog box of machine brand data example for Enshu machine The above Figure 5 2 is an example for ENSHU vertical machining center The machine uses YASNUC controller as the NC control device There are three alternatives for T Code numbering for user to decide In the next Okuma horizontal machining center example as shown in Figure 5 3 a Fixed T Code is selected to create a fixed T number for each tool in the production plant and also to match the T Code and H Code since up
19. Fa M Ae E P E A a F Won Tu P E F F rea 1 N os e M on SAS eter Bs A tum n eS 3 a y Ln mA baia MM a Mg treu Bar eT xS E w CM uARU C Wu 77 0 us S n v N A Yu f Un A n EE LN Fi Om UN t T xe penc rur A MCA rie ia qn LE com AF en LN E erp ah kx A y oe es a A dy t sa a ur i K F i A Figure 2 12 Raw material modeling process in P CAD The incoming sections will explain some detail explanations regarding the raw material modeling 2 6 1 Raw Material Design Start the AutoCAD program and bring up the dialog box to display the base material design Input same value in XYZ direction in raw and product columns When the raw and product have the same input value six surfaces in the base material quality will automatically be given NONE value as shown in the lower part of the dialog box Click OK button to finish the base material design Design any machining features on a surface of the BASE to model the raw material by running an operation called Boolean Operation of union to add a body subtract to remove or intersection to overlap the body The icon of these operations is located in PCAD toolbar The display of the machining feature designed will have its specific color at the PCadCam Software beginning and it will change into white as 1t is merged with the base material As an example the illustration in Figure 2 13A describes the union o
20. Feature to display the same name of machining feature 5 Click the pull down menu arrow on Method to display the new first operation data that 1s just created 6 Using the record navigator in the lower left part of the dialog box display the second operation data created from the former machining method and perform necessary correction 7 Repeat step 6 to create the third operation data 8 User can apply the above procedure to create a special machining method based on Click Add Machining Method button located in the left part of the dialog box as shown in Figure 4 16 the type of machine and material In that case copy the common data value for PCadCam Software each machine and material type Perform further correction and repeat step 3 4 2 4 2 3 Procedure to Revise Machining Method Data 1 Perform revision on the first operation data of the specific machining method on display 2 Repeat the procedure 6 in the above to create the second third etc of the operation data 4 2 4 3 Setting of Machining Method Display in CAD As explained in the previous section user can create several different machining methods for a machining feature User can follow the procedure below to decide which case or which machining method to prepare First step 1s to open the CAM database menu as shown in Figure 4 1 and click on the Method Setting button Click on the pull down menu arrow on Feature i
21. Fixture ID A number assigned to identify each fixture e Fixture Name Aname given to each fixture e X Y Z X Y and Z coordinate values of the Work Piece Origin point WPO refer to Figure 4 18 with reference to fixture Origin point FXO Note Input the coordinate values relative to the FXO point and not the machine coordinate value e Orientation Orientation of the Work Piece Origin point placed on the fixture e Index Angle It describes the B angle orientation of the FRONT surface of work piece e Application The machining process that will utilize the fixture refer to process design in CAM system Based on the selection of orientation data as explained in the above there are three types of fixture that will be explained in the following sections 4 2 7 1 Type 1 Fixture type that assigns Work Piece Origin at a corner of the work piece for Vertical MC work This type as illustrated 1n Figure 4 20 defines the corner of the work piece where PCadCam Software Work Piece Origin WPO is defined either one of bottom left bottom right top left or top right corners Figure 4 20 shows an example fixture named SFX7 in which the Work Piece Origin WPO is set at the corner of FRONT and LEFT surfaces of the work piece as illustrated in Figure 4 21 and lists XYZ coordinate values of WPO as measured relative to the Fixture Origin FXO Fixture Origin FXO is the reference point of the fixture as placed on the machine
22. G22L4 G22PL52 MOSSIS3S GOOX210 000Y 20 000 G437 2 000H2l Me GOI Y30 000F888 GOl Y 20 000 G22L5 G25 LOO05 Mousey MO MU G9IGZO0ZD M5 G23 L52 THR Gu Lm 7 3 h prt0055 RFE JE A G22L55 G O0GBOGGI7 GOOX 3l2 5007 87 5007700 GOIG2BX0 GO2X0 YO Z6l2 175 GonG55600X0 523 YO G23 Figure 3 3 Main and sub program structure examples on different controller 3 10 Operator Instruction 3 10 1 Tool and Operation Lists Bring up CAM database dialog box and click on the Report button of Operator Instruction to view cutting tool and operation lists Open the NC program name related to the tool or operation list to be viewed followed by clicking on each button Click on Print button to print the list 3 10 2 Instruction for Workpiece Clamping NCPR NC program origin or workpiece origin point 1s generated to create an origin point of the design surface Pay attention to create one when rotating top to bottom by flipping the right to left around Y axis 3 10 3 Drawing for Confirmation PCadCam Software The NCPR NC program origin or workpiece origin point should match the coordinate origin point generated at the end of the CAD operation therefore it 1s important to confirm the point generated in NC program with the design drawing 3 11 Sequence to Manually Input Workpiece Origin Point Data Measured on Machine into Controller 3 11 1 Two Methods to Generate Workpiece Origin Point
23. Lines Tap Data Counter Bore Data Tap Line Types TUP Tap Line Types BOTTOM System Configuration Auxiliary Lines Ream hole Data Syetem Mode r Man tangent arcs in cortour Pre processor Local Origin Point Method C Automatic f Include in Contour feature Active v Based on Global Origin Point PGE Da LVS Separated feature Mot Active C Lower Right Corner Butac AD Link Falvline Generation wiew Design Surface Edit Feature v Not Active Visible Surface C Mat Active C In POSDYCAM C Hidden Surface uei C Active fe I FRGAD f Visible amp Hidden Surfaces Tolerance values ad a Gonnectivity Tarigency normal and parallel 0 95 Er Schematic Symbol 3 ea FROAD Directory CX Program Files PCadCam TM Figure 6 16 System Configuration data page AJL System Mode It is a toggle box to select an automatic recognition of the imaginary workpiece boundary or thru interaction mode for each projection view in the case when FR system has to run on three projection views Select on Automatic for an automatic recognition process Select Interactive for the user to input the data interactively on a dialog box If the user select Automatic but the system fails to run the designated function the system will switch into Interactive promptly Non Tangent Arcs in Contour It is a toggle box to assign the selection on the
24. ML Myuus DAS ru ue i a iur en i meo Rl o T ren T gerunt i Mill t 2p MU KE A wr E i F at am r at ec T a A e v B ln f is a be Na EL 3 Tu m Figure 2 7 Adding features on the sample exercise 2 4 Using Polyline as Auxiliary Machining Features The polyline function of AutoCAD can be used to design two auxiliary machining features namely cut off and cutter path features A chamfer can also be assigned in the cut off machining feature In CAD process polyline function will only design an contour of a feature and at this point the machining process cannot be viewed User will use polyline to draw the contour then choose the cut off or cutter path icon to start 2 4 1 Design a feature with AutoCAD polyline function e Polyline is a function that makes combination of straight and circular lines possible Type in pline or pl in AutoCAD command line followed by ENTER to start drawing one e Follow the directions appear in command line to draw the polyline e tis important to consider several items as listed below in drawing a polyline e Cut off machining will take place offset on the left side removing material on the left of the polyline When a polyline contour will be designed as the binding geometry of the final product draw the polyline in a clock wise direction CW When the polyline contour is designed as a binding geometry of a pocket to be removed design the polyline in coun
25. Machine Brand Machine Brand IO Mame TTHak Machine Type Horizontal w c Peed Rate Max rm min Y Controller IV 5SMak Feed Rate Min mmimin Z TCode Policy Fixed TCode Feed Rate Max mrimin 2 Feed Rate Min deg min A Feed Rate Max degimin A Feed Rate Min deg min B A X 20000 Feed Rate Max deg min B i 30000 Rapid Traverse degimin A Y Feed Rate Min mm min Y spindle sp Min trom apindle op Max rpm Feed Rate Min mm min Feed Rate Max mm min Rapid Traverse degmin 80000 Rapid Traverse degimin B 30000 Rapid Traverse deglmin Rapid Traverse deg min Grid View Add Delete search Close M 4 Record 2 or nj Figure 4 6 Dialog box of machine brand Machine Brand ID ID number for each machine brand Name The name of the machine Machine Type Vertical or horizontal etc Controller The name of the control device PCadCam Software T code Policy There are three methodology to decide the T code policy l Fixed T Code A certain T number is given to each tool in this method The T number is decided in cutting tool database 2 ToolPodID TCode In this method a T number is given to each cutting tool that 1s attached and corresponds to Toolpod ID of a machine User defines the ToolpodID in tool pod database for each machine 3 Sequenced T Code In this method a T number for each cutting tool will be automatically assigned during NC program
26. PCadCam Software Five Axes Machining on Horizontal MC ConA B on A A on B C on B 1 Rotational Axis A A B B 20d Rotational Axis C B Ac C 34 Avis Direction Y Z Five Axes Machining on Vertical MC ConA Bon A A on B Con B 1 Rotational Axis A A gt B B 271 Rotational Axis C B A C 3 d Axis Direction Y 3 3 Operation Planning CAM system will automatically decide the content of each operation in the second stage of operation planning following the first stage of process planning PCadCam Software Following the progress of an operation the system will provide a drawing that shows each operation for the user to confirm cutting condition as shown below For each machining operation shown on the list user can input new data to modify the cutting condition for the tool to be used on the right side of the dialog box When the toggle box of Copy Cutting Condition With Same Tool is checked the system will apply the same cutting condition to all similar tools to be used If the toggle is not checked the revised cutting condition will only be applied to that particular cutting tool selected If the Save Cutting Condition button is clicked after cutting condition revision the revised data will be registered in the cutting condition database Another dialog box will appear to confirm the data revision Click on OK button at the bottom of the dialog box to end the cutting condition confirmation m Cutt
27. The lower edge of the designed workpiece is facing front machine door side for 0 Deg the left edge for 90 Deg the upper edge for 180 Deg and the right edge for 270 Deg These orientations are not applicable on horizontal MC NC Program NC Program No fif Description Workpiece Orientation Rotation amp 0 Dez la J iaz a e 270 Deg J Initial Pt 0 The value on the Initial Pt column is one that user sets on CAM database to be the height initial point mm User can modify and input another value to be used only on that particular process 3 6 Fixture Origin Confirmation Confirmation of Fixture A dialog box to confirm fixture origin point will appear only PCadCam Software Origin Point when using horizontal MC CAM system will automatically generate NC program with NC Program Reference Point NCPR as the origin The NCPR is the same origin point in CAD operation stage that 1s located at the bottom left of each design surface of the CAD display The position of the point is shown in the figure below There is an occasion when the origin is shifted to an optional point during CAD operation If that happens the new optional origin point created on a design surface will be used as NCPR in NC program at the end of CAD operation NCPR Shift Fixtere Han F s Orientation rS 1 A 17 o E Iun t m leat lstun E i EFR Vec
28. X axis as well as the distances Push ENTER for each data input eH egre erg vv lu vd Polar Array Lt Select objects objects selected EI Haw 4 Im Columns 4 Offset distance and direction Row offset 1 fl Column offset 1 l Angle of aray 0 he fp By default if the row offset is negative Y rows are added downward If the DK column offset is negative columns are added to the left Cancel Click the Select Object icon and move the cursor to select the object to copy Push ENTER to finish selection Display will resume the dialog box in the above Click on PREVIEW button second from bottom on the right corner PCadCam Software Array Ed Accept Modify Cancel If approved click on ACCEPT then four blind bores will be modeled as shown in the above 13 Grouping Click the icon as shown on the right to group or ungroup iy features Jr Follow the instruction on the command line to select the feature on an active surface The feature selection can be done individually or apply a window to cover the feature area When applying a window click the icon and select a feature then apply a window to cover the whole features to be grouped Push ENTER to complete the task The line of the features will be changed to red Push ENTER again to complete After group ungroup icon is clic
29. a T i T UM a um y T v ua lw Dg Cae n ea a x oy A E ca ia QS pad F t E T a T A um E i Pu E P e m Z7 ur e LA i a m T E af mn ma za ra ng T 3 Lal i T QU ule Figure 2 3 Sample of CAD operation exercise Start PCadCam2000 software and complete each step on Table 1 to finish the sample design Table 1 Step by step CAD Operation Step Description Note Icon 1 Start ACAD Double click the icon as shown on the right m 2 Wait while AutoCAD loads PCadCam2000 and the Database 3 Base material and Click the icon as shown on the right to design a base T dimension design material A dialog box below will appear and input the base dimension The base material data can be viewed again anytime The data shown on the left part of the dialog box to input the raw material dimension can be revised The data on the right part is the product data and cannot be revised later on PCadCam Software Base Material Material Name ee Base Material Size Raw x 405 000 Y 405 000 Z gt 50 000 Base Material Quality mm Top Botto Front Back Left Eight None b Rough b Medium Finish 4 Origin Shift Click the icon as shown on the right when it is required to move the origin from the bottom left corner to another point Input the data on a dialog box as shown below The origin coordinate can be revised anytime during CAD operation Surface Origi
30. advisable to display the three toolbars of AutoCAD and all of five toolbars of PCadCam2000 The detailed description of each machining feature listed on pfeature toolbar is shown in Figure 2 2 User may follow the procedure described below to design a part in CAD system of PCadCam2000 Click Base Material icon from pcad toolbar to design a workpiece A dialog box to input the data of a workpiece description will appear User may choose a common name for the Material Name as a default or click on the drop down menu PCadCam Software Spindle w Orientation Origin p SLOT ROUNDED SLOT BLIND SLOT LONG HOLE D2 Figure 2 2 Description of machining features 1 to choose several materials provided The next step is for the user to choose the PCadCam Software dimension of the raw and final product The final product thus defined is termed as BASE BASE is a rectangular parallel hexahedron that binds the final product to be machined 2 The machining surface quality of the six surfaces of the BASE can be assigned to be rough medium or finish when the Product dimension BASE dimension is designed to be smaller than Raw Material The NC program generated will automatically include the machining process for each surface depending on the machining quality assigned 3 Modeling of Machining Features on each design surface of the BASE material repeat the following operations 2 1 Select design surf
31. drill etc 8 Cutting Tool The category of tool to be used for a specific operation 9 Usage A setting based on machining feature dimension in which a different tool category could be selected 10 Tool Diameter A formula to set the parameter of nominal tool diameter Dopt selection 11 selection Rule Parameter of machining feature to select the nominal tool diameter Dopt range 12 dl to d4 Formula to edit the feature parameter 13 U V W Formula to edit the origin of machining feature b The columns of Dopt the dimension from dl to d4 and UVW are called modifier User can input a simple formula as listed in table 4 1 into the modifier Capital D or lower case d operates the same Table 4 1 Example of formula D1 3 46 without spacebar 3 46 D1 D2 3 46 with spacebar 3 46 D2 D3 3 45 D3 245 2 D1 D3 D4 3 14 D4 3 14 22 2 CAM system will automatically select the operation data based on the following priority l Inacase when both the material and machine vertical or horizontal are selected 2 Inacase when material type only is selected 3 Inacase when machine type vertical or horizontal only 1s selected 4 Inacase when neither of both item is selected 4 2 4 2 Procedure to Edit Machining Method User can assign different machining methods with specific names so that user can recognize and understand each machining method clear It 1s also possible to edit the PCadCam S
32. generation in CAM process The columns in the lower part of the dialog box allow user to input the minimum and maximum of spindle speed feed rate and positioning rapid traverse of each axis Note The upper part of Figure 4 6 shows that the value for machine name and type 1s Common for machine brand ID 1 DO NOT ERASE nor EDIT this Common for this specific ID number User can register ID 2 or onward data for specific machine name or specific machine type 4 2 2 2 Machine Database Machine database dialog box is shown in Figure 4 7 and it consists of the following Machine ID A recognition number given to each machine Machine Name A name given to each machine Machine Brand Machine brand name Dummy Tool Number Tool number in dummy condition Tool Change Sub Program Number A sub program number to do tool change End Machining Sub Program Number A sub program number to retreat Z axis stop spindle and coolant as well as tool change Local Coordinate Sub Program Number An NCPR sub program to shift the origin from FXO to NCPR There is a chance that the number is ignored based on the setting of ACS automatic calculation of workpiece origin point For example user may ignore the function in horizontal MC or vertical MC with indexing device and instead a sub program number 56 is set to always run Fixture Origin Sub Program Number A sub program number to define the XYZ coordinate of fixture origin point Helical Int
33. inclusion of angle non tangent in polyline The polyline itself may consist of arc and arc arc and straight line or straight line to and straight line There is a case when angle exists in between the lines therefore user has to decide whether to include the angle as a different machining feature or it 1s included in the polyline itself PCadCam Software Pre Processor This toggle box will allow the user to activate segment subdivision response in between projection views for a significant automatic looping when dealing with running FR on three projection views The function will not be run on ONE VIEW operation Local Origin Point Method This toggle box is used to assign the origin on each design surface of a workpiece Based on Global Origin Point means that the origin point on each of design surface is a projection of the origin point on the workpiece Lower Right Corner means that the origin point will always be on the lower right corner for each design surface Both selections apply the right hand rule Based on Global Origin Point is the default option AutoCAD Link Set the toggle into Active mode so that FRCAD system can download a DXF file automatically when the user clicks on INPUT DXF FILE in the earlier stage of PCadCam operation At that time the DXF file name will be acad2frcad dxf and it should be located in C Program Files PCadCam folder Polyline Generation Set the toggle to allow FRCAD to p
34. the work piece surface set downward termed as Datum Surface and the work piece surface facing the fixture XYZ coordinate values of WPO is entered as measured relative to the Fixture Point FXO Machining will be performed on three connected surfaces through indexing B axis by either or 90 degree so that the surface under machining will be oriented normal to the machine spindle Each of three surfaces has respective NC Program Reference point NCPR that has been defined by the user during P CAD modeling stage PCadCam Software Based on the fixture data and the dimension of the work piece model BASE CAM system will automatically generate a sub program to find NCPR for each of three surfaces to be machined 4 2 8 Setting data for rigid tapping Rigid TAP For setting a Machining Center to do thread tapping by Rigid Tapping cycle in stead of conventional tapping Cyple following two arrangement are to be prepared 4 2 8 1 Machine database Section 4 2 2 2 Rigid Tap setting of the machine database is set YES 4 2 8 0 Controller database Section 4 2 2 5 In the Rigid Tap Code of the controller database M code for preparing start of the spindle rotation for rigid tapping cycle The M code 1s different according to the controller For example M23 for some FANUC controllers should be entered PCadCam Software V SETTING UP NEW MACHINING CENTER for PCadCam2000 There are three important setup preparations of P
35. traveling in rapid traverse to approach The default value 1s 50 but user can assign a smaller value for example 12 3 13 Starting Point and subsequent Sequence of Positions in repeating Canned Cycle 13 1 Starting Point The initial starting point is taken from the next closest position from the left bottom corner of the design surface 13 2 Subsequent position The operation will progress to the next closest position 3 14 Additional Feature Design If one or more machining feature 1s found missing from a drawing that has already finished CAM processing user may add those missing features to the drawing and do CAM processing again But in this case the results of previous CAM processing are all lost and PCadCam Software user have to repeat checking on all tools and cutting conditions again that incurs substantial loss of time In such a situation by using Additional Machining Feature icon CAM processing may be conducted only of added features of which results are added to the tail end of the previous Operation Sequence Table The procedure is as follow 3 14 1 Click on Additional Machining Feature icon Pee 3 14 2 The user will be displayed of a question asking Keeping the results of CAM processing for existing machining features new machining features may be modeled and additionally processed for CAM Proceed Yes No Respond with answer Yes 3 14 3 Additional machining feature s will be modeled 3 14
36. v dz 70 y da 10 LU 10 Radial FR mm min BE Coolant Coolant 4 d or d3 W ingle Copy Cutting Condition With Same Tool nave Cutting Condition Operation o 641 42 Time Caloulation Edit Operation zi 189 63 Canned Cycle um ux oOo oa o ine HO 0 85 1 j O FUJ qo o E Machine Brand L G8 FUJE a o 98 78 Material Before 0C After Delete discas shift Undo View Feature 3 Cancel PCadCam Software Upon completion of editing process click on OK button The display will return to AutoCAD then proceed to the procedure to generate NC program PCadCam Software 3 5 NC Program Generation 3 NC Program Generation Click on the icon as shown on the right to generate NC HE program of the confirmed process and operation sequence done at step 2 4 Cutting Tool A dialog box for each cutting tool selected at 3 3 and 3 4 Confirmation sections will be displayed Input the tool length and diameter compensation data for each tool Confirmation only will be needed if the tool listed is a standard resident cutting tool of the machine If not the cutting tool data should be prepared to mount the tool on the machine Use a tool pre setter to measure the tool length and diameter data and input the data into the dialog box Perform the same operation for the rest of the tool and click on Finish to continue to the next ste
37. vision File Folder E G Control Panel zl E My Documents O Alcohol 120 C Corel User Files gt Downloaded Program Updates Incomplete Inna Setup Examples Output 77 My Albums PCadCam Software Xi INE Select View Tab Rig ac eee z General View File Types Offline Files E l Folder views Tou can apply the view such as Details or Tiles that vau are using for this folder to all folders E Apply to All Folders Reset All Folders Advanced settings 5 Files and Folders l Automatically search for network folders and printers I Display file size information in folder tips Display simple folder view in Explorer s Folders list Display the contents of system folders Display the full e ea 5 Select Show hidden C Donotcachet files and folders i3 Hidden files and mues e Do nat show hid den files and folders Show hidden files and folders LL Hide extensions for known file Apply f OK z 1 2 2 Delete previous PCadCam Uninstall previous version of PCadCam using Add or Delete Application of Control Panel I 3 PCadCam Software Installation PCadCam software may be obtained in following two ways 1 Down load Free Tial license of PCadCam from English page of http pcadcam lspitb org Free trial license will stay valid for some while While using the trial license user 1s advised to decide which CAM options will be necessary when Formal Licensed Version wil
38. 39 30 0 Foughing end mill Mash A MIa8Ps2 100 185 000 101 185 000 102 2 000 i 103 1 000 SOO 10 01 250 nO Sca 32 50 OOOHS9 MOSP404L3 Ma E ME tee Ga1Gasuzn ME M1 Figure 4 8 Sub program example Sub pro gram 0101 41 s pocket rough Co Ost O41 01 1 0310202 S0 1Z 103F 171 0 zu 000F 1 7 30 0060 z amp 30 000 20 000 z amp 15 000 20 000 760 000 SO 345 0004 S 00015 00d cau 1v60 000 cu E S 0004 S OOOl5 000 30 14 60 000 cU 34 5 OOOV 5 000 5 O00 cu 1 60 000 cO mS O00 5 00015 000 cuu m1359 0102 Tap hole t4o0 000 100 000 300 000 SOO 000 100 000 ae Mas ACS Automatic Coordinate System for automatically calculating NC Program PCadCam Software Reference NCPR point Select YES to calculate the NC program reference point NCPR in NC program based the fixture data and workpiece dimension data automatically User has to perform on machine measurement and input the data manually if NO 1s selected e Advanced TCall Select YES to use T code tool number or NO to ignore the function e Rigid Tap Select YES to use rigid tap cycle in tap machining or NO if not e Time Calculation Parameter Click this button to display a dialog box as shown in Figure 4 9 Input the data to estimate and calculate the operation time Provide the following data ATC Time in second input the average time required f
39. 6 000 5 100 15 000 20 000 PTI Z18 7700 6 500 12 000 22 000 MB 8 000 6 900 20 000 25 000 PTI 8 9728 B 5565 12 000 20 000 M10 10 000 8600 20 000 30 000 HIE 12 000 10 400 30 000 30 000 PT1 4 718 15 11445 18 000 26 000 M14 14 000 12200 35 000 40 000 M16 16 000 14 200 40 000 45 000 PT3 8 16 662 14 500 21 000 29 0100 MIS 18 000 15 700 45 000 o0 000 20 000 17 700 50 000 60 000 Delete Record r Record Insertion Options 2 v Always insert below highlighted record C Always insert above highlighted record een Figure 6 6 Tap data page B 1 Tap Data B 2 Counter Bore Data Input the standard design data for counter bore Drafting Database Tap Line Types BUT TUM System Configuration Auxiliary Lines Ream hole Data Solid Lines Hidden Lines Tap Data Counter Bore Data Tap Line Types TOP Mam o i o dda A YOSE M3 3 500 6 000 4500 M4 4500 6 000 5500 MB 5500 9 000 6500 M 7000 17 000 7500 ME 9 000 14 000 10 000 MIO 11 000 17000 12500 MI2 13 000 19 000 15 008 M14 16000 23008 17500 M18 18 000 96 0010 90 0010 M18 20 08 28 Dan 22 5D M20 99 Dp 92 000 94 5010 M24 26 B0B 38 080 2050 M27 0 00 42 p00 32500 D Record Insertion Options x Always insert below highlighted record C Always insert above highlighted record Jl dl Delete Record PCadCam Software B 3 Solid Line Data The display shows all solid line data that is used in design drawing Figure
40. 6 10 The line type is managed under Layer Name User can add this line type data during FRCAD operation automatically and the same case applies on hidden and auxiliary lines Drafting Database Fa T Du Du n 213 e p m ee M M M a M CONTINUOUS CONTINUOUS CONTINUOUS CONTINUOUS CONTINUOUS DASHED CONTINUOUS CONTINUOUS NUL CONTINUOUS NULL de PP Se sel eet ea m Mo o2 Po Po c t ses iile e Figure 6 10 Solid line data page PCadCam Software B 4 Hidden Line Data The display shows all solid line data that is used in design drawing Figure 6 11 I Drafting Database x CONTINUOUS DASHED DASHED DASHED z golos DASHED CONTINUOUS CONTINUOUS DASHED MEEN 000000 DASHED i IU ST Figure 6 11 Hidden line data page B 5 Auxiliary Line Data i Crafting Database DASHDOT DASHDOT DASHDOT DIVIDE DASHDOT DASHDOT DASHDOT D DIVIDE DASHDOT DIVIDE Nx ces g ils E et PCadCam Software B 6 Tap Line Types TOP Data There is a case when tap exists on both top and bottom surfaces The data describes herewith regulates the tap hole design on top surface There are two concentric line symbols for each tap drawn the tap Tap LT and the under hole Un Hole LT symbols User should fill in the name type and color data on each as shown on Figure 6 13 Dirafting Database Tap Line Types BOTTOUM System Configuration Auxiliary Li
41. AD2002 4 Support acad mns PCadCam Software 2 AutoCAD 2005 C Documents and Settings UserName ApplicationData Autodesk AutoCAD 2005 R16 1 enu Support acad mns 3 AutoCAD 2006 C Documents and Settings UserName ApplicationData Autodesk AutoCAD 2006 R16 2 enu Support acad cu1 4 AutoCAD 2007 C Documents and Settings UserName ApplicationData Autodesk AutoCAD 2007 R17 0 enu Support acad cu1 5 AutoCAD 2008 C Documents and Settings UserName ApplicationData Autodesk AutoCAD 2008 R17 1 enu Support acad cu1 User Name in the above represents a folder in C Documents and Settings directory whose folder name is the same with Login Name of the user For example if user name used for Log in is hoshi it should be C Documents and Settings hoshi By default folder Application Data is hidden by WINDOWS To set to show that folder open the WINDOWS EXPLOLER and conduct stepsl to 7 illustrated in figures below File Edit View Favorites MES Seep 1 Open WINDOWS EXPLOLER O 2 5 Map Network Drive gt Click on Tools 3 Back eg EE p t Network Drive ipe 3 AS esee d 3 Click on Folder Options dem Synchronize Address Sat Dui Folders nent Size Type E Desktop jdata File Folder fl y My Computer SPCadcam File Folder E a RAISA C yPCadCam MET File Folder EE a LIMA Lis Source File Folder Jk DVD RAM Drive E Tesis File Falder E 2h DVD Drive Gs
42. CadCam2000 software to run on a new machining center They are 1 Data preparation for CAM database This includes Machine Name database Machine database Tool pod database Controller database Index table database for five axes machining or using an index table on vertical or horizontal M C 2 Preparation of sub program registration on the machine This includes 2 222 2 3 2 4 Tool change sub program Ending operation sub program FXO sub program Index table sub program for five axes machining or using an index table on vertical or horizontal M C 3 Setting up fixture origin point for external setup only setting up fixture origin point 1s different based on the type and usage of the machine or the type of its controller such as FANUC YASNUC MELDAS OSP etc The following will explain a concrete example User should decide the following items on the machining center before starting any operation 1 Decide the data symbol for machine name and controller name 2 Decide a T number for dummy tool in tool pod setting to provide one that allocates a dummy condition of spindle 3 Check if the machine is capable to do helical interpolation 4 Check if the machine controller utilizes common variable on sub program If YES check from which number that it can be used 5 Read carefully P CAD CAM manual section 4 2 2 5 Controller Database and prepare to input the code to be used for machine controller 6 Decide th
43. ES The original blind bore feature dialog box will appear Change blind bore to tap M12 in feature name of the pull down menu and input the data accordingly Create Feature Feature Fane lop rin Ti DO Oriemtation Y fend 000 surface Tap JM Bick Hama Feature Parameter dl 12 000 fiz ie d EDD efaatura erin y di 35 000 ER db Chanter fi 0ni ingle Wachining Standard tap mith confer z B paerat LE d Cancel Select Repeat button and four MI2 tap features will be designed in the position of blind bore holes Click Cancel to complete 15 16 Four sided pocket design PCadCam Software Click the icon as shown on the right to design a four sided pocket feature The following dialog box will appear Input the data accordingly L Crean Fealerr Feature Hase 4 cide pocket T A xu E Orientation ve za m Sarface T z A n i Wick Hame Feature Parameter dl EL av di Er rv dai 211 On di Li dh MT Chanter 10 000 Dresta qngn usse inele nmm Machinina Ecuah Operation Data Repeat OK Cancel Face feature surface Face feature design is not required if the raw material machining design dimension has been set greater than the product as assigned in step 3 In such a case NC program for machining side surfaces will be generated automatically in CAM process However for example to face machining low
44. Ho No format TL Offset Mo cwele Grid View Add Delete Search Close I 4 Controler Record 3 of gt pi 1 P G11P E 24 Yn T HE LO TChange Prep Code Controller Mame Heldas Mag Format M33 Format 552 Format sub Repeat format 352 Reverse Macro format ME Arlow Initial Return R Return Gag is E Rigid Tap Code Data in the above is for OSP controller Okuma The machine does not have a command to specify Metric Inch therefore the format is nullified by entering wn PGadCam Database Controller Controller ID 310 Lenath 310 Diameter 310 Value Min Address ID Max Address ID Metric Inch Format T Format NO No format TL Offset Mo cycle Grid View Add Delete Search Close 14 4 Controler Record 3 of 6 gt pi Data in the above 1s for Meldas controller GLOP GLP E l 24 n T HE Tiene Piep Dade Controller Name Heldas Mas Format MSS Format 552 Format sub Repeat format 352 Reverse Macro format MSZ Arblow Initial Return R Return Gy ie E Rigid Tap Code PCadCam Software Pad Gam Database Controller VH cthfanuc MasP M99 _Normatview Add Delete Search close _ M 4 comcte Recoasas gt Pil Controller Name Xi amu a O a 3 Meldaz 31 UP G11P 9 pMelds l0 P JR HM OSP dn o
45. ID number that allows them to set a more detail classification of the tool as shown in a diagram below As example in case of o 6 drill 10 0060 000 Type Drill 10 Tap 20 Endmill 30 etc Dia 6 0060 4 6 8 0068 etc e Tool Type TCategory Material HSS 0 Carbide 2 etc Finishing Rough 0 Finish 2 etc Length Short 0 Long l etc Perform the following to see the list of cutting tool type 1 Click on Utilities 2 Select Table View from the pull down menu 3 Select TCategory from the Table Name PCadCam Software PCadCam Database Table View Table Namelll eres Name Romanize Abriviation 3lide Tat tery ID Dk Roush Face will Rough face wil REM i23 ctesomal tip end mill tasomal tip end will EM Hi Roushine end ill Roughing end will REM We Bo Big chipper side mill Biz chipper side mill ECM tlllxx FN quare end mill Square end mill GP Kg TLategary Record 1 of 21 nn Figure 4 4 Partial display of Tool type Warning DO NOT ERASE ANY ROW on the list User may revise the name etc when it is needed but not the TCategoryID on the right side of the table User can add a new type of tool at the end of the list Adding a data is possible but deleting one 1s prohibited e T Code t is an ID number given to each cutting tool in NC program The number will be assigned only when Fixed TCode is selected in the TCode
46. Il HI IV VI PCadCam Software For AutoCAD2000 and above PCadCam2000 Software User Manual PCadCam2000 SOFTWARE INSTALLATION CAD User Manual CAM User Manual CAM DATABASE Manual Setting up new MC for PCadCam2000 Feature Recognition System User Manual PCadCam International PCI 20 January 2008 PCadCam Software I PCadCam2000 SOFTWARE INSTALLATION I 1 System Requirements Hardware Pentium or equal Processor 500MB or more Memory 40GB or more Hard disk Software Windows 2000 XP Home or XP Professional AutoCAD2000 20001 2001 2003 2004 2005 2006 2007 or 2008 It is important that either one of those AutoCAD is installed with COMPLETE option not STANDARD option PCadCam will not run on AutoCAD LT of any version Microsoft Access 97 2000 or above If going to install PCadCam for the first time conduct procedures I 3 to I 6 If going to install update on computers with previous install of PCadCam conduct procedures 1 2 1 3 and I 4 I 2 Delete previous version If previous version of PCadCam2000 2008 is installed it should be deleted from computer following procedures below 1 2 1 Open AutoCAD and return PCadCam menu to AutoCAD menu First open AutoCAD then key in MENU and push ENTER Select following file and close AutoCAD Following file has to be selected according to the versions of AutoCAD 1 For versions AutoCAD2000 to 2004 C Program Files AC
47. MC As VZOF 55 is used in the Fixture Origin FXO sub program G55 Work Piece Coordinate of the machine controller is set as follows G55 X 0 Y Z 200 Y 1s the height of FXO as measured in the machine coordinate Z 200 is so set because the Z machine coordinate of the center of table rotation of the machine is at Z 200 5 3 3 5 axes MC Fixture Origin FXO point of a 5 axes MC has to be set at the intersection of two axes of rotational motions namely at the intersection of either A and B A and C or B and C axis of rotation PCadCam Software XYZ values are the machine coordinate of the Fixture Origin FXO as it is described in the above PCadCam Software VI Feature Recognition System User Manual This chapter will explain the installation procedure and operation example of feature recognition CAD FRCAD software The explanation on how to use the software 1s covered in Chapter II Section 6 This chapter will cover the following 6 1 Outline The installation procedure and structure of the software FRCAD software is supplied merged with PCadCam2000 software however user has to install the software independently 6 2 Drawing Database Registration The procedure to register data into drawing database to prepare FRCAD operation on two dimensional CAD system that the user used 6 3 Examples Several examples will be presented 6 1 Outline This section will describe the preparation for FRCAD softwar
48. PCadCam Software Edit a machining feature change of type of machining feature dimension location and or machining method and click on OK button A dialog box will be displayed asking if the original machining feature prior to the change and all machining operations for cutting it can be deleted or not If user replies by clicking on YES they will be deleted and the machining feature after the change will be further processed If user replies by clicking on NO the design change will be cancelled and original feature will be still there User may repeat 3 16 1 and 3 16 2 for editing other machining features After finishing editing all features that need change user clicks CAM start icon A dialog box will be displayed saying CAM process will launch for edited machining features only If user replies by clicking on OK button CAM process will launch so that new operations for edited features will be added to the end of the list of remaining operations If user replies by clicking on CANCEL button CAM processing will not launch but wait for user to click on start CAM icon for doing CAM again of all machining features in the drawing PCadCam Software IV CAM DATABASE The standard CAM database file Sft mdb is included in C Program Files PCadCam folder DO NOT DELETE NOR EDIT THIS FILE User specific CAM Database can be constructed independently by modifying the Sft mdb file The original standard database Sft mdb should be copied i
49. Policy of the Machine Brand database User can ignore the ID number when Tool Pod ID or Sequenced T Code is selected e Diameter Title diameter the value supplied is handled as a nominal data and will not be used in NC program generation e Length Title length described in Figure 4 5 A It will be equal to tool length compensation The value supplied 1s handled as a nominal data and will not be used in NC program generation e Axial direction cutting edge Length described in Figure 4 5 B e Length of chuck described in Figure 4 5 C e Drill Mode Input a depth of cut value when it is possible to execute a drill mode operation and supply 0 when it is not e Ramping Mode Assign YES when ramping mode is possible or NO when it is not Note Assign the minimum adjustable teeth diameter for the diameter value and maximum adjustable teeth diameter for the length value when using boring tool PCadCam Software Hase Surface A i Tool Length Compensation TOOL wW G Minus Under Chuck Value Length Depth of machining E feature d2 ordi Axial Edge Length Figure 4 5 Three types of cutting tool length A Tool Length Compensation B Axial Edge Length C Under Chuck Length 4 2 1 2 Cutting Condition Right Part of Figure 4 3 e Tool ID It will display the ID number of cutting tool and its cutting condition e Machine Brand It will display the cutting condition of the tool used in that specific name of machine
50. Ro vyra LES Be a sede te BL an ft EwWiIEmBT SAY NCU E E UIL BIE OAS m min 30 i Ale mm 2 0 xp I XMEOBISOS x T SEA EI OO 0 mm 3 0 253 HEE mm3 rev 0 o m Ela Fl 3 eur 8o it UCET MADONY Ap UHELUm 21 5 6 LACEABLT FODOKoh ADU BSOD ASH Eom n TINE MLULAOSBKRT LAF 4 2 2 Machine Database The machine database includes the following Machine Brand Database Machine Database Tool Pod Database Controller Database Index Table Database for horizontal machining center only eS em The following sections will describe the detail explanation of the each item 4 2 2 1 Machine Brand Database The machine brand dialog box is shown in Figure 4 6 and it consists of the following PCadCam Software PCadCam Database Machine Brand Machine Brand ID l Mame Common Machine Type Connon W Feed Rate Max mimmin Y Controller Fanuc Feed Rate Min imm min Z Teade Palicy Fixed TCode xl Feed Rate Max mmimin 2 Feed Rate Min degimin A Feed Rate Max deg min A Feed Rate Min degimin B Feed Rate Max deg mini B Rapid Traverse deg min A Feed Rate Min mrnimin Y spindle op Min rpm spindle Sp Max ram Feed Rate Min mrmimin Feed Rate Max mmimin Rapid Traverse tdegimin Rapid Traverse Rapid Traverse degmin B X X K it i i deqimin Rapid Traverse degmin Grid View Add Delete Search Close n a Record 1 of 5 nj PCadCam Database
51. a number for polyline and the 11 1s the number of polyline generated and this file should also be copied and saved to the same folder Click on FILE then END or close the window to end FRCAD operation 2 7 7 Import Product Data to P CAD Exit AutoCAD system once upon completion of FRCAD Restart AutoCAD and click on Import PData icon as shown on Figure 2 14 A dialog box will appear to open a file as shown on Figure 2 29 Select frcad2pcad txt file name or another name as assigned Click on OPEN button Prt LOPRD Cx PCadCam amp cr Er Database frcadzpcadFrant txt frcadzpcadBught txt Headme txt Jy Hot NE fread2pcad txt Bg cn zy HADTREBC Text Document b tet Arar TI sxGHPROSHHA rt Ibe Bas IU Figure 2 29 Dialog box to open a product data file A question will appear on AutoCAD command line Confirm machining feature Y N Press N or ENTER to display all machining feature recognized by FR on a display as shown on Figure 2 30 Press Y followed by ENTER to bring up a dialog box that PCadCam Software will display each machining feature to be edited Click on OK to switch the dialog box for editing the next machining feature The system will no longer displaying the dialog box once all machining feature have been reviewed and it will bring up a display as shown on Figure 2 30 The outer part of plate like workpiece is a tentative base as explained in Sec
52. ace Click Design surface icon from pcad toolbar and user can choose top bottom left right front or back surfaces 2 2 Select machining feature Click pfeature to select and design the machining feature on the surface of the base 2 3 Select the position dimension or machining method for each machining feature Section 2 3 of CAD Operation will provide self learning guide for users Follow the instruction to understand the CAD CAM operation The description of cutter path using polyline function or 2D cut off and cutter path features will be explained on Section 2 4 Section 2 5 explains the sequence to model an optional 3D perform work piece using Boolean operations The operation to convert a 2D design by other CAD system in PCadCam2000 utilizes Feature Recognition System The detail will be explained in Section 2 6 section 2 7 and thereafter will describe the CAM and other operations PCadCam Software 2 3 Self Learning Guide for CAD Operation First time user is recommended to follow a sample exercise presented below by performing the step by step guidance as numbered Figure 2 3 shows the sample exercise to model two square slots one 2 sided pocket one 4 sided pocket and four blind bore features on the top surface with four M12 taps overlaid concentric to the bore The machining origin is assigned at the left lower corner a T T h ol pode Em pu 7 F E Mir AD 7 A T it T n d oF
53. achine coordinate in X Y Z to G56 manually Input the touch probe radius compensation value for X and Y coordinate for example 5 000mm Input the touch probe length compensation value for Z axis for example 200 000mm The illustration is shown in Figure 3 4 THEY e EE E X Figure 3 4 Workpiece Origin Point Measured on Vertical MC 3 11 4 Manual Input of Workpiece Origin Point on Horizontal MC PCadCam Software pon moot AGE Basis B saic ATUS a J B 270 Y pap BAITARA V4 E I eser ARS Figure 3 5 Workpiece Origin Point Measured on Horizontal MC Measure the workpiece origin point by using a touch probe then input the measured coordinate value machine coordinate in X Y Z to either one of G56 G57 G58 or G59 shown in the above figure manually 3 12 Handling Z Direction over travel When machining a tall workpiece using vertical MC the machining surface in Z direction will be located in a high position Z direction over travel alarm will occur especially when the spindle approaches the surface after tool change The alarm may also occur when the spindle tries to retract itself into the highest position Similar problem also occurs in horizontal MC When such problem occurs modify the Initial Point value in the Database Click on Default Values of Settings and view the value on the Initial Point The initial point is the position where the tool stops at the given value in front of the workpiece after
54. aterial Size a X MENU X 40 Y 405 000 Y 400 Z p0 000 b Base Material Quality mm Top Botto Front Back Left Eight Hone r C Rough r b Hedium Finish 5 v Figure 3 1 Example design confirmation Figure 3 1 shows that XYZ value of the raw material and product are given so that it requires machining for all six surfaces If the drawing opened is found either too large or too small drawing size may be manually adjusted by the following procedure PCadCam Software 1 Key in limits then press ENTER key 2 Command line displays instruction to specify Left Lower corner Key in for example 500 500 then press ENTER key 3 Command line displays instruction to specify Right Upper corner Key in for example 500 500 then press ENTER key 4 By displaying Operation Sequence table on the screen the drawing is adjusted to the new size specified in by the above procedure Drawing size in PCadCam is adjusted by the default to 50 50 from the Left Lower corner of the screen and 50 50 from the Right Upper corner 3 2 Process Planning Process Planning and Operation Planning are the two operation stages that will be conducted in CAM Operation Process planning includes the selection of machining process to machine a part type of machinery and fixture to be used or which surface to be machined User will be involved in making the selection CAM system will assist user in making th
55. be installed Select the components you want to install clear the components you do nat want to install Click Nest when pou are ready to continue AutoCAD 2000 AutoCAD 2000 AutoCAD 2002 AutoCAD 2004 AutoCAD 2005 AutoCAD 2006 Current selection requires at least 23 7 MB of disk space Cancel PCadCam Software A dialog box 1s displayed in which user specifies AutoCAD version and the Operation System of the computer that are used Also language should be correctly selected for each software Butac ap ett Ing Tor POADIGAM Automatic EO English C Japanese POadGam Path a c EKProgzram Files PCadGam AutoCAD Type hutoCAD 2 002 Jasanese Operating System Type Windows AP Professional Japanese FINISH Click on START button Infor mation E 3 xj Start setting up PCADCAM for AutoCAD 2002 Japanese Version on Windows 2000 Japanese Version Kx Click OK Intormatian Click OK PCadCam Software AutoCAD Setting for PG A Ot TU D Automatic tv English Japanese Peadeam Fath C Progran Files PCadCam AutoGal Type autacaD 2 005 Japanese Operating ovetem Type Windows KF Professional EEE z FINISH Click on FINISH button Installation is finished and PCadCam may be operated If Free Trial License has been installed please be careful that it can not be i
56. button The dialog box will disappear and user has to follow the message that appears on AutoCAD command line The first is message will be to select the design origin using snap function Move the cursor and click once on the selected point The messages continue to select a point on left bottom corner and right top corner The point selection sequence will be as followed e Design origin Select one point on the view e Left bottom corner Select one point on the view e Right top corner Select one point on the view 2 7 3 3 Selection on two or more projections A dialog box as shown on Figure 2 21 will appear when the above selection 1s made and same as one view Selection user should select one point for design origin left bottom and right top corners At the lower part of the dialog box there are three choices on surface of machining feature VISIBLE means for example a front view for plate type workpiece PCadCam Software INVISIBLE means the feature designed to be recognized is on the back view m ETd T 0 5x LJ pE F a fe ai CIE L I En CENE zz EE a 1 hn IB m RASE ORAHE CRASHERARL E E Cancel rum a TTE LG CENE IM A a k Ti an TL Und T EM MM NUES GENER REEL ER J E 2 1 NN TL 7I r E RUN EN NR S H L TT s a ke i S a HS a a M T d ety Figure 2 21 Dialog box to inpu
57. button to modify the decimal point on UVW and parameters of the feature being highlighted Copy amp Paste Press this button and the highlighted column will be copied under the last column with a new sequential number Insert Feature Press this button and the highlighted column will be inserted to the next one Delete Press this button to delete the highlighted column Cancel Press this button to abort any revision operation made on the machining feature data OK Press this button to end editing operation and P CAD will generate a text formatted product data automatically as shown in Figure 2 28 PCadCam Software The display on Figure 2 28 shows the dimension of a finished product the coordinate origin of each design surface and machining feature in sequence On the column of machining feature on the left 1s the name of the feature followed by design surface level of finish machining top bottom orientation chamfer width position UVW then specific parameter D1 D6 orientation angle There will be an additional column when polyline exists The file of Figure 2 28 display will be saved in C N Program Files PCadCam folder with frcad2pcad txt name automatically assign This file name will be overwritten when the next results of FR operation is generated Therefore it 1s recommended to copy and save the file to a different folder for a record If polyline exists the file name given will be p11 txt 1 is
58. ce of workpiece 0 degree surface User should also create five axes machining in machine brand data before creating the data in machine data Input the data for Primary Axis and Secondary Axis and orientation after assigning five axes machining in machine brand column as shown in Figure 4 11 PCadCam Database Machine Machine ID 19 X max Machine Name HMcConh X min Machine Brand Ib xes MC gt Y max Dummy Tool ID Tb Y min Tool Change SPID 6000 Zmax End Machining SPID 6001 Zmin Local Coordinat SPID 6003 Common Variable Fixture Origin SPID he Generate Sub Helical Interpolation Teg ACS l Adv T Call Time Calc Pararneter TE Primary Axis PA n Secondary Axis S Primary Orientation Secondary Orientation Normal wiew Add Delete search Close IEEE nm MachndD Nane MachineBrand DummwToolD ZF scape 39 fMeboh s z00 j20 BH chon 43107 mTMb j B chonb 1 1 Mb 12 17 PCadCam Software User has to confirm the machine data in relation to other elements in the main database system when a new five axes machining machine data is created l Tool Pod database Set the tool pod database for this machine 2 Index Table database Set the index table database 3 Standard Fixture database There should be at least one fixture available for five axis machin
59. chine tools in which two rotational axes tilt work piece It is not applicable to such machine tools that the spindle is tilted in both or either one of the two rotational axes There are four types of two rotational axes combination that can be applied in horizontal or vertical MC as shown in Figure 4 10 Five Axes Machining on Horizontal MC C on A B on A on B C on B 1 Rotational Axis A A B B 24 Rotational Axis C B AT C 3rd Axis Direction Y Z Z X Five Axes Machining on Vertical MC ConA Bon A on B C on B 1 Rotational Axis A A B B 2nd Rotational Axis B A Cu 3 Axis Direction Y Z X PCadCam Software Figure 4 10 Types of five axes machining on horizontal or vertical MC For example when A axis is in 0 degree position there are two types on the left side of the illustration whose difference relates to the rotational axis of the tilting table faces either Z axis or Y axis The rotational axis 1s called C axis when it 1s facing Z axis and it is called B axis when it faces Y axis The first rotational axis in the illustration is an inclined axis that carries the second rotational axis The second rotational axis 1s the rotational axis of the tilting table In addition notice the sign when A and X axes B and Y axes or C and Z axes head to the same direction and sign when they head to the opposite direction The third axis direction column describes the direction of the reference surfa
60. chining features and also to continue to CAM process after completing CAD design Save the file step 17 after any revision 1 Click the Tapped Hole Feature icon to display the following dialog box of Figure 2 4 Repeat OK Came PCadCam Software Tea Pe Le Feature ase Tap n ani Orientation f D eurface Tap l Wl Bick Mame Feature Parameter dl i 000 LMCE AG d f gi d 13 800 Of ealuna origin y i d4 0 000 IES i 4 e Dhanfer i 000 Ane 0 Kachining Etandard tap with cenfer Operation Data t aE Figure 2 4 Tap feature dialog box 2 User can click on the pull down menu next to dl to display all type and size of taps available as listed in CAM database PAARMA HEURES Ie UT nam rieatation T nn Surface Wm zit mmm Wick Mame Feature Parameter di 0 000 RENE d 000 d 14 RH Qaa ura origin y d i 000 IES Chanter fi 000 Ansla Machining Etandard tap with confer Operation Data t C Figure 2 5 Display the size of tap 3 When a tap type is highlighted user can key in m then the pull down menu display M type The size of M type will be listed starting from M3 regular pitch thread upward in tap size then followed by the fine pitch ones PCadCam Software Feature Kame Tap Origin j i i riemtatiom Y Am Surface Top gt M Wick Hama Feature Parameter di TZ 000
61. con notice that the d3 parameter is not the depth of cut but it 1s the thickness of the workpiece material The depth of the cut off will be decided by the data assigned in the database e By selecting the chamfer in machining method the polyline will be chamfered along the line In such a case the d3 will be the data for the width of the chamfer e When selecting the cutter path icon the width of cutter path will be assigned temporarily Later in CAM process will the width of cutter path be given according to the cutting tool diameter chosen by the user 2 4 3 Nesting Nesting can be performed on cut off or cutter path operation using polyline as well as on other machining features whenever it becomes necessary to copy move rotate or mirror a feature Select the object of polyline or machining feature to be copied moved rotated or mirrored once Do not select the object repeatedly Do no use the window or group selection function provided by AutoCAD to select the object PCadCam Software 2 4 4 Operation data for cut off machining User can change the operation data for cut off machining in a similar way as on the other machining features Refer to Figure 2 8 that describes the data generated and its machining sequence in three operations Operation 1 Tool 18mm roughing end mill Spindle speed 710rpm Axial depth of cut 15mm Feed rate 125mm min Down cut Coolant Product Operation 2 Tool Tool
62. controller device Controller Name A name of the controller device G10 Length A writing of compensation value in H address format when sending the tool length compensation value to memory G10 Diameter A writing of compensation value in D address format when sending the tool diameter compensation value to memory Note When the memory transfer of tool offset data tool length and diameter compensation values is not going to be used and instead the data will be input manually input n to G10 Length and G10 Diameter For example if n 1s only assigned to G10 Diameter the data of tool length compensation will be taken from the tool offset data of tool pod database G10 Value The writing format to transfer the tool compensation value in G10 code from memory Min Max AddressID An address to input the minimum or maximum value of tool diameter D or length H compensation Metric Inch Format G code to set the unit of length 1n meter or inch Note When the G code setting for meter inch is not available input n in the column T Format A T code format to classify the tool in NC program Example 1 T Normal case when ATC 1s possible Example 2 T In case of machine that can not do ATC so that manual tool change is to be performed and T code is to be written in brackets Example 3 MO6T In case when it is necessary to write M06 and T codes in the same block NC No Format The format to set the number of NC program TL O
63. cted user can display all vertical or horizontal MC available It 1s also possible to change the name of the machine to create an NC program for that selected machine name PCadCam Software Apply Tool Diameter Compensation G41 G42 A column for G41 G42 is located on the right part of the operation sequence list Click a finish operation that will use tool diameter compensation and point the cursor to the bottom of G41 G42 and click once to bring up a X mark The tool diameter compensation will not be applied to any rough or canned cycle machining even if the check X mark is given Click on Time Calculation toggle to bring up an extension colum at the right part in which the time data will be displayed Click on Calculate Time to start the calculation of time quatation The result of the calculation will be displayed on a text processor so that user can save the file by using the same name for the drawing with added TIME to easily locate the file in the future Closing the text display and the time data unit second will be displayed on the operation sequence list m Operation Sequencing E afk Tool Parameter Operation Name Dopt Tool Type Die fee Se Re ih col PG e por SC Axial Edge Length 4 Sub eer S Under Chuck Length f DO Guiting Condition Spindle Speed rpm 557 Radial DOC mm 10 Feature Parameter Axial FR mm min BE Dwell tzec 3J di 105 U Axial DOG mm 10 Cutting Logic F5 hsk
64. d by a comma and press ENTER This step is necessary only for AutoCAD2005 and above This step may be omitted when using AutoCAD2004 or below Key in UCS and then push ENTER Key in S and push ENTER Key in A actually the key may be any alphabet and push ENTER Click the Design Surface icon and click on Create button A dialog box of Figure 2 10 will appear listing all of the origin point to confirm the new surface Give a name of the design surface and select the color for machining features that will be generated on the new surface red is a default Click OK then a small message window will appear to ask if user want to display the cut base material select YES ee Surface Rad Dia stu vant ip cut bar rere EI alt Se Lee zl M PF k pump m Figure 2 10 Confirmation of the new surface generated Click ALL and OK to display the outline of the new cut base material Click on the Design Surface and select the name of the new surface User can proceed to design machining features on the new surface 2 5 2 A Method to specify two points on the surface normal It is a method convenient to set an inclined surface rotated around either two of A B or C axes PCadCam Software The description of the method is shown in Figure 2 11 NEW ORIGIN 2 y eot Y P ae STANDARD ORIGIN Figure 2 11 Two point relation on principal line method
65. e selection by referring to Table 3 1 in which several process planning are listed The graphical explanation of machining process for process planning A B C I is shown in Figure 3 2 Table 3 2 lists further guidance in selection of operation User can refer to Table 3 3 for further step by step and detail explanation Table 3 1 Process Planning Alternative Top and Bottom Surface V MC B 2 Parallel Surface V MC amp H MC Four surface with Index V MC A Index D 3 Surface H MC Other Process Plan 5 Axes machining AB or AC Index Not available V MC A Index arbitrary angle H MC B arbitrary angle Process Process Machine Machining Surface Number o Pe Bottom amp some Side o Pe Top amp Side V M C User 1 surface H M C User 4 surfaces V M C User 1 surface C MC User 4 surfaces PCadCam Software H M C User 3 surfaces Pfs fime sees E tT YV MC JUser lsufac PET Fs axes ME User lt sure TC E Plate Machining A Bottom amp Side continue to Top amp Sides A 1 Bottom amp Side A 2 Top amp Side Block amp Block B Machining 2 paralell surfaces and the other four surfaces B 2 4 Side C 1 User to decide 4 surfaces D 1 Three surfaces machining D 2 Other three surfaces machining Other Process E User to decide one surface machining Figure 3 2 Machining Process in Machining Center Process Planning PCadCam Software Table 3 3 CAM Operation No
66. e data symbol for material types on normal machining condition In the mean time install the tool data and machining method database belong to TUT While using the database user can modify the data to create their own unique database PCadCam Software 5 1 Data Preparation inside CAM Database 5 1 1 Machine Brand Database Preparation Input 1 for machine brand ID and input common value for machine name and machine type Also type other data as shown in Figure 5 1 PCadCam Database Machine Brand Machine Brand ID Name Common Machine Type Comon B Feed Rate Max mrn min Y Controller Fan Feed Rate Min mmimin Z TGade Palicy Fixed Toode Feed Rate Max mm min z Spindle Sp Min rpm Feed Rate Min deg min A Feed Rate Max degirmin A Feed Rate Min ideg min B A x 000 Feed Rate Max degimin B X 30000 Rapid Traverse degimin A Y fa Feed Rate Min mmmin Y spindle Sp Max rpm Feed Rate Min mrmirmin Feed Rate Max mmmin Rapid Traverse deg min 30000 Rapid Traverse degmin B 30000 Rapid Traverse deg min Rapid Traverse deg min Noral View Add Dee cose Ia 4 Reco ers nni MachineBrandlD TCaodePaolice SpindleS Phin Hu Cii TI mu 3 8 H l hm E bees We 8 fp 1 M rr YHE with index 4 b 1 10 k Figure 5 1 Dialog box of machine brand data example for Common machine
67. e installation There are two important files to run FRCAD frarx and frcad mdb and these two files will be set automatically when user installs PCadCam2000 to C Program Files PCadCam folder The following section will describe the method to install FRCAD database 6 1 1 Connecting Database FRCAD 1s operational in database administration system using Microsoft Office ACCESS software The database is connected via ODBC application which is included automatically when installing Microsoft WINDOWS operating system User can also download ODBC application from Microsoft com Perform the following operation to set ODBC 1 Open Control Panel to bring up a display as shown on Figure 6 1 Depends on the operating system ODBC maybe be located in control system under administrative tool ar HES Ims Ci Pasa engen r EI a Eva Vee Fi Fi ei i e PCadCam Software 2 Click on the ODBC icon and the display is switched as Figure 6 2 to display the ODBC data source administrator Click on Add button MOOBC Data Source Administrator User DSN System DSM File DSN ODBC Drivers Tracing About User Data Sources Mame Driver dBASE Files Microsoft dBase Driver dbf Excel Files Microsoft Excel Driver xls FoxPro Files Microsoft FoxPro Driver dbf Configure MS Access 37 Database Microsoft Access Driver mdb Text Files Microsoft Text Driver tet ce An ODBC User data
68. e reduced in a sequence of 51 50 49 If the sign is not given the sub program number will be increasing in sequence of 53 54 55 Sub program number 6003 is a machine resident sub program for finding FXO that will move the spindle to above the fixture origin point This machine provides helical interpolation machining capability movement in Z direction to operate helical interpolation on XY planes using G41 G42 therefore assign YES to the helical interpolation column If such capability does not exist assign NO The present CAM system does not handle maximum stroke in X X Y Y therefore 0 is assigned to each column Input in the maximum stroke in Z column maximum height of the spindle relative to PCadCam Software the Z value at FXO Fixture Origin Point being 0 Input in the minimum stroke Z column Z value subtracted with Z stroke of the machine Z axis escape 250 means that as the spindle moves to next XY position after finishing an operation the spindle is first escaped to Z 250 height relative to Z 0 at FXO then lateral motion in XY As the machine allows use of 100 or greater number as the common variable number common variable is set 100 Capability of automatically calculating XYZ coordinate values of the NC Program Reference NCPR point is activated by setting Yes Advanced T Call function is inactivated by setting No Also Rigid Tapping is cancelled by se
69. eature Recognition or FR is a function to import a file in DWG or DXF format of two dimensional CAD drawing that is used widely in industry FR software is not meant to provide a multi function system in principal but user can make good use of this software in PCadCam as an auxiliary input function User has to register the sign or drawing method of the two dimensional CAD system in the drawing database to start FR software Refer to the last chapter of Feature Recognition System for detailed explanation PCadCam system calls the boundary of a part as BASE that represents a rectangular parallel hexahedral plate or block When using FR system user will assign two corners from one projection in the drawing and the system will build the BASE automatically FR will recognize the position and shape of any hole pocket step and slot features designed on the BASE then supplies the data to P CAD Data input from FR to P CAD can be done in a simple way It 1s most effective when there 1s a great number of shape or feature designed 2 7 1 File Input Preparation Drawing from 2 D CAD system has to be prepared in either DWG or DXF format to be imported into FR system The drawing should contain projection of the part that will show all the machining features to be processed in CAM operation Erase or remove the frame of the drawing table or dimension that exists 1n the drawing before starting FR operation 2 7 2 Input the Drawing File into FR
70. egister COMMON for the type of material and machine brand when the data is ready Additional registeration can also be done later in the CAM operation The priority of selecting cutting condition by CAM system and presentation to user is as follows 1 When data for specific type of material and specific machine brand are found it is selected with top priority 2 When data only for specific type of material 1s found it 1s selected with the next priority 3 When data only for specific machine brand is found it is selected with further next priority 4 When no data is found for specific material or specific machine brand data for CMMOM material and COMMON machiine brand is finally selected 4 2 1 3 Additional registration of cutting tool By clicking on Add Tool button in previous Fig 4 3 following kialog box will be displayed for registering new cutting tool in the database By following procedures to 3 instructed in the figure a new Tool Number has to be selected that does not overlap with existing ToolID PCadCam Software Toob EE 8 Crillkdode AxialE daeLength LinderChuckLength Sumba 18 5 D D 40 100 4126 100 427 lE JE 20 oo X n 0 4 iw gt GE EE IHE d 0 o E Ej 100 das a e2 HELE TA MEMOTooMDFAMOEHSS ZOOTN Jal Phic 01107 AP FOSC ene quED uo e THES M98 Tool Cat GEOP TES E EE TREIZ 21 5 eva kun 1 1 Bf f d CHE IHERSG 100 FUE E Lo
71. er left part of 35mm square 2mm depth click the icon as shown on the right and input the data as 17 16 19 20 21 Switch to view ALL Save design Change to solid model FINISH Tap Feature Design PCadCam Software Crenit healer Feature Waso Facing AEE rlentatil n Loser Lafi yi n tee A n mgl Surface ee Mick Fane Feature Parameter E Lower lett machining d r 2i dt iz dE Chanter i i iele n am Machining Finish __Operat iow Data Later in CAM tool path will be generated starting on the edge opposite to the reference point in parallel to the length dl and in the down milling mode Change the view as in steps 5 and 6 to view ALL to display all surfaces with the designed features Click the icon as shown on the right to save the file As for example save the above sample design as SAMPLE and the AutoCAD will assign dwg automatically to the file as its extension The sample design has been completed and saved However to display the sample file as in Figure 2 3 change the display steps 5 6 to SOLID User can view the part in an optional orientation by typing in VPOINT in the command line followed by ENTER Input the value of XYZ to the desired orientation followed by ENTER Type in HIDE to put out the hidden line followed by ENTER Return the design surface to drawing mode the display before SOLID to revise or add ma
72. eration sequence dialog box or change cutting tool and cutting condition Select an operation then click on the Delete or Edit button Keep pressing Ctrl key while selecting multiple operations to erase all at once In such a case undo function is enabled only once The default display of the workpiece when opening operation sequence is TOP view User can change the view by selecting the surface listed on the left bottom part of the dialog box to confirm the origin position if necessary Move the scroll bar up and down to change the view scale of the workpiece Editing a cutting tool to be used and its cutting condition on an operation will bring up a dialog box of Edit Operation Data At the lower part of the dialog box if the toggle box of Copy Cutting Condition with Same Tool is checked the system will apply the same changes to other operations that use the same tool automatically If the toggle 1s not checked the revision will only apply to that particular operation Returning to Operation Sequence dialog box if an operation with canned cycle is selected Initial point return will be displayed next to the canned cycle shown at the bottom right This is to describe that tool returning to the initial point will be performed and if it 1s required user can also change to PCadCam Software R point return for the tool to return to an R point At the bottom part if the pull down menu on Machine is sele
73. erpolation Select YES to allow G02 G03 helical interpolation function to run and a helical tool path will occur during a circular machining The circular machining will run in drill mode if NO is selected Maximum stroke Overrun limit of X Y Z User should input the zero point setting of FXO fixture origin point not the machine origin coordinate PCadCam Software e Z Axis Escape A number that defines that height distance in Z direction for the cutting tool to escape during operation In case of machining more than one but similar feature the cutting tool will escape and return to this height after each machining before continuing to the next one PCadCam Database Machine Machine ILI 1 X max Machine Name Common X min Machine Brand Connon Y max Dummy Tool ID T999 Y min Tool Change SPID 4 Z max End Machining SPID b Z min Local Coordinat SPID 57 Common Variable Fixture Origin SPID bb Generate Sub Helical Interpolation No ACS EUIS Adv T Call Img t aib r aramieter Rigid Tap ardien Add Delete Search Close IE gg PCadCam Database Machine Machine ID 2 X max Machine Name Enshu ji X min Machine Brand Enzhu Y max Dummy Tool ID T145 Y min Tool Change SPID 6000 Z max End Machining SPID 6001 min Local Coordinat SPID abe Common variable Fixture Origin SPID 6003 Generate Sub Helical Interpolation Yeg ACS Adv T Call Time Calc Parameter asi Tap cili lese Add
74. ffset The format of tool length compensation command No Cycle A symbol to avoid executing the block after defining a canned cycle Sub program call A format to call a sub program Sub program return A format to return to main program Local coordinate A G code to shift the origin to NCPR Input G52 or G52Q2 command when using local origin shift In such a case the common variable will not be activated Input G56 when using macro variable or when the workpiece origin is measured on the machine and manually input Input G92 when all the above is not applicable Sub Repeat Format A format to define repetition of sub program execution Local coordinate return Select NO when G52 or G56 1s entered for Local coordinate code If G92 is set for Local coordinate code Local coordinate return code should be a code specified for canceling G92 PCadCam Software e Macro Format A symbol to write common variables in macro program For example user has to write in FANUC or MELDAS controller Input n when a machine cannot run a macro program with common variable or when the macro program itself will be executed User should input n when using a PC with Japanese letter e M57 Airblow M code to activate air blow operation e Initial Return A command to return to the initial point after completion of fix cycle e R Return A command to return to point R after completion of fix cycle e TChange Prep Code Input an M code f
75. ght It is called a machining feature list Polyline data will not be included in this list urea Cr grin AM al Foyjhirang ark by Pii Fa P itil4 br 4 E uri d a di nei E I J oe i i i e i l l l l Feu n i dime F an Ws Fain Cian A om EGE D ak E em 56 zr 56 ET e E A 25 iB i Pararwriar Anglo Figure 2 27 Dialog box for correction on results of FR operation Right click on any column using the mouse pointer to highlight all machining features on the same position Left click to highlight each column It is also possible to highlight by optional on several columns by pressing SHIFT or CTRL key while clicking the mouse User can edit the parameter of the highlighted machining feature shown on the left of the dialog box There is a possibility for the system to mistakenly recognized the feature therefore it is highly recommended for the user to confirm the results with the drawing and correct them PCadCam Software accordingly User should also correct the depth of feature because the value listed 1s only tentative Highlight each column to revise the position of machining feature U and V values as well as orientation angle The digit of accuracy for machining feature position UVW and variable D1 D6 1s set to be three decimal point The system will round off the decimal point if it is smaller than three Tap and step hole only use one digit of accuracy Apply Click this
76. h First click on New Tool button of the above dialog box to bring up another one as shown below PCadCam Software New Tool TCode h Symbe 4 roe C NN est LE RR RR EMMYBID 5 R soo J Jo 0 ig fos s E m0 0 0 50 Emos L smoexwin 9 W0 15 0 i00 Emos o 5 a 30 5 4 4 I Tool Parameter EE Tool ID 00631012 per Sas n T Code ig Diameter B3 1 tt iv kamping Mode Length i300 nder Chuck 40 Drill Mode l 5 0 00t Axial Edge Length 30 symbol PO Cutting Condition Cutting Speed 150 06351 Radial FE mm tooth 0 19991 Ho Tooth B Radial DOC A417 Axial FR mm tooth 0 11008 WERE mm rev 500 Coolant hirblow Axial DOC Rough mm pn Axial DOC Finish mm p 3 4 Operation Sequence Click on the icon to view the sequence of machining operation generated by CAM User can decide and rearrange the sequence whenever necessary There are two methods to change the sequence by changing the sequence one after another or by grouping them then apply the change Select an operation then push the Up or Down button on the right to change the sequence on a single operation To change the sequence by group input the starting sequence number in From column under the Move Group Operation and the ending sequence number in To column on the right Input a number in Insert column in which the group will be
77. ical change milling machine O 0004 O 0004 G21 G54 G40 G49 G80 G40 G80 G49 G90 G17 G52 X0 YO ZO G52 X0 YO ZO G91 G30 ZO M98 P55 G91 Z 5 M00 G90 G00 M99 G55 X0 YO M00 20 X300 G91 G30 ZO M99 FANUC Controller FANUC Controller In the case of three machines in the upper table since the Tool Change sub program number has been set to be 6000 in the Machine Database Tool Change sub program starts with sub program number 06000 L6000 for MELDAS controller 04000 1n the case of two machines listed in the lower table First line after the sub program number lists a code for canceling Local Coordinate Shift G52 for Enshu400machine G92G53XY Z0 for OKK machine and G52X0 Y0 Z0 for Pindad and MAKINO machines Subsequently the spindle is moved to a position appropriate for the tool change motion then Tool Change code M6 is listed In the case of Pindad and MAKINO machines which are for manual tool change M06 is replaced with a machine stop code M00 5 2 2 Ending Operation Sub Program Enshu Vertical MC O6001 M9 G91 G30 ZO M5 M99 YASNUC Controller PCadCam Software 5 2 3 Fixture Origin Point FXO Sub Program Fixture Origin point FXO sub program is necessary if Automatic Coordinate System ACS calculation is set activated in the Machine Data base It is not necessary if Work Piece Reference Point 1s measured on the machine and manually input to the machine controller Okuma Horizontal MC Hor
78. in the drawing database 2 7 5 Polyline Operation Figure 2 26 displays a dialog box for polyline selection that will appear when FR system detects an existing polyline in the two dimensional drawing The system will bring up PCadCam Software the dialog box only if the operation of polyline generation is registered in the system setting data in the drawing database Palvline Selection Selection an element of polwine Feature Mame Festure Orientation 4 iB hn RUS tte e DERI Bizr B ow 2 n i j FARR a e as Ara c t res nm C at Glee cow r70 AEW Feature Name Orientation Design Surface Depth Figure 2 26 Dialog box to confirm polyline selection Add Polyline Refrain from using this button temporarily because of technical problems User is advised to use next function Select ATI This button is used to recognize line elements that exist in the drawing but not yet listed as polyline in the dialog box Polylines that need to be processed by either Cut Off or Cutter Path operation are listed in the dialog box by following procedures Click on Add Polyline button a message is displayed test of bully Escape from the message by clicking on OK button Then click on a line element in the drawing that user wants to add Name type Cut off or Cutter path se
79. ine data have been completed then close the window 6 3 Examples It is necessary to revise the setting based on the type of drawing will undergo feature recognition operation The following section will present several examples of the operation 6 3 1 Recognition on One View with Polyline Set the following into System Configuration of Figure 6 16 Polyline Generation Set to Active for automatic recognition on polyline View Design Set to Visible Surface to run recognition only on the front surface or set on Surface Visible amp Hidden Surfaces to run recognition on both the front and back surfaces select CONVENTIONAL ONE VIEW on the dialog box after clicking on feature recognition icon to start the operation Input the Material Thickness data accordingly Figure 6 17 Example drawing for ONE VIEW projection with Polyline 6 3 2 Recognition on Multi View Mi L r pene H i uh bm du mL m Liza Figure 6 16 Example drawing for MULTI VIEW PCadCam Software The example shown on Figure 6 18 contains multiple polyline on the boundary of the cast material however none of them will be machined Therefore set the System Configuration into Polyline Generation NotActive View Design Surface Visible Surface Select MULTI VIEW PROCESS on the dialog box after clicking on feature recognition icon to start the operation Assign the following surface design name for each projec
80. ing 4 2 2 4 Tool Pod Database Tool Pod database dialog box is shown in Figure 4 12 and it consists of the following Machine name A name given to each machine Machine ID An ID number given to the machine Tool Pod ID Tool magazine pod number Tool ID An ID number of the tool in the tool magazine Tool Diameter Tool Length Tool length compensation Tool usage frequency Accumulation of the usage of a particular tool in CAM process PCadCam Database Toolpod Machine Machine ToolPodID Tool TDiamter TLeeniath 27 1 q7T40iz0000 i 100 j27 e 7e0z00000 20 100 j27 a Qgv40iz0000 i 100 27 4 200007103 5 100 j27 8 110043000 4 3 10 27 8 110051000 5 1 18l 27 7 200007104 8 10d z27 Q8 gi 068000 6 8 1 1 100 j27 8 200007105 8 10 j27 Q0 ii 088000 3 6 10 Ir nn 134 nn 3 m 4 Figure 4 12 Dialog box of tool pod Note 1 The number of tool magazine should be somewhere in the lowest and highest range of address data in controller database Take ASSFANUC Controller as an example if the lowest address number is 1 and the highest address number is 201 then the tool pod number should be from 1 to 201 If it is not done accordingly an error will occur during the NC program generation PCadCam Software 2 Tool usage frequency is updated a
81. ing Condition Inol Parameter Tool Type HRLACRUMR v Tool 1 100 Axial Edge Length 40 Symbol pe Under Chuck Length in Cutting Condition i mer ns E 2 x Spindle Speed Kon rs 88 eun 18 000 i38 Bre Pune mm z eed Rate mm min TUER z aret o mmo o 2 Axial DOC mm Radial FR m min Radial DOC mm 1 000 I Cutting Logic Gal EL Coolant Coolant Machine JEET T E CEE Copy Cutting Condition With Same Tool 4 Lad EEN iew Feature View Feature Cancel When automatic selection of cutting tool is not available during process planning the next dialog box will appear for the user to select cutting tool The machining feature is marked red in the drawing beneath dialog box for which the tool will be used User should select and input the appropriate tool type and diameter length data then click on OK button PCadCam Software Non Selected Tool Feature Name Operation Feature Parameter eO fearure origin lu vw dl d d d Angle Chamfe d2 or d3 W Tool Parameter Tool Type Tool Size 11 100 Axial Edge Length Under Chuck Length D pt ormbo A kL Bl New Tool a Lancel If there is not any tool available even after searching for the tool type and D L data a new tool data should be registered in database system The method to register a new tool is explained herewit
82. ing user to confirm or revise the dimension of raw material when the raw and product dimension are different When they are originally the same user cannot do any dimension revision as shown in the above example Workpiece Origin Shift Workpiece origin can also be shifted in the next dialog box when the use of spacer etc is required to clamp the raw material Input the new data and click on OK geen Ta Petr Pr El Bore Bkck ra B SURFACE Src CH fce n pere g 4EPockerT m Oo nic M Bae BET v n u Ez Pacha nc B him H BaraBicck52 nec B 45Pocketz2 re u ac m Bare ioc zz ne i 42 Packattinc E BereBicch re U Bara Blech ore BxeBkekTlne ju BareBlockzee re E BaraBickii wrz W BaraBieckatre Hj Bys Blech 18 ec uj Be Block ov ng PCadCam Software nee Bckzwne m Braz M Barre ne Baza a Basel re B Ba H Erai irc T Herei n Bape Wim E Esni M Erin Bj Brin u Boge re B Based M Brati rez H Biim B Bri DECHE Input NC Program Input the NC program number the machine will Number differentiate NC programs based on their number not name for example 1000 in the next dialog box The automatically generated NC program will have O 1000 number at the top indicating the number Input a comment in the Description column if needed such as sample The comment could also be abbreviated In the case of vertical MC user can select or revise the workpiece orientation CCW orientation
83. ion accordingly and create a name for the file 2 6 3 Machining Feature Design Upon completion of the preform raw material model user can continue to design machining features on the model as described in the lower part of Figure 2 12 The machining features will be displayed in color and will be processed in CAM operation to generate the NC generation Input a negative value W column in machining feature dialog box when the user needs to shift the origin of machining features lower than the BASE surface The value is the distance from the surface Input a positive one when the origin point 1s located higher than the surface 2 6 4 Closing CAD Operation User should examine carefully the two factors explained in this section after completing CAD operation and before continuing to CAM operation 1 Origin point for each design surface PCadCam Software The last origin point given for each design surface will be processed in CAM operation as the NC Program Reference Point NCPR that is X 0 Y 0 and Z 0 Refer to Section 2 3 step 4 to display the origin point for each design surface or to shift the point 1f necessary Save the design and proceed to CAM operation 2 Save the design User should save the file after any revision done on the design as explained in Section 2 3 step 17 2 7 Feature Recognition FR Input None of the previous steps in P CAD operation will be used to design a part when using this function F
84. ired parameter in a dialog box below for the horizontal direction PCadCam Software Puare slot E ETE E lorizonia creature origin uM si User may click OK to complete the design However since the next feature to be designed will also be a slot feature click REPEAT to display the same dialog box Note The repeat function is only applicable to the same design surface It cannot be used to design a same feature on a different surface 9 Repeat slot feature Click the icon as shown on the right to repeat the same ii feature but in a different orientation Med d reatie origin ac lu ysl I 4 rr 10 Two sided pocket Click the icon as shown on the right and input the design machining parameter required as shown in a dialog box below PCadCam Software Fenture Wome f 2d p ch t T Heist ino Orientation Wr Fight zu xn Sur nce tT F ne E an Mick Mame Fenksre Parameter ad fim a foo d3 Eun JU Eun 4d p Cheater 0 ink I linchininn E ugh BRE a ee Edit a machining Click the icon EDIT as shown on the right to revise the Le feature parameter on a machining feature that has been designed AutoCAD will display a command to Select Feature Move the cursor to select any line of the machining feature to execute the command The same data will be shown in a same dialog box of the feature selected Revise the data
85. izontal MC Enshu Vertical MC O 6003 O 6003 O 6003 VC111 VZOFX 55 G40 G80 G17 G40 G49 G80 G90 G17 G52 VC112 VZOFY 55 111 5241 G91 G30 ZO VC113 VZOFZ 551 112 5242 111 5241 113 5243 112 5242 G55 113 5243 RTS M99 YO M99 OS Controller FANUC Controller YASNUC Controller FXO sub program number for those machines have been set to be 6003 in Machine database sub program number is written O6003 in examples in the above First line after the sub program number lists a number of cancel codes including Local Coordinate Shift cancel Examples in the above are for machines whose Local Coordinate Format has been set G56 in the controller database Following examples are for machines whose Local Coordinate Format has been set G52 in the controller database PINDAD Vertical MC MAKINO CNC Vertical Milling Machine O0055 O0055 G40 G49 G80 G90 G17 G40 G49 G80 G90 G17 G52 X0 YO ZO G52 X0 YO ZO G91 G30 ZO G91 G28 ZO G90 G55 GOO XO G90 G55 GOO XO YO YO M99 M99 PCadCam Software FANUC Controller FANUC Controller 5 2 4 Table Index Sub Program Required only for Horizontal MC Vertical MC attached with rotary Index devise or 5 axes machine Okuma J MC Nfbt 87 MC O6010 O6010 GOO G00 M15 B 110 B VC110 M99 RTS OSP Controller FANUC Controller In examples shown in the above since sub program number for B axis table index has been set to be 6010 in the Index Tab
86. ked choose one feature in Group Confirmation the group and push ENTER The highlighted feature and others in the same group will change color to red and a dialog box associated with the feature will appear for confirmation At the same time the command line of AutoCAD will display a question of Group more feature G or Ungroup existing feature U Press G for confirmation followed by ENTER twice to complete When adding a feature to a group becomes necessary select Adding Group G and push ENTER once Click the feature to be added and followed by ENTER twice Select U and ENTER to cancel the grouping command Ungrouping A statement select or all A S features to ungroup will appear Press ENTER to ungroup all features Press S and click the feature or features to be removed from the group followed by ENTER Note Pay attention when grouping hole features belonging to different heights namely having different W When some hole features with different W is grouped together the NC program will be generated with the same process cycle therefore W value will be ignored Never group hole features with different W value 14 Overlap features Click EDIT and select any blind bore hole that has been design designed and grouped in the above step 13 Push ENTER or right click the mouse The following dialog box will appear PCadCam Software Select Y
87. l Click the item from the list to be revised before pressing this button then input the new value to execute Note a FATAL ERROR message will appear when trying to edit design surface of the polyline at this stage When editting becomes necessary do so when the Figure 2 28 of product data appears and edit the surface design number 1 to 6 DELETE Press this button to delete a polyline while it is highlighted on the list MOVE Click on this button to move a drawing by adjusting the cursor left click the mouse then dragto the new position Right click to cancel REAL TIME ZOOM Highlight the column in the dialog box using the mouse Click on this button and the color of polyline listed 1n the column will be changed into red Move the cursor into the drawing then left click to magnify or reduce the drawing Right click to cancel PCadCam Software CANCEL Click on this button to cancel all the process on the polyline and progress to the next step FINISH Pressing on this button will carry the polyline data listed in the dialog box and proceed the process as explained in Section 2 7 7 2 7 6 Correction on Results of FR Operation Figure 2 27 displays the results of FR operation that will appear if machining feature correction during FRCAD 1s set in the system setting data of the drawing database The name design surface position and dimension etc of automatically recognized machining feature are listed on the ri
88. l be acquired among options A to I available Free trial license can not be installed two times or more in the same computer 2 Purchase Formal License of PCadCam software From START button of WINDOWS execute Setup exe of the software obtained PCadCam Software A dialog box is displayed in which language to use is selected Select Setup Language Next dialog box is to enter password If by some other means a password has been sent to the user please key in that password If not key in PCadCam2000 The password is case sensitive ie Setup PCadCam Password This installation is password protected Please provide the password then click Next to continue Current Password iz FLadL amet Passwords are case sensitive Password Next user data dialog box is displayed When installing Free Trial License do not change any letter in the dialog box If any single letter is changed installation will be canceled When installing Free Trial License do not click on CANCEL button here If cancelled Free Trial License can not be installed for the second time PCadCam Software ie Setup PCadCam User Information Please enter your information User Name USER Organization TLIFES ULTIMA Serial Number 13E 030830101 D62C3646 Next dialog box will be displayed in which AutoCAD version is selected that is used on the computer ie Setup PCadCam Select Components Which components should
89. le database sub programs listed starts with the sub program number 06010 Next example is for a 5 axes machine a Vertical MC attached with a B axis rotary index carried on a A axis rotary tranion with FANUC controller In the sub program listed on the left side which is for rotation around A axis rotation angle A given by a common variable 511 is re calculated into a negative value by subtracting 360 degree if the given value is greater than 180 degree A axis rotation sub B axis rotation sub program program O 6012 O6011 G00 IF 511LE180 GOTO BH512 100 M99 511 511 360 N100 GOO A 511 M99 5 3 Setting of Fixture Origin Point Coordinate Fixture Origin point FXO is set in the Work Piece Coordinate usually G55 of the machine controller if Automatic Coordinate System ACS calculation is set activated in PCadCam Software the Machine Data base It is not necessary if Work Piece Reference Point is measured on the machine and manually input to the machine controller 5 3 1 Vertical MC Example for Enshu Vertical MC As G55 is used in the Fixture Origin FXO sub program G55 Work Piece Coordinate of the machine controller is set as follows XYZ values are the machine coordinate of the Fixture Origin FXO of the fixture asit 1s mounted on the machine table 5 3 2 Horizontal MC Fixture Origin FXO point of a Horizontal MC has to be set on the axis of table rotation Example for Okuma Horizontal
90. move after or before that particular number then activate on Before or After toggle followed by clicking on Shift button When changing selection that violates the sequence of machining logic for example to perform tapping operation before drilling the system will bring up a message that asks the user whether to proceed the change Select Y to proceed shifting and ignore the machining logic PCadCam Software Operation Sequencing Seles Tool Parameter Operation Name ast FL JL Dopt Tool Type EE FIL Tool Size Rene gt Axial Edge Length fC Symbol oOo o Cutting Condition Spindle Speed rpm 1500 Radial DOC mm 1 Axial FR mm min ini Dwell feeo 3 di di Axial DOC mm n Cutting Logic 581 KU aL d 10 4 Radial FR mm min 1 Coolant Canlant d 85 Angle p d or da W Under Chuck Length hnn Copy Cutting Condition With Same Tool nave Cutting Condition Mo Tool Surface NMichName O j Edit Operation GIE J 16 0 i Canned Cycle Initial Point return 2 CR 18 0100 0 Top 8 Mach aJ DE 10 0 100 0 Top PO run pra x 4 TOR 10 4 H100 0 Tos PO Machine Brand iti 5 IDR 32 0 100 0 Top B TAP 12 0 100 0 Top d DB Move Single peration Move Group Operation C Before After Sites Insert shift Ganoel gt User can delete operations listed on the op
91. n Show selected surface after cloge The orientation for each surface is shown below Top and bottom surfaces are switched from each other by rotation either around X axis top to bottom or around Y axis left to right It depends of the setup specified in the Utility display of CAM database main menu Switching among four side surfaces Front Back Left and Right surfaces is by rotation around Z axis PCadCam Software N E Ve Ba 7X QUU CBE i ie Sua ie zx wae murs T od zT Au er ael 5 Selection or revision Click the icon as shown on the right of design surface 6 Assign design surface The dialog box to select the design surface will appear Surface Selection Cancel 7 Assign top as a Double click on TOP or click on TOP and OK once design surface Other surfaces will be displayed by hidden lines Adjust the setting of dash line interval if it appears as solid line The setting will be adjusted automatically as a default based on the size of the worpiece base Perform the next command input when manual setting is required Type in Itscale and push ENTER The present setting value will be shown ex 0 06 Input the desired value ex 0 2 and push ENTER to execute the command Press ENTER again to repeat the same command to further revise the value Square slot feature Click on the icon as shown on the right to design a square design on top surface slot feature Input the requ
92. n the dialog box to bring up a list of machining method that has been set for each machining feature On the right side STD value given into CONDITION column indicates that the machining method is set into a default value It is also possible to indicate a machining method when designing one that matches when dimension data dl d3 d3 etc range is given as a condition instead of STD For example Machining feature Drill Hole Machining method Standard drill hole di lt 18 Machining with large diameter drill will d 1718 be done after the small diameter drill Assign a semicolon after each condition to create multiple union of conditions in the machining method database For example Give the following data to for PT1 8 Tap in which d1 9 7mm or smaller PT d1 lt 10 Give the following data to for PT1 8 Tap 1n which dl 9 7mm or larger PT d1 gt 10 An NDP value given into the CONDITION column means that the machining method will not been used PCadCam Software 4 2 5 Settings There are default values and canned cycle database Each cycle should be utilized based on the operation condition in the machining plant The following sections will explain how to set each database 4 2 5 1 Default Values Database PGadGam Database Default Values Raw Material X ar 40 Produk X 400 Raw Material Y 405 Produk Y 400 Raw Material Z 50 Produkz O 45 Drill Escape O 5 niialPoi
93. nce CW or CCW surface and depth data are automatically entered in the dialog box Feature Name to assign a machining operation of the polyline If the line element is not recognized as a polyline a message is displayed If the user wants to process the line element as the polyline the line element has to be modified to polyline by conducting procedures described in succeeding section 2 7 6 and return to section 2 7 2 3 PCadCam Software Select All Push this button for the system to select all the polyline exist in the drawing and show them in the dialog box User can choose each polyline or select them in a group to edit confirm or delete Add Approach Push this button to add a polyline at the start and end points that will be used as an approach line of the cutting tool to start and finish machining Left click the target polyline on the drawing after pushing the button to display a dialog box that confirm the polyline Fill in the necessary items and press OK button to execute adding a linear approach line on the polyline In the case of a close loop polyline move the cursor to the command at the left bottom part of the display then left click to bring up a message that will ask the user to define the inside or outside of polyline Move the cursor then left click on the selection EDIT Use this button to revise the selection of polyline type cut off or cutter path direction CW or CCW or the thickness of the materia
94. ne Common Material Common Method Rough gt Rename Method Copy Delete Method Add Machining Method Sl Tool Category Usage Delete Operation Copy Operation f Uctagonal tip end mil z id 415 R Roughing end mil id 4e 5 Operation 4 Squence Mo of 1 z Path Logie Roush Add Tool Alternative Delete Tool Alt Cutting Logig Down cut E Diameter DOpt d4x1 8 di Clase Figure 4 16 Operation data setting dialog box 4 2 4 1 Content of Operation Database User selects the machining feature method and machine in the operation data dialog box to view or edit Selecting machining method will view the operation data that was set earlier Operation database consists of the following 1 Feature Name of machining feature 2 Machine Type of machine tool vertical horizontal etc 3 Material Type of material PCadCam Software 4 Method The machining method of the selected feature 5 Sequence No A number in which sequence the operation will be executed 6 Path Logic The type of tool path logic to be used in a specific operation There are at least two types of tool path rough and finish machining available for each machining feature for user to choose Depending on the machining feature more tool path logic 1s available for example bottom only finish etc 7 Cutting Logic Down cut or up cut or else continuous drill or step
95. ned machining features The method to assign those points will be explained in the following section 2 7 3 1 Selection on three projections based on the third angle projection When the first selection on Drawing Options dialog box is highlighted as shown in Figure 2 17 and followed by pressing the OK button a new dialog box will appear as shown in Figure 2 19 for the user to select two points on top and right side views eS T mbp Be 22g FAR Bee rp iar eD won J amp c pe SE XS Oo a alw ae ala oa ala altl elma r xpx eas aered Ell m LAER dalai RB ole e mm men ain wi Frari v e Burley D de Lenrer tat Come NITIDO I r l z pu 711 7 72223 Eg F LGRARARABEDERBEDARRoEh Figure 2 19 Dialog box to input two points on top and side views when the third angle projection method is implemented 2 7 3 2 Selection on a single projection When the second selection on the dialog box shown on Figure 2 17 1s highlighted the thickness of the raw material is inputted and followed by pressing the OK button a new dialog box as shown in Figure 2 20 will appear PCadCam Software X ET2 4 08 amp bl T 08 e S s om Cance Figure 2 20 Dialog box to input design origin and two corner point data when Conventional One View is selected As shown in the figure user will assign one origin point then click on OK
96. nes Ream hole Data Solid Lines Hidden Lines Tap Data Counter Bore Data Tap Line Types TUP Tap LT Name Tap LT Type Tap LT Color Un Hole LT Na Un Hole LT Type Un Hole LT Co CONTINUOUS GREEN CONTINUOUS CYAN CONTINUOUS GYAN CONTINUOUS GREEN CONTINUOUS GYAN CONTINUOUS GYAN CONTINUOUS RED CONTINUOUS RED CONTINUOUS GREEN CONTINUOUS GREEN CONTINUOUS GYAN CONTINUOUS CYAN CONTINUOUS CYAN CONTINUOUS GREEN CONTINUOUS CYAN CONTINUOUS GREEN DASHED GYAN DASHED GREEN NULL WHITE NULL WHITE CONTINUOUS GREEN CONTINUOUS GREEN CONTINUOUS CYAN CONTINUOUS GREEN CONTINUOUS GREEN CONTINUOUS GREEN CONTINUOUS GREEN CONTINUOUS CYAN CONTINUOUS CYAN CONTINUOUS CYAN k Record Insertion Options Fl I i Ini te er r Inset t le rd b H hli ht id I d ee Figure 6 13 Tap Line Types TOP data page B 7 Tap Line Types BOTTOM Data The dialog box as shown on Figure 6 14 is used to input data for the tap that is designed on Bottom surface PCadCam Software i Drafting Database Figure 6 14 Tap Line Type BOTTOM data page B 8 Ream Hole Data Input the standard design data for ream hole in the dialog box as shown on Figure 6 Drafting ETE 6 000 SUD 10 000 12000 16008 20000 PCadCam Software B 9 System Configuration Data User will conduct system setting based on the data supplied in the dialog box as shown on Figure 6 16 EMEN xi Solid Lines Hidden
97. nstalled for the second time PCadCam menu has been automatically set and displayed By the installation procedure noted in the above following files are set in C Program Files PCadCam directory Directory PCadCam Folder Support Many files File pcadcame mns English menu File pcadcamj mns Japanese menu File fr arx FR software File frcad arx FR database software File frcad mdb frcad database File Olte xls File Oltj xls File Pcad dll PCad software PCadCam Software File Pcadcam bat File Pcadcam dvb PcadCam2000 control software File PcadcamReg exe installation software File Pcam dll PCam software File Pdb dll CAM database File PDB exe CAM database software File PDB INI File Pnc dll NC Program generation software File Pos dll Operation sequence software File PTime dll Operation time calculation software File Readme txt File Sft mdb Standard CAM database File ST6UNST Log File Tlte xls File TItj xls File fr2pcad txt File to store results of FR Automatically created by FR File pl number dxf file to store polyline data recognized by FR Automatically created by FR I 4 Setting CAM Database 1 4 1 Standard Database Setup Open AutoCAD and click on P Database icon t3 Then the main menu of the database 1 1 will show up Click on Utilities and Setting Options from the drop down menu C Program Files PCadCam Sft mdb is displayed which is Standard
98. nto a different folder which user can modify to construct user specific database The user of PCadCam2000 can modify the content of CAM database using Database Management System Figure 4 1 describes eight important elements of the database to be arranged Tool Database Machine Database Material Database Operation Database I A eue cube settings Database Operator Instruction Standard Fixture Database Standard Size Database ca mm PCadCam Software Database management is an operation to execute data input delete or edit The database operation is mainly done from the dialog box as shown in Figure 4 1 PCadCam Database Management Utilities P CAD CAM Database Management System Tool Database Machine Database Material Database Machine 3 Cutting Tool Brand Machine Operation Database Tool Pod Controller Standard Fixture d ius Index Table Fite Data etting i i standard size Settings Operator instruction Report de Default Values Ream Canned Cycle EXIT Step Figure 4 1 CAM Database main menu 4 1 CAM Database Operation 4 1 1 Starting CAM Database PCadCam database system can be started from PCadCam display click on icon or directly from Windows double click on E icon User has to make a short cut from C Program files PCadCam PDB exe file and copy the shortcut to desktop Click on any item shown on Figure 4 1 to start database management operation 1 1 Use the
99. number 1 to 4 c When top and bottom views exist It is important that the TOP and BOTTOM surface of the design are positioned on the left right turn over relation as shown on Figure 2 18 number 5 When the views are positioned on top bottom turn over relation it 1s required that of the one projection view has to be rotated 180 later on d When left and right side as well as front and back views are positioned side by side Name each design surface as shown on Figure 2 18 number 6 After giving a name of a design surface user will be asked to input the depth of machining feature on that particular design surface in the lower box At this stage user may input a temporary depth value then edit later on Click OK button on the dialog box of Figure 2 22 to complete the process There will be two more dialog box refer to Section 7 4 before a dialog box as shown in Figure 2 23 appears to let user choose another projection view Select NO to complete the process or YES to bring up the dialog box on Figure 2 21 for the user to proceed on the next projection view Would like to process for another wie wt Eee ERN Figure 2 23 Dialog box to select the next projection view to be imported 2 7 4 FR Operation FR system will analyze the projection drawing data however when there is one or more PCadCam Software layer that is not registered in the database a pop up dialog box will appear as shown on Figure 2 24 Use
100. oftware content of the existing machining method There are two ways available for user to create a new machining method A Register a new machining method data as new B Copy the existed machining method data exist in the list revise the data partially to create a new machining method The following sections will explain the two methods above 4 2 4 2 1 Procedure to Input a New Machining Method Data 1 2 A dialog box will appear that lists all items of 1 to 13 as explained in section 4 2 4 1 User will input machining method name and first operation data Apply sign to CONDITION column 3 Click OK button 4 Click the pull down menu arrow on Feature to display the same name of machining feature 5 Click the pull down menu arrow on Method to display the new first operation data that 1s just created 6 The new first machining method data will be displayed User can click Copy button to create the second method after correction and revision required on the data Repeat step 5 and 6 to create the next operation data 4 2 4 2 2 Procedure to Copy the Existed Data to Create a New Machining Method 1 Display a machining method of a feature then click Copy button 2 The same former data of the first operation data will be displayed Overwrite the name of the machining method after doing revision on the data 3 Click OK button 4 Click the pull down menu arrow on
101. ontroller NCPR sub program is calculated from the local coordinate shift G52 In this case make sure that inside the machine resident sub program of fixture origin point FXO and tool changing subprogram to input On FANUC controller G52X0 Y 0 Z0 On YASNUC controller G52 to cancel the local coordinate shift Copy the following of fixture origin point FXO subprogram for example on FANUC controller O55 G40G49G80G90G17 G52X0 Y0 Z0 G91G30Z0 G55 1 2 3 When using OSP controller with VZOF input The same explanation of 1 2 1 will be applied herewith Input VC symbol into the macro format of the controller database and prepare the common variable to be used Also input VC110 into the index address of index table database Input the following fixture origin point subprogram to be registered as a resident in the machine controller PCadCam Software O55 VCIII VZOFX 55 VC112 VZOFY 55 VCII3 2VZOFZ 55 RTS 2 To change into measurement on machine then input manually 2 1 Assign NO to Machine Database ACS 2 2 Inthe local coordinate format of the controller database Input G56 for FANUC or YASNUC controller Input VZOF for OSP controller alphabet capital O or G15H56 In that case the subprogram number of NCPR is O56 3 11 3 Manual Input of Workpiece Origin Point on Vertical MC Measure the workpiece origin point by using a touch probe then input the measured coordinate value m
102. or standard tool change in the next block after T code for the program to read the T code first e Rigid Tap Code Input the M code for starting the standard spindle rotation for rigid tap operation Note The upper part of Figure 4 13 shows FANUC on the Controller Name of Controller ID 1 DO NOT ERASE nor EDIT this data User can create other data as shown in the lower part of the figure after registering Machine ID 2 or later 4 2 2 6 Index Table Database Index table database dialog box is shown in Figure 4 14 and it consists of the following PCadCam Software PCadCam Database Index Table Machine A Index Address A Index Sub Program Number A Min Angle of Rotation B Index Address B Index sub Program Number B Min Angle of Rotation C Index Address C Index sub Program Number GC Min Angle of Rotation E Index table Record 1 of 20 nij search Cancel Close Figure 4 1 4 Index Table dialog box e Machine A name given to each machine e The following three elements have similar input item from top is angle A angle B and angle C have 1 Index Address Input in the block in text format the rotational angle variable in of the rotational angle in degree before calling the index table sub program The example shows a case when index angle A is specified by a common variable 511 B 512 and C 513 2 Index Sub Program Number A sub program number to rotate the table 3 Min Angle of Rotation The
103. or the spindle to return to its last position after completing an automatic tool change from the second origin point position of Z axis in any XY axes position Spindle acceleration deceleration time per 500 rpm Feed rate acceleration deceleration in m s Rapid traverse acceleration deceleration in m s sii wm alaha Marte r3 Marhnr 5 ATC Time gaard Machine Hame CARL iz Machine Brand Ta Durma Tod iD Tod Change SPO oprie ALD ec calaradio n Bec 2 Ema bw ery C min Fc ape cc el erat on of Aera Local Caprdnat SAID Comm on fan able X imie 2 In A res Fpiure Onan SPO Ten FLEE End Machinim SPID En Z min FINI FINI Genera eub i Y res Helical brier krion Ho a l Z im Ata T Gal Time Calc Paramebei Rind Tan hope of Rapid Tiani mis i Atdegk 2 Y mk is Bidege T mk IN B im amp 2 d d Cd Vig Cien Figure 4 9 Dialog box of time calc parameter 4 2 2 3 Machine Data for Five Axes Machining PCadCam2000 has the capability to conduct five axes machining in which a surface of optional inclination is calculated on two perpendicular rotational axes any two of ABC PCadCam Software axes and two or 2 5 axes machining is to be performed on the surface The operation is called a five axes machining However it does not provide the capability to do five axes machining in which two rotational axes rotate simultaneously PCadCam2000 1s also limited to those ma
104. orizontally at the center of an indexing device on a vertical M C The dialog box for C 1s similar to B Process Type D Select this option to mount a workpiece perpendicularly to a tooling block in H M C User will select three surfaces to be machined The other three surfaces that were not selected will not be machined and will be inactive Remove the selection mark from one surface to make revise the selection Take a surface that 1s clamped at its bottom and faced the palette in H M C as a datum surface Horizontal M C Surface 3 Datum m w Back w Left ie Right 5 Cancel PCadCam Software Process Type E Other Process Plan Select this option when neither of process A D is applicable Process Plan E will not process the operation to mill out the BASE from raw material User should select a single surface User then decides whether the whole machining features or selected ones on the surface will be machined Selection of machining center to be used machine name and fixtures should also be completed m User Defined Process Plan Sil Ej ourface C Bottom C Front oelect Feature Al C User Select Machine Vertical W G Horizontal H C C Vertical H C with Index Machine OEE Fixture Special desien Cancel Later on when the machining is completed select the next machining surface and repeat the same CAM procedure PCadCam Software Process Planning F 5 axes machining H V M C
105. own on Figure 2 32 Edit the feature accordingly then press on OK button Figure 2 32 shows an example of changing the type of machining feature PCadCam Software Bu mil x SD ee a E E Te eum Figure 2 32 Operation to change the type of machining feature The system cannot run CAM operation if a polyline recognized by FE exists since the polyline is still in 2 dimensional type Follow the step below to convert polyline into a Light Weight Polyline so that the system can continue to CAM operation 1 Type in convert and press ENTER 2 Type in p and press ENTER 3 Type in a and press ENTER Conversion operation is completed 2 7 9 Machining Feature Design not Included in FR User has to design machining feature that is not included in automatic feature recognition FR system 2 7 10 Save Drawing Click on m save icon to save the file PCadCam Software IH PCadCam2000 Software CAM User Manual 3 1 Part Design Review Open the file that was saved previously in CAD operation following step 17 of Table 1 and review the design by using the design surface function Click on the base material 1con to confirm the dimension of raw and product as shown in Figure 3 1 At this stage user can modify the dimension of the raw material to be cut and the machining quality User cannot modify the dimension of the BASE that binds the product Base Material Material Name Common Base M
106. p Tool Presetting Tools Used in Tool Pod Tool ID T Code Category 74a ee Te RSM oymbal aa eM p 18 8 1 100 xial Edge Under Chuck po 100 Machine ORR 000000 Hext Cancel Note The tool length H and diameter D data supplied will be recorded in the tool pod database and at the same time it will be used in NC program generation The diameter data D relates to the side surface machining by end mill of such machining features as step slot pocket PCadCam Software hole and boss etc Therefore it is critically important to input correct diameter data When the tool diameter compensation G41 G42 is not used CAM system will perform offset calculation using the inputted data User should define whether or not to use tool diameter compensation G41 G42 at the earlier step User can upload the H and D data to CNC by using G10 codes written at the beginning part of NC program user has to register use of the G10 codes in controller database The data will be taken from the Tool Pod database having the exact diameter in radius and length values of cutting tool If user does not wish to do so the H value will not matter therefore an exact value is not critical However user has to carefully input the exact H data into machine controller manually Base Material Ghange Raw Mtrl Product 100 000 100 000 l 100 000 s it Powe EE pesci The above dialog box will appear next ask
107. peration to model a round bar added at the top surface of a rectangular parallel hexahedral body blind bore raw material new raw material blind bore subtract raw material new raw material blind bore intersect new raw material raw material Figure 2 13 Description of Boolean Operation for Union Subtract and Intersection Figure 2 13B describes the subtract operation to create a hole in the new raw material model PCadCam Software by using a blind bore feature The bottom part of Figure 2 13C describes the intersection operation to model a round bar from the base material by using a through bore feature Various machining features can be used repeatedly to design a preform raw material User can run the union subtract or intersection operation by clicking the icon or type in union subtract or intersection in command line and push ENTER Follow the instruction in command line to select the object User should select the base material before machining feature when doing the union subtract and intersection operations Press ENTER after each selection 2 6 2 STL File Generation The preform raw material model built as explained in Section 2 6 1 can be saved in STL format file to be used in Super Verify software for NC program verification after CAM process 1s completed To save the file in STL format type in stlout in command line and press ENTER Follow the instruct
108. piece NC program file name the machine to be used cutting tool list sequence number N number etc Refer to Chapter IV of Database manual to print the sheet Depending on the number allocation for NC program to be saved assigned in the database the NC program listed will be PCadCam Software only the recent ones and the older program will be ignored 3 8 Operation Planning for the Second Process and Thereafter Planning of the next The NC program generation and operation planning of step Operation Process l or 3 as explained in the above at the same time second operation and thereafter will be done User can proceed to design Process 2 or do so upon completion of Process 1 then continue designing the Process 2 Repeat designing the rest of the processes 3 9 Structure of NC Program There are four types of program in NC program generated by CAM system l Main Program To execute machining operation 2 NCPR NC Program Reference Point Sub Program To provide a reference point of surface design of workpiece set on a fixture to be machined 3 Machining Sub Program Refer to CAM Database Manual Section 4 2 2 2 Figure 4 8 4 Machine Resident Sub Program The following four sub programs are peculiar program on machine that user has to create new and load permanently into the machine controller Tool Changing Sub Program To execute the sequence of specific tool changing operation on machine End Machining Sub Program To e
109. r C Min Angle of Rotation EN Index table Record 10 of 10 I pi earch Cancel Close 1 Index Address is a text form data in which the angle of table index is substituted by 96 In the example shown in the above which is for Okuma Horizontal MC the text form reads VC110 so that if angle value is 90 degree NC program will be written VC110 90 2 Index Sub Program number is the sub program number of the machine resident sub program that rotates B axis The sub program number is 6010 in the example above 3 Min Angle of Rotation 1s the unit angle value that corresponds to value 1 of the angle entered in 1 in the above It is usually set to be 1 PCadCam Software PCadCam Database Index Table Some eo DIR ELEME MN MN Data in the above is for a Vertical MC attached with A axis index devise PCadCam Software PCadCam Database Index Table Mime mesnan SSC Mid Search o Came Ome Data in the above is for five axes Vertical MC attached with B axis rotary index carried on A axis indexing rotation 3 2 Machine Resident Sub Program Preparation 5 2 1 Tool Change Sub Program Enshu 400 OKK Okuma O 6000 L 6000 O 6000 G21 G91 G00 G28 G40 G80 G52 X0 Y0 Z0 M6 G54 G92 Gd38XYZO RTS G40 G80 M06 G91 G30 G23 Z0 06 G28 YO G28 XO G28 ZO M6 M99 PCadCam Software YASNUC Controller MELDAS Controller OSP Controller Pindad manual tool MAKINO CNC vert
110. r will assign the line type solid hidden auxiliary or none on each identified layer in the dialog box The system will highlight the line in red or blue color on the background display er Ub be vo E Ix 8 Lot PEE RO Left fem Lis Let T pE TPES Lea a Entity LINE Le A OBI i Entity data on Paper Drawing start Point ow U 000 m Y 247 0010 Pe ete EE End Point Xe 0 000 Y 255 000 Ler yep WHITE a 151 Entity data on DAF file a Me Died 2 Y OF iw Figure 2 24 Dialog box to confirmed the non registered layer in the drawing database The system will bring up another dialog box as shown on Figure 2 25 when it detects a non registered feature symbol in the drawing database User will assign whether the feature belongs to the Top or Bottom surface The system will highlight the feature in red or blue color on the background display CNLZIDITZEEEEEEE er ae aoe ibe a One ge e Tew eile Sheet Teele oe rar Pa DDR rar uode mec a MEM arc a our XR rna Trr UTER m ae eR mm tpa A um T rmn coh den em na ra e an ye MM CH a ARE Lu oT purae cO m ar Lane mare va erg EEE ag eile LAT a Aan hE Tate TECUM Ue ee te EY ELS Hd SEAT GOSAA Gud fice AGERE GRAL dw el pt ou uus men pr r Dum Sau cEackB com 20g e Euer Cute ge puce ee eee Ter TIE r rre A EE e oe AE A Ll ER ar a J nnum m Figure 2 25 Dialog box confirmed the non registered feature
111. record navigator to search to retrieve a data from the database Click the Utilities on the pull down menu and select View Table Click the down arrow on Table Name and user can the item to view the data in the dialog box Push the scroll bar to move the list up and down 1 2 User can input a new data to the item of element by clicking on Add button in the data window 1 3 Click on Delete button to erase a data 1 4 Revise the data directly when it is on the display Click on the Close button in PCadCam Software the dialog box to update the revision Exit from the database main dialog box once User should start the database again and open the data that has just been revised for confirmation 1 5 There are cases in which the user may not be able to revise the data directly on the PCadCam Database box In this case user should revise the data by opening the database file in Microsoft Access program 4 1 2 Changing CAM Database to use The following procedure can be used to change to another CAM database to use in PCadCam2000 It is advisable to save the outgoing database in a different directory 2 1 Click on Utilities and select Setting Options 2 2 Click on Browse button of the Database Name The file and directory searching dialog box will appear Select the new database file to be used User may change the Language to display 2 3 Click on OK button to close the database 2 4
112. rmat T M57 Airblow NC No format D Initial Return TL Offset bts R Return Mo cycle LO TChange Prep Code M16 Rigid Tap Code The database assigned with Controller ID 1 holds a set of data for FANUC controller Do not delete this dataset because it is necessary for automatic data management inside the software Padam Database Controller Controller ID 5 Controller Name 310 Length Yn M38 Format 310 Diameter Yn M39 Format 310 Value Yn 352 Format Min Address ID Sub Repeat format Max Address ID 150 352 Reverse Metric Inch Format Gel Macro format T Formal I M57 Airblow NC No format i Initial Return TL Offset G43 R Return GY No cycle ILO TChanae Prep Code MLG Rigid Tap Code En Grid View Add Delete Search Close I4 4 Controler Record 2 of gt pi Data in the above is an example for Yasnuc controller Tool offset values both for tool length and diameter are not written in the NC program for this machine but manually set by the operator to the machine controller as H and D PCadCam Software codes Therefore in order to cancel data transfer capability of NC program G10 Length G10 Diameter and G10 Value lines are all nullified by entering Nuin mark in the example data above is a replacement for backslash N PGadCam Database Controller Controller ID 310 Length 310 Diameter 310 Value Min Address ID Max Address ID Metric Inch Format T Format
113. rocess any polyline exists in the design drawing In such a case FRCAD will generate a DXF file that contains a polyline or more It 1s also possible to process the generated DXF file by PCadCam later on View Design Surface Set this toggle box to perform recognition for the ONE VIEW projection so that either the operation will be done only on the visible surface Visible Surface or the hidden surface Hidden Surface or both visible and hidden Visible amp Hidden Surfaces The default will be Visible amp Hidden Surfaces and in this setting the feature recognition process will be done on front and back surfaces Edit Feature It 1s necessary for the user to correct machining feature data after automatic recognition operation by FR system The manual correction may be done only in PCadCam or FRCAD Tolerance Values The value set on the left side radius mm 1s an allowable error on connectivity tangency normal and parallel between the starting and end points of segment data exists in a DXF file The value on the right 1s the allowable error unit mm on the difference of standard value for tap data and the actual tap diameter on the drawing Set the accuracy value by adjusting it to the drawing will undergo feature recognition process FRCAD Directory PCadCam Software Input the directory where PCadCam2000 software is located usually it is set to C Program Files PCadCam Click on OK button once all the n
114. rogram Display When FINISH button of the previous figure 1s clicked Microsoft Notepad text editor will bring up a display showing the NC program automatically 2305 113 5 AiUGH FACE MILL 2101 30 0 COCTAGORUU TIF EMG MILL Hoe Cd 16 0 nouzHrHz EHO MIELL RE EFE MILL LOL nd 7d 25 wolo 1 2 ALP RCI Ho HI wollos2 70 000 CALL D OIOLTOR LEFT I Sometimes it happens by chance that the NC program display does not appear and this will cause the computer to halt This problem occurs mostly when by any mistake at a certain operation the cutting tool has a zero 0 value on its axial depth of cut Close PCadCam and reboot the AutoCAD then start again Open the CAD file and click on the operation sequence icon to display the operation list Highlight the operation that may be the source of the problem and click on Edit button at the bottom left of dialog box Find the zero value on axial depth of cut and revise Save the cutting condition to avoid repeating the mistake in the future then click on OK Proceed to NC program generation NC Program Verification The generated NC program can be verified by using software program such as SuperVerify software etc to check the program 3 7 Printing Operation Sheet The Operator Instruction on CAM Database provides some important information automatically regarding the NC program to run on the machine The information corresponds to the drawing file name of the work
115. roller o Tool Wear Offset Lost amount of tool radius due to tool wear attached with minus sign 1s set in D code of the machine controller PCadCam Software Owner Input TUT 4 2 5 2 Canned Cycle Database Canned cycle database allows user to assign the type and command to be used It consists of the following as shown in Figure 4 18 Operation The name of operation in canned cycle Command The command assigned in NC program to execute canned cycle Input n in the column for rigid tap to specify the location where a carriage return will be inserted in the text of the comm Canned cycle An ID number to differentiate each canned cycle Parameter Parameter addition NONE P dowel or Q peck or P Q Note l The first line that lists CANNED 01 should only have drilling cycle 2 Editing canned cycle Click on Edit button to revise canned cycle Perform the necessary revision in the dialog box and press OR Setting canned cycle addition Click on Add to add new canned cycle and follow step 2 Deleting an existed canned cycle is not possible Referring to Section 4 2 7 3 canned cycle may be reselected in CAM process at the cutting condition dialog box of the operation planning stage In such a case values for P and Q can be specified using the data entered on the right part of Figure 4 16 in the following way In case of G73 High speed drilling or G83 Deep drilling
116. rotation angle value corresponding to a unit value 1 entered in 1 in the above Normally the value is set to 1 4 2 3 Material Database The material database dialog box is shown in Figure 4 15 and it consists of the following e Material ID An identification number of material e Material Name Name of material PCadCam Software PCadCam Database Material Material ID l Material Name Common Add Delete aearch Close Hg Material Record 1 of 8 nni Normal View MateriallD l Common eod 9 ADG M ALB PCadCam Database Material Material ID 2 Material Name S84 Add Delete earch Close mg Material Record 2 of 14 nmn Marrmal View Maea Nam BUE 000 00 if SIS 304 Figure 4 15 Dialog box of material database Note The material name of material ID 1 has Common on its value as shown in the upper part of Figure 4 15 DO NOT ERASE nor EDIT any data with COMMON value User should create other material data with ID 2 or later 4 2 4 Operation Database CAM system generates machining method automatically for each machining feature based on the operation database Click Operation Data button on Operation Database as shown in Figure 4 1 A dialog box of the operation data will be displayed as shown in Figure 4 16 PCadCam Software PCadcam Database Operation Data bd Feature a Side pocket Machi
117. s e 01 nm PCadCam Software Figure 5 4 Dialog box of Common machine data PCadCam Database Machine Machine ID Bo x max Machine Name Enshu l x min Machine Brand Enzhu Y max Dummy Tool ID Tb Y min Tool Change SPID 6000 Emax End Machining SPID 6001 Emin Local Coordinat SPIC bg Common Variable Fixture Origin SPID 6003 Generate Sub Helical Interpolation Teg ives Ady T Call Time Calc Parameter Rigid Tan Grid View Add Delete Search Close TIE gt fri Figure 5 5 Dialog box of Enshu I machine data The above Figure 5 5 is the machine dialog box for a machine called Enshu There are two units of Enshu machine in one of the user s plant the first one is registered to be Enshu 1 In the example T145 is given to Dummy Tool ID which sets a tool number T145 when no tool exists dummy on machine spindle after ATC operation Sub program number 6000 is for the tool changing sequence and 6001 is for ending machining sequence sub program Both of these two programs are machine resident sub program Program number 52 is assigned to shift the coordinate from FXO fixture origin point to NCPR NC program reference point sub program There is a sign ahead of number 52 When this mark is given for example on vertical MC equipped with the X rotational axis of workpiece index device or on horizontal MC when switching to a different design surface the correspondence sub program number 52 will b
118. s could be modeled as a raw material using INTERSECTION SUBTRACT and UNION operations on a rectangular parallel hexahedron BASE The process is shown in the upper part of Figure 2 12 When modeling a perform raw material the machining features applied will not be processed in CAM operation Upon completion of the raw material modeling user can continue the PCadCam Software process of adding machining features to design the final product as shown in the lower part of Figure 2 12 CAM operation will only generate an NC program for the machining features data applied at this stage to be machined on Machining Center FC Pen fy S Pf AS E Fl ALT p y j Fl U Bs Fi J ff V et ae amp y fy KoS LY P Fa he oe x POET aay s F Fa M C i Y l1 s y ri did A F z i Zu TOM Fa E s o 1 5 J 4 _ ELE A LE V oun T E F T nee zl Pa F LM 7 F X ae B LH So o J r K r Lh go Fd a ut m F s _ Veg F no NO s LN s f X Je J Ten Ay K F fiai F A Fa ra T 7 F F F vis k S Bani Nez T Ribes aec ei eS 1 mm L KU 3 M ui IN Cooma Vi ahaa i PLE F a ON m r z p x ra ru i T J B 1 Fa ft 2 Pd Ww R E F r FONON x F ps Jl Te Fa i F L e y S a Fi Fa F E LI 7 F 5 E vo oe Gi j p a A h oo Vo d p E rd h i x f se F Su i MATT 225 j em V X OM uu oh F an b 5 wg
119. so used in PCadCam2000 therefore allowing the execution of AutoCAD menu PCadCam utilizes its own menu for user to run CAD CAM or Database system Figure 1 shows the starting display of PCadCam2000 software Ir Em Ap FG EDI ATEIMAL VERSION reial dew 1 E n Eg Fie Edt Wem Jeet Foret Took Dee Dv Medy Medos Heb Ew ARS III Dg Hd Emm OO Bl im sm ercaemesgagTlz s425n7o0n0o FECT RL F El ages CP ot ww EX L i VAEA H RAELE 223 17 arap r Wk ug s 1 4953 159 REB O00 AST TUE ar E F RB OS AF TRACK LWT Exit Figure 1 Starting display of PCadCam2000 software PCadCam Software 2 2 Description of Icon Toolbar and Cad Cam Functions Figure 2 1 lists five toolbars associated with PCadCam2000 software in AutoCAD Each toolbar contains several icons for different purposes All machining features available in PCadCam2000 for operation on machining center or numerically controlled milling machines are listed in pfeature toolbar Toolbar pcad will list all icons for modeling component Toolbar pcam toolbar lists CAM processing functions fr lists the feature recognition utility and putility toolbar lists the database utility A e D amp dd ml ni ED 3 T OD ICQ ED GB na ICI 8d OL o A h Te S5 Eel Figure 2 1 PCadCam2000 toolbars in AutoCAD PCadCam2000 software uses several toolbars of AutoCAD such as Standard Toolbar Object Properties and Object Snap toolbars It is
120. source stores information about how to connect to the indicated data provider A User data source is only visible to vau Lear ee ee a ee m m Carnes Ok Tell FT MILD Figure 6 2 ODBC data source administrator saved c aha 3 Figure 6 3 will show the next dialog box to select database driver Select Microsoft Access Driver then click on FINISH button Create New Data Source Driver da Microsoft para arquivos texto Ext csv 4 Driver da Microsoft Access mdb 4 Driver da Microsoft dB ase dbf Driver da Microsoft Excel xl Driver da Microsoft Parados db Driver para o Microsoft Visual FoxPro Microsoft Access Driver mdb Microsoft Access Treiber rdb Microsoft dBase Driver dbf kKdiaras oF HDI awn PICO Men sor F ABET lt i 14 _ eee err REOR Back Cancel Figure 6 3 Selection on database driver 4 The display will switch into Figure 6 4 for the user to input Data Source Name The data source name for FRCAD is fread Input the name in small letter Do not change the name or FRCAD will not run User can input any description in the lower column Click on Select button PCadCam Software ODEC Microsoft Access 87 Setup LIF LES up af up cns ufi E LU E Le Em 1 1 T 3 i Data Source Name fread L escriptor Automatic Feature Recognition Database Cancel Database Help Advanced
121. ss ENTER key 5 Key in UCS once again followed by pressing ENTER key Type in N and press ENTER key Input the distance from the point 1 in the above to the new design surface by giving Z axis coordinate values For example if the distance is a key in 0 0 a separated by a comma and press ENTER key 6 This step is necessary only for AutoCAD2005 and above This step may be omitted when using AutoCAD2004 or below Key in UCS and then push ENTER Key in S and push ENTER Key in A actually the key may be any alphabet and push ENTER 7 Click the Design Surface icon and click on Create button A dialog box of Figure 2 10 will appear listing all of the origin point to confirm the new surface Give a name of the design surface and select the color for machining features that will be generated on the new surface red is a default Click OK then a small message window will appear to ask if user want to display the cut base material Select YES ama Surface amp Red PF it cel Figure 2 10 Confirmation of the new surface generated 8 Click ALL and OK to display the outline of the new cut base material 9 Click on the Design Surface and select the name of the new surface User can proceed to design machining features on the new surface 2 6 Modeling Pre form Material Pre form material made by welding foundry or other processe
122. t design origin and two corner point data when two or more view are selected Click on the OK button then follow the message on the command line of AutoCAD to select the design origin and two corner points for the first projection view FR system will process the given point data then bring up another dialog box as shown on Figure 2 22 for the user to appoint a surface design For example TOP surface is given to the projection view Besides naming a design surface to a projection view refer to the condition below when there are several views exist anat BICI WEERA CT pal bh 0 1 seat Ale F ee Figure 2 22 Dialog box to assign a design surface on a projection view a There are two projection views When there are two views with one is positioned on above of the other for example the upper view 1s taken as TOP surface then the view below has to be taken as FRONT surface The upper view can also be taken as BACK surface and the lower view is TOP PCadCam Software When the two views are laid side by side if the left view is taken as LEFT surface then the view on the right has to be taken as FRONT surface If the left view on the drawing is taken as FRONT surface then the view on the right will become RIGHT surface b There are three projection views Depends on the position of side views in the drawing user has to name each design surface 1n correspond with Figure 2 18
123. table and it is assigned with a G code that specify Work Piece Reference such as G55 This code has to be written in a machine resident sub program called FXO Fixture Origin Sub Program whose sub program number is registered in Machine Database In the example the index angle 0 found in Fig 4 20 specifies that FRONT surface of the work piece 1s oriented in Y direction WO 282 9 4 767 541 34 863 Figure 4 21 Example of fixture SFX7 4 2 7 2 Type 2 Fixture type that sets WPO at center of the work piece bottom surface either for Vertical or Horizontal MC work A type of fixture in which the center of workpiece bottom surface 1s specified to be the Work Piece Origin point WPO PCadCam Software As illustrated in Figure 4 22 Orientation NONE is registered to designate a fixture of this type XYZ coordinate values of WPO is entered as measured relative to the Fixture Point FXO PCadCam Database Fixture Fixture ID Fixture Mame Datum X Datum Y Datum Z Orientation Index Angle Application l H HC B arbitrary angle Add Delete Search Close gg Fixture Record 3 af 16 gg Grid Wier Figure 4 22 Type 2 Example of fixture data SFX1 with orientation NONE 4 2 7 3 Type 3 Fixture type used for Three Surface Machining by Horizontal MC As illustrated in Figure 4 23 Orientation BACK is registered to designate a fixture of this type PCadCam Software PCadCam Database Fixture
124. tated on the base surface around either one of A B or C axes User will key in three values XYZ by the following steps 1 Specify the position of origin of the new XYZ coordinate system 2 Specify the position of one point on the positive X axis direction of the new coordinate system 3 Specify the position of one point on the positive Y axis direction of the new coordinate system By specifying three values in the above the direction of the Z axis of the new coordinate system will be decided by right hand screw rule In other words when X axis is rotated toward Y axis the direction of the advance of right hand screw is the direction of Z axis The area of the part having positive value of Z axis from the point 1 as specified in the PCadCam Software above belongs outside the part and therefore it is sliced and deleted from the display When the Z value is minus the range will be inside the work piece When the external geometry BASE of the part is designed as a rectangular parallel hexahedral the procedure is as follows oo ES ug 8 9 Click on the icon to select the design surface and select ALL Key in UCS in command line input and press ENTER Key in N and ENTER and then key in 3 and ENTER Key in XYZ values of the point 1 each separated by a comma and press ENTER Key in XYZ values of the point 2 each separated by a comma and press ENTER Key in XYZ values of the point 3 each separate
125. te Click the icon as shown on the right to start CAM process and it will bring up a dialog box show below Select a process planning and click on OK button recess Planning ap ae Botton wise MAE Paralel Surface EE E amp H E Four Surface with Index V W A Index 4 aurface H Other Process Plan A Axes Machining AB or AG Index Turn Ker Operation CMS A Index arbitrary angle H E B arbitrarg angle ee lischine Trpe Fixture Face c The type of the process is displayed in the upper part of the dialog box and further selection of the process planning for example select A is shown in the lower part Try to select other processes and review the process Return to A and click OK to continue this example The next dialog box as shown below will appear for user to select further selection on the first process design User will decide in the dialog box which machining center to use and select the name of the machine The machine name OKK1 is selected for this example and Special design fixture is selected by default for this machine Click OK button to bring up another dialog box that will allow user to select the Side Surface to be machined Side surfaces selected at this stage will be processed by CAM for machining using peripheral cutting edge of end mill type tools The next process design will continue automatically Operation Planning Process Type 4 Top and Bottom Surface V MC Machine Fixture S
126. ter clock wise direction CCW e The polyline can be either an open contour start cut from the side or an close loop start cut in Z axis Confirm the clearance of start and end points of the PCadCam Software polyline for cutting tool to approach the workpiece when the polyline is open not a close loop The start and end points should be a straight line not a circular arc of the polyline It is an important condition for the CAM process to design the cutting tool path when it approaches the workpiece The cutting tool will start at a point 5mm offset to approach and the finish point will also be 5mm offset 2 4 2 Click the cut off or cutter path icon e After completion of a polyline design make sure to click on either cut off or cutter path icon before conducting any other operation e The dialog box of either cut off or cutter path will appear and the user will select machining method and input the value of d3 parameter e tis possible by using MODIFY M icons to rotate or copy a polyline in cut off or cutter path features using polyline however the EDIT E icons cannot be used It is not advisable however to mirror copy using MODIFY M icon because it mirror copies the geometry of polyline as well as the CW CCW sence For the purpose of accommodating mirror copy including CAM requirements a special Mirror Copy capability is prepared among PCAD icons as described previously in Step 22 e When selecting the cut off i
127. tion Upper Right LEFT Projection Upper Left BACK Projection Bottom Left TOP Projection Refer to Chapter II Figure 2 18 to assign a name on projection view 6 3 2 Recognition on Third Quadrant In this example the operation will zoom three projection views from the RIGHT PCadCam Software View of the drawing that 1s positioned on the right bottom as shown on Figure 6 19 Set the following into System Configuration Pre Processor Active Polyline Generation NotActive select MULTI VIEW PROCESS on the dialog box after clicking on feature recognition icon to start the operation Figure 6 19 Example drawing for THIRD QUADRANT
128. tion 2 7 3 by combining two corners to recognize XYZ dimension automatically Click on DESIGN SURFACE icon to switch between surfaces as shown on Figure 2 31 Pes Drawing deve SS ae St ee a 2048 amp 8 m ii L5 e B o e 6 DE Figure 2 30 Example of workpiece built using product data PCadCam Software CA n Draw ine dwe L9 9 otis e 8 il oes s Tila ME Figure 2 31 Editing machining feature on FRONT surface design 2 7 8 Editing Machining Feature on P CAD This section will explain the operation to edit machining feature generated automatically by FR after they have been imported to P CAD All information on the depth dimension are tentative either it is processed on ONE VIEW or MULTI VIEW therefore user has to correct them according to the design drawing Machining method for each feature will also be done at this stage User should also decide the type of machining feature and edit accordingly User can also group multiple similar features and use the function of grouping to edit all features at once Table 1 Step 13 Press ENTER upon completion of grouping Perform the same grouping operation on the other features Click on EDIT icon and select any feature that has been grouped previously Command line will ask if user wants to edit the group Y or the individual feature N Input Y or N followed by ENTER to bring up a dialog box of machining feature as sh
129. to four digits H Code address could be applied for tool length compensation data PCadCam Database Machine Brand PCadCam Software Machine Brand ID E Okuma Horizontal W G Feed Rate Max mrm min Y i Feed Rate Min mmimin Z Fixed TCode Feed Rate Max mm min 2 Marne Machine Type Controller TCode Policy spindle sp Min rpm apindle op Max rom Feed Rate Min immimin X Feed Rate Max mrm min X Rapid Traverse degimin X Rapid Traverse deg min Y J Rapid Traverse degimin Feed Rate Min rrmmin Y fi Feed Rate Min deg min A Boo Feed Rate Max deg min A H Feed Rate Min deg rin B 5000 Feed Rate Max degimin B 80000 Rapid Traverse deg min A as n D Rapid Traverse deg mini B 30000 5 Grid View Adi Delete Search cose 14 4 Recon 3 of 5 nj Figure 5 3 Dialog box of machine brand data example for Okuma machine 5 1 2 Machine Database Input 1 for machine ID and input common value for machine name and Machine brand Also type other data as shown in Figure 5 4 PCadCam Database Machine Machine ID Machine Name Machine Brand Dummy Tool ID Tool Change SPID End Machining SPIC Lacal Coardinat SPID Fixture Origin SPID Il Common Common T999 Helical Interpolation Time Calc Parameter A max A min Y max Y min max min Common Variable Generate Suh AGS Adv T Call Rigid Tap eid Vee Add Delete Search cle
130. tool e Material It will display the cutting condition of the tool to be used in machining the material e Cutting Speed Cutting speed of the tool in m min e Number of tooth The number of tooth of cutting tool e Coolant Type of coolant to be used PCadCam Software Axial Feed Rate The maximum allowable axial feed rate in mm tooth Radial Feed Rate The maximum allowable radial feed rate in mm tooth Axial Depth of Cut in Rough Machining The maximum allowable axial depth of cut in rough machining in mm When the planetary type of cutting tool is used supply the value of its thread pitch Axial Depth of Cut in Finish Machining The maximum allowable axial depth of cut in finish machining in mm When the planetary type of cutting tool is used supply the value of its thread pitch Radial Depth of Cut The maximum allowable radial depth of cut in mm Material Removal Rate MRR The allowable cutting volume per rotation MRR mm rev Note l 2 The display on Figure 4 3 shows that material and machine brand columns have same value COMMON A set of data for COMMON material and COMMON machine has to be given for each cutting tool CAM system will fall into an error if the COMMON COMMON data cannot be found during the calculation of cutting condition CAM system will automatically prioritize the selection of data for specific material and specific machine brand when available User should first r
131. tor x Ed X A Errr ST hr Sub Wo Surface Index rl LUN TT XHEES uu C Hext Fininh There are two methods to calculate NCPR refer to 3 11 for further details The following will describe on of the methods of performing a fully external setup First assign a necessary position vector V3 X3 Y3 Z3 to shift the NCPR to the fixture origin point FXO If the fixture data already exists in database CAM system will calculate V3 and report the result to user As described in Chapter II Table 1 Step 4 if the origin point is going to be shifted further to X Y value the X3 Y3 coordinate value will be deducted by the X Y value to obtain a new X3 Y3 value User 1s advised to confirm the value of X3 Y3 Z3 Depending on CAM system the newly created V3 X3 Y3 Z3 value will be automatically inputted into NCPR sub program a program that will generate coordinate shift automatically In case revising origin point becomes necessary during machining it is possible to edit the NCPR sub program in machine controller In the above figure the Sub No shows the NCPR subprogram number The number shows in the above example is 59 and the sub program number is O 59 for Fanuc or Yasnuc PCadCam Software specification User can add up to two more digits ahead the sub program number This function is meant to avoid duplication of sub program number when generating NC program for multiple workpiece or pallet NC P
132. tting No PCadCGam Database Machine Machine ID Bo 0000 A Max D Machine Mame Enshu 2 A min D Machine Brand Enzhu T max D Dummy Tool ID 4b Y min D Tool Change SPID e000 Emax B0 End Machining SPID po Zmin 00 Local Coordinat SPID F Common Variable 100 Fixture Origin SPID 6003 3enerate Suh Ho Helical Interpolation Yes acs No Feed rate option Feed Rate in mm mi Ach T Call Mo T for TAF T Rigid Tap Ho Time Calc Parameter Grid View Add Delete Search GEE IDEE gt f Data in the above registers the second machine of ENSHU as ENSHU2 PCadCam Software PCadCam Database Machine Okura E D fe Feed Hate in oai ERIT Data in the above 1s for Okuma Horizontal MC PCadCam Software a Or t No Feed Hate in wn aiy dal 5 r Data in tha above is for Pindad Vertical MC The user inactivates ATC and practices manual tool change so that the controller database 1s set for writing tool number T code inside a bracket Accordingly The Dummy Tool ID is specified inside a bracket as T33 PCadCam Software Data in the above is for a Vertical NC Milling Machine on which user practices manual tool change NC controller of the machine is so set to neglect all T codes written in NC program Therefore Dummy Tool ID does not have to be placed in a bracket It is therefore specified simply as T999 PCadCam Software
133. urface Bottom Coupler Machine OEE m Ax e Fixture Note When the user select machining process number 2 CAM system assumes that machining process number has already completed which means that the bottom surface has been finished There may be an occasion when the bottom surface has not been machined and the top surface of machining process number 2 will be machined first In that case refer to section 3 6 when calculating the distance from the fixture to workpiece origin the Z3 value of Z axis direction will be calculated by reducing the part of material to be removed at the bottom surface User should do the calculation and revision The next dialog box will appear when user selects process type B C or D on Horizontal M C Fill in the selection accordingly PCadCam Software Process Type B Select this option when clamping a base plate horizontally on an H Machining Center User should select 4 surfaces as shown in the dialog box to machine the four surfaces using H M C Remove the selection mark before making revision to choose other surfaces Take a surface that is clamped at its bottom and faced the palette in H M C as a datum surface Select any surface as zero degree direction on B axis Horizontal M C Surface 3 MW Surface Datum 0 Deer Top i C C Bottom Front Back Left Right s 4 sb d Process Type C Select this option to machine four surfaces of a workpiece in which it is clamped h
134. utomatically by CAM system when it generates the NC program When there several tools that can be used for one operation CAM will prioritize and select the tool that has been used the most Use the function by assigning a large number for example 500 in the frequency column when loading the standard tool data 4 2 2 5 Controller Database Controller database dialog box is shown in Figure 4 13 and it consists of the following PCadCam Database Controller Controller ID Controller Name 310 Lenath MSs Format 310 Diameter MSS Format 310 Value 552 Format Min Address ID sub Repeat format Max Address ID 352 Reverse Metric Inch Format Macro format T Format MSY Airblow NC Mo format Initial Return TL Offset R Return EE No cycle TChange Prep Code En Rigid Tap Code En Grid View Add Delete Search Close M 4 Eortoter Record 1 of 16 0t PCadCam Database Controller Controller ID Controller Name ASSFANDC 310 Lenath WSs Format M9SP 310 Diameter M99 Format M99 310 Value 352 Format G52 Min Address ID sub Repeat format Max Address ID 352 Reverse Metric Inch Format Macro format T Format MS Amblow MC No format Initial Return TL Offset R Return No cvele TChange Prep Code Rigid Tap Code Grid View Add Delete Search Close M 4 Cortoler Record 16 of 16 gt pi PCadCam Software Figure 4 13 Dialog box of controller Controller ID An identification number of the
135. ver mdb MS Access 97 Database Microsoft Access Driver mdb SFT Microsoft Access Driver mdb Text Files Microsoft Test Drier txt csv An ODBC User data source stores information about how to connect to the indicated data provider 4 User data source is only visible to you ws CLE rm Ev LI mx a Ls MI i al irr mh s oed lenire OK Tert PT I Lom ree __ Figure 6 6 Data Sources frcad addition 6 2 Drawing Database Registration This section will explain the method to register the important data into drawing database based on the rule on how the user creates their design drawing using CAD system 1 Start PCadCam software and click on FR Database icon in FR toolbar as shown on Figure 6 7 FR Database Figure 6 7 FR Database icon 2 The drawing database dialog box will be displayed as shown on Figure 6 8 There are nine data page on the dialog box and the display shows tap data page 3 The complete type of tap including pipe screw PT type that 1s used in the design drawing is registered in Figure 6 6 Tap data page PCadCam Software Tap Line Types BOTTOM System Configuration Auxiliary Lines Ream hole Data Solid Lines Hidden Lines Tap Data Counter Bore Data Tap Line Types TUP M Tap Diameter D Un Hole Diameter d Tap Depth H lin Hale Depth hi Ma 3 000 2 600 8 000 13 000 M4 4 000 3400 10 000 15 000 M5 6 000 4 800 12 000 17 000 ME
136. with index or I H M C Select this option to machine a surface with more than 90 angle using index angle A B or C A dialog box as shown below will appear The system will list all surfaces on the left part of Available Surface column User should select one or more surfaces to be machined and move it to Machining Surface column by clicking the arrow Next from the remaining datum surface list not including inclined Surfacel or Surface2 defined by user select one surface to be clamped on the rotational table and input into the Datum Surface box User then decides which surface out of six design surfaces top bottom front back left and right to be A 0 angle or B 0 angle or C 0 surface and input into the box on the right side of 0 Degree surface The surface selected should be among those four surfaces connected to the Datum Surface Check the toggle box that defines from which surfaces that the 0 Degree Surface is selected orizontal MC 1B Index E x E Available Surface Machining Surface Degree Surface l i From Available Surface 2 BI 3 ourface l surface Z2 From Machining Surface OF Cancel In five axes machining 0 Degree Surface will be defined from the design surface that faces the third rotational axis in positive orientation when the first and second rotational axes are indexed at 0 Refer to the next drawing for the explanation of third rotational axis orientation
137. xecute the preparation of tool changing operation before the next machining operation FXO Fixture Origin Point To provide fixture origin point on machine table Table Index Sub Program To execute rotational indexing operation of machine table on horizontal MC The structure example of main NC program and each sub program are shown on Figure 3 3 below CAM will generate all sub programs such as NCPR sub program every time as well as the tool changing end machining FXO and table index sub program to be loaded into the machine CNC controller permanently The resident sub program contain special sequence operation that is peculiar to each machine that user has to create and load into the CNC memory FANLICZI LAM CAMPER L7 NC7 n7 34 TUB se 7 EE OOOO Ez Oy xq ym G90 G2 NI SiH Ar F G52 T2L 50 0 RAT v FLY FSI G5 MOBP GL0G80 MOBPB5Z GOlG30Z0 MOSSIS33 G28Y0 GOOX 210 000Y 20 000 G28X0 G43Z 2 0DOH2I G28Z0 Me M GOlY30 000FB888 M99 GOl Y 20 000 0000s MITAT Maro Mg Mao G9lGSOF0 Mo Meu 052 CETERIS ates od p Goose HS B MOBP55 GLOGA9GS80G90GI7 G52 G52X 3 2 500Y 87 500745 000 GolGsozo GO0GOOXO YD GO0G55X0 Moo YA Moo PCadCam Software MELDAS IL MBE T CAMPER L JENCI DISA Tieni EVI T DP PA LOODA BAH GoIGn0G28X0 YO ZO GOZGSIXYZO T2 30 0 B BEP s SEY FEEN M LIV 24 7 ps ods Goo Nl CSIR Ar a h
138. y to avoid losing the file by overwriting Click on Export button on the upper left corner of the display to save the file Give a name and click on Save S TERTE By xd A Jc io C ADrawings 000 Pci Oram DF fb BB dwg T ULM herd HA NU ZOEF FAT ed og aa b CAOramings2000 Pci Drawin WS AY TOF ABB2 ne ane HG d lur 01000 Hou cup 01001 O1003 LALA P Mo l 4 2 7 IBID TIzu F ILE THz 1904 2n Dg nup 1501 35 3g EIS 4115 55 HU db 141Z luz Abb bBIc 1405 ng Abb bIc 1407 Sr Aabb hBIc rly ll Su H1z 1601 zn iU hy aR Figure 4 19 Example of an operation sheet Standard Fixture PCadCam Software LEB Sees s 05 Fm a 15 10 3 ea 18 15 l l 95 40 40 40 40 40 40 Ph 40 100 140 140 1g 100 19g eu 140 The standard fixture database handles the reference point of fixture It generates a reference point data during CAM process by a calculation to shift the NC Program Reference point NCPR from Fixture origin point FXO The display of standard fixture database is shown in Figure 4 20 PCadCam Software PCadCam Database Fixture Fixture ID il Fixture Name Special degien Datum X Datum Y Datum Orientation Index Angle Application Top amp Bottom HC Add Delete search Close gg Fixture Record 1 of 3 gg Grid Wier Figure 4 20 Standard fixture dialog box The following explains each item listed in the standard fixture database display e

PCadCam2000 Software User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents