PCadCam2000 Software CAD User Manual PCadCam2000
Contents
1. 0 fone Ome a a a a a a a oA a G e ieat o Oca tt x 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 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 International PCI 2 CAD E l ROUNDED STEF fl Spindle w Orientation Origin ov F PCadCam International PCI 3 CAD 1 to choose several materials provided The next step is for the user to choose the 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 1s designed to be smaller than Raw Material The NC program generated will automatically include the machi2. features and also to continue to CAM process after completing CAD design Save the file step 17 after any revision PCadCam International PCI CAD Step 21 Tap Feature Design 1 Click the Tapped Hole Feature icon to display the following dialog box of Figure 2 4 Lr Fa une izis TERNI ii 0 nii riemtatiom 2 Ste face Top Bick Hama Feature Parameter LL EEE ton TS o gahua origin y i n 0 000 UERJ Chanfer 0 000 Anala 0 2 Bachining Gtandard tap with confer EE Qeeratien Data Repeat Tancel Figure 2 4 Tap feature dialog box Feature Base Tap a T F 2 User can click on the pull down menu next to d1 to display all type and size of taps available as listed in CAM database Feature Hame Tap x yi oi 0 ot Oriewtatiom e ETT Surface Top pj tau Bick Hami Feature Parameter dl 0 000 S di mo ee J 13 600 i qfuatura origin y dt ffi lial J5 Chanter i fii Ansla Hachining Etendard tap with canfer cation ta Room 0 emee PCadCam International PCI 16 CAD 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 Create Feature Feature Name Tap wee 0 000 Orientation y 0 000 burface Top u 0 000 Hic
3. and it will be explained in following two sections 2 5 1 Three point Method NEW ORIGIN gt STANDARD ORIGIN Figure 2 9 Three point origin shift method It 1s a method convenient to set an inclined surface rotated on the base surface around either one of A B or C axes User will key in three values XYZ by the following steps l 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 PCadCam International PCI 22 CAD The area of the part having positive value of Z axis from the point l as specified in the 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 Click on the icon to select the design surface and select ALL 2 Key in UCS in command line input and press ENTER Key in N and ENT
4. E i HIN TH 1 When the side view is placed at 2 When the side view is placed at the bottom right the bottom right Figure 2 18 Layout and name of view on Third Angle Projection Method PCadCam International PCI 33 CAD 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 designed 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 A Hb Be 2 2 RD Cee Pai eo Se AF 18 oie tmx plo a OE So oa ale aa aa oa aa altl alma AJ Cle le le Al eee Fo 0 El m MLR dalai RE oale o l aa ale ain wi TALCE ECELLELLrEEELEECELCIEY 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 is highlighted the thickness of the raw material is inputted and followed by pressing the OK button a new dialog box as sho
5. net eka t ose fe fe 5 fo mre Faas Pty ELLES a MT 8 oo il BASE C RASLE CRASMLRASL Cancel ae Sa Fi mA a ga ee r E a T BLL miii TE BER O TAF Erare E ee ee I i T ik L Figure 2 21 Dialog box to input design origin and two corner point data when two or more view are selected NEED ENGLISH DIALOB G BOX 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 x Reta a MITHA EA Fall 0 1 rt AOAO Ff 7 pm Cancel Figure 2 22 Dialog box to assign a design surface on a projection view NEED ENG DG BOX 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 is taken as TOP surface then the view below has to be taken as FRONT surface PCadCam International PCI 36 CAD The upper view can also be taken as BACK surface and the lower view is TOP When the two views are laid si
6. 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 When selecting the cut off icon notice that the d3 parameter is not the depth of cut but it is 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 PCadCam International PCI 19 CAD 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 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
7. Pran re oF Ten F r s oa r F k Fa en F r k yy fy 3 F _ Fa 7 Fa r auf TN TE saui nding Es Make eV aN Acan T eaae Tenna ome Veet F P le i 1 Fs T E E AS r Ti i A ie k 5 amp wos pe t a a a i pS F 5 i k s are s B an Tr a a er o ae oS D r MAS i n S F ao 2 a pa k a Sy ba 7 l Er g m rat nit 1 A et N g p r s gt Mie vi F FT e 7 ae LEDY EON Fa J s T _ p F M A oe F Sa WR aa E a i P i z d wh k Fa Mah Fa AO MA wh ee E TAF 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 PCadCam International PCI 26 CAD 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
8. ae ae ns Pd a p in mi on one ii _ a T in om ae a i a rs es aa Ti a ae oe oe AS we ea p b Pi f ic k ee a a moa et i na e goers a a Pra i J aoe AT ia ee Te m E il M e on maj a s mm oa J a ae e i Ti a Se Dan oo es a i 5 me oe p pe es 1 se i i mn T a a ot a oo a x peor a a n oe Ee 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 It is 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 bind
9. as orientation angle The digit of accuracy for machining feature position UVW and variable D1 D6 is 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 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 a Se he sb rm ae F m g a E r a a hi T 2 m he amr 2 ak E a ah Pea a ee F nE Figure 2 28 Example of product data display at the end of FR operation 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 is the name of the feature followed by design surface level of finish machining top bottom orientation chamfer width position UVW then specific parameter PCadCam International PCI 42 CAD D1 D6 or
10. 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 sence CW or CCW surface and depth data are automatically PCadCam International PCI 39 CAD 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 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 insi
11. A ee ta pre Ame Aboot AIN bedi AE ciggke AIE ED aa aRar edie Aene e er e a a JEE hoe Ree e TA yapa AU AAAF i ae Figure 2 25 Dialog box confirmed the non registered feature in the drawing database PCadCam International PCI 38 CAD 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 the dialog box only if the operation of polyline generation is registered in the system setting data in the drawing database Polvline Selection Selection an element of polwine Feature Mame gt Festure Orientation 2 2 7 AN BAO RUS tte fe ERP EI Eta eN tf Bt eeow 3 FER fC bon NA E oa m e N C ERRE OCW E AN FSO AEN E Design Surface TOP Bill Bee Feature Name Orientation Design Surface Depth Dr Wath AE 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 All 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
12. CAD JI 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 also 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 uR s oe H File Edt Wea pest Foret Took Dray Dirswbn Wody Waja Hap B ARS ma aj x sk KR Ha Eala ar oe oe a z A Hi Bi ee al 2 Eyler aana 1 AA O00 ate UE are E F HE SOSHAF TRACE LATTES IL Figure 1 Starting display of PCadCam2000 software PCadCam International PCI i CAD 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 AGSCU
13. ER and then key in 3 and ENTER 3 Key in XYZ values of the point 1 each separated by a comma and press ENTER 4 Key in XYZ values of the point 2 each separated by a comma and press ENTER 5 Key in XYZ values of the point 3 each separated by a comma and press ENTER 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 ates Eyrface B Fad 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 PCadCam International PCI PAE CAD 2 5 2 A Method to specify two points on the surface normal It is a method convenient to set an inclined sur
14. Home fo e di d d4 df Chanter J i00 eM eyre Erk luy Pachining I A Operation Date Repeat a Cancel Click on REPEAT to add another blind bore or OK to complete the design Click the icon as shown on the right 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 X axis as well as the distances Push ENTER for each data input 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 13 Grouping Group Confirmation Adding Group If approved click on ACCEPT then four blind bores will be modeled as shown in the above Click the icon as shown on the right to group or ungroup features 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 compl
15. ain to repeat the same command to further revise the value Square slot Click on the icon as shown on the right to design feature design on a square slot feature Input the required parameter top surface in a dialog box below for the horizontal direction Feature Hame uare slot Orientation Rerizeotal Ty rface or A Hick Fame Featere Paraseter dl da Origin T aleahire ar Ejn lua wl Vachloine ell werntie a tot Ta tae 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 Repeat Click the icon as shown on the right to repeat the feature same feature but in a different orientation Feature Hame uare slot Orientation flertical TF rface or A Featare Paraseter dl da Origin T Or alire arigi lyy sA Vachloine Roush Ore rat jm Pata PCadCam International PCI 8 design Edit a machining feature Delete a machining feature machining parameter required as shown in a dialog box below elda pocket Persia iio Neeser Kisht Y Ao0 000 te ff a noon Festere Parameter di iii a fim a fon rfegture crigin a io hi wal Jp Cheater oo o inle TT Wachiniog ugh metia
16. 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 16mm square end mill Product Spindle speed 600rpm Axial depth of cut 24mm Feed rate 150mm min Up cut Coolant Operation 3 i Tool Tool 16mm corner end mill Product Spindle speed 2500rpm Axial depth of cut 2 4mm Feed rate 125mm min Down cut Airblow Material SS41 PCadCam International PCI 20 CAD Figure 2 8 Example of machining operation sequence for cut off with machining method of Medium 0 Imm 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 International PCI 21 CAD 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
17. 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 right It is called a machining feature list Polyline data will not be included in this list Fiia eit pei vea ir gin DN EZ M ML nak at H 3 i R 2 H freer Arty CFE Biaih iniaa tayka py Peba 5 Fa P on i Se l l ee 1 I a A 1 1 al 1 1 1 EEL Pararrir fig he eset ee p cease E 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 International PCI 4 CAD 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
18. ck 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 Origin 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 CAD PCadCam International PCI database main menu Switching among four side surfaces Front Back Left and Right surfaces is by rotation around Z axis Selection or revision of design surface Assign design The dialog box to select the design surface will surface appear Surface Selection Cancel Assign top as a Doubleclick 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 PCadCam International PCI 7 CAD ag
19. de 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 material 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 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 drag to 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 in the column will be changed into red Move the cursor into the PCadCam International PCI 40 CAD drawing then left click to magnify or reduce the drawing Right click to cancel 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
20. de by side if the left view 1s 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 in correspond with Figure 2 18 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 is 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 v
21. designed will have its specific color at the beginning and it will change into white as it is merged with the base material As an example the illustration in Figure 2 13A describes the union operation 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 AD raw material new raw material PCadCam International PCI By CAD blind bore CD 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 by using a blind bore feature The bottom part of Figure 2 138C 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 f
22. e 2 7 2 3 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 PCadCam International PCI 31 CAD EIDE J WWE Drawing options CS Bale fop Dore E Peep Ses C 2 ah bope Cance Figure 2 17 FRCAD frame for selection of projection 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 International PCI a CAD FRONT BACK Hil TH 2 Hl BOTTOM TOP CF Ta Em Both side and front back view are placed on the side BOTTOM FHE 5 When Top and Bottom view exist RIGHT BACK 75 TE m TOP TOP Em Emi 3 When the side view is placed at 4 When the side view is placed at the upper right the upper left TOP EH Em FRONT RIGHT LEFT FRONT CHIN TH
23. e 2 30 Press Y followed by ENTER to bring up a dialog box that 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 Section 2 7 3 by combining two corners PCadCam International PCI 43 CAD to recognize XYZ dimension automatically Click on DESIGN SURFACE icon to switch between surfaces as shown on Figure 2 31 I r za tE Draven dye SS a St ee Toy E 4S fo h aa a ia kol fe El ban TA Figure 2 30 Example of workpiece built using product data PCadCam International PCI 44 CAD TE Draw ine dwe OPS F e 8 il oes E ITENS t 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 ty
24. ete After group ungroup icon is clicked choose one feature in the group and push ENTER The highlighted feature and others in the same group will change color to red anda 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 for confirmation followed by ENTER twice to complete When adding a feature to a group becomes necessary select G and push ENTER once Click the feature to be added and followed by ENTER twice CAD PCadCam International PCI CAD Ungrouping Select U and ENTER to cancel the grouping command 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 Wis 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 design been designed and grouped in the above step 13 Push ENTER or right click the mouse The
25. face rotated around either two of A B or C axes The description of the method is shown in Figure 2 11 at ue NEW ORIGIN E e ee STANDARD ORIGIN Figure 2 11 Two point relation on principal line method 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 1 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 is already designed as a rectangular PCadCam International PCI 24 CAD 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
26. features on the top surface with four M12 taps overlaid concentric to the bore The machining origin 1s assigned at the left lower corner oa al e 5 T a F Sari i F sa ii i a an a i i i Ba a a e a ote oa in aa a ir a m in ei e m oa 5 A lt pa aL Hk r pm J T a a mi Ta ar T eli ir wn oa ae era ay 4 Ba i i _ ifn k 7 a i aa R hag ere al ne Pal a wE z sd z aa TL F al 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 Note Start ACAD Double click the icon as shown on the right E 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 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 International PCI 5 4 Origin Shift Base Material Material Name WE Base Material Size Raw X 1405 000 ie 405 000 gt 50 000 Base Material Quality mm Top Botto Front Back gt Left gt Right Hone a b Rough Hedium b Finigh a o cancel Cli
27. following dialog box will appear Select YES 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 PCadCam International PCI L 15 Four sided design Create Feature rizia Feature Hame Tap T Tim on Oriemtation T fend 000 Sar inen fa F 5000 Bick Hama Feature Parameter dl 12 000 fiz des an O00 d EDD d 36 000 di Chanter fi 000 gH atire akin y UER ingl Bachining Etandard tap with confer z Repent LL Cancel Select Repeat button and four M12 tap features will be designed in the position of blind bore holes Click Cancel to complete pocket Click the icon as shown on the right to design a four sided pocket feature The following dialog box Input the data accordingly will appear CAD PCadCam International PCI 13 CAD reals fealere Feature Hame 4 side pocket Orientation Pi re ee ee Tx W Tl tee Hick Hame l Feature Farameter di EG mr Bn on a On 14 Chanter 0000 Oreste gngn lu wl Angle 90 On Wachining Rough Operation Data Repeat OK 16 Face feature Face feature design is not required if the raw surface material dimension has been set greater than the machining design product as assigned in step 3 In such a case NC program for machining side surfaces will be generated auto
28. ientation angle There will be an additional column when polyline exists The file of Figure 2 28 display will be saved in C Program Files PCadCam folder with fread2pcad txt name automatically assign This file name will be overwritten when the next results of FR operation is generated Therefore it is 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 a number for polyline and the 11 is 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 LOBRRD EY PCadCam q amp cr Er Database fread pcadFront txt El froad pcadRieht txt 2 Feadmetxt FFA IPAS Ne fread2pcadtxt Fels tn Sra NDE ERC Text Document OF tet a oe M aohARO SAA rt Ibe LBs Ro 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 Figur
29. iew Would like to process for another wew PCadCam International PCI I7 CAD 2 7 4 FR Operation FR system will analyze the projection drawing data however when there is one or more layer that is not registered in the database a pop up dialog box will appear as shown on Figure 2 24 User 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 Ix Bh Lot TEE 2 RO LPH Boni la Poet i o A Eha Entity LINE is La Pee i Entity data on Paper Drawing o He 0000 LA yoo a CENTERKE End Point He 0 000 Y 265 000 Let Et WHITE Frit ity data on EXE tile Mack Dated 8 We aka 191 4 PHIR PATLE FHEDTE cancel 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 a ieee A ae a s se a r Fa gm M ee ee e Fee cee ee creer e P Fa ae bas Fhe PPA Re er Pt ieee g ee r a T wenn rr a el bel Dele ee eee ot e 7 aor ere Alp r pe ae ie oa m ge a aa nPE ye a eel soy el en ae a ee A ae prr vier at eS ahs avira iS
30. in wat tet Feature Home Orientation Sarfoce Hick Hame Click the icon EDIT as shown on the right to revise the 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 accordingly click OK to complete This command can also be applied for data reconfirmation on machining features that have been designed previously 66 99 Type in e or erase in the command input and push 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 CAD PCadCam International PCI 11 Blind bore design 12 Rectangular Array WE NEED ACAD2002 ENGLISH DIALOG BOX PCadCam International PCI CAD Click the icon as shown on the right to display the following dialog box and supply the necessary data eo ee Feature Mame RM H oa Oriemtat ios fe ee Surface fe S Hick
31. ing geometry of the final product draw the polyline PCadCam International PCI CAD 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 counter 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 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 bmm 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 It is 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
32. k Hame Feature Parameter dl 12 000 nl dz d3 d4 db Chamfer 0 000 Angle Wachining Standard tap with camfer Operation Data Repeat 0K Cancel Figure 2 6 Change the type of tap ofeature origin v u v wl 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 Step 22 Mirror Copying Click on Mirror Feature icon k 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 copy lng PCadCam International PCI I CAD Step Zo 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 a a nt a a E a A x Ta i _ J e 5 m a 4 p g a je Er nae i i Ban a k _ Toe amn ne m s a pam gory Pe as ai Tk ed w Tn a Pa P ae bf a
33. 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 press ENTER key 4 Key in the XYZ values of the point 2 in the above separated by a comma and press 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 Pra eA Erfa E fied E Hira Sarre Di stu AE be ut Ea rea Figure 2 10 Confirmation of the new surface generated 8 Click ALL and OK t
34. matically in CAM process However for example to face machining lower left part of 35mm square 2mm depth click the icon as shown on the right and input the data as fete healer Feature Hame Facing ee no Orientation Lover Left P00 Sarface Top fe Hick Boge Lower left machining Feature Parameter ad di E5 a Chater knele D Om i Wachiaisg Finish Operation Data Repeal OK Came 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 PCadCam International PCI 14 Switch to view ALL Save design Change to solid model 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 machining
35. national PCI 46
36. ning 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 surface 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 International PCI 4 CAD 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
37. o 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 PCadCam International PCI 25 CAD 2 6 Modeling Pre form Material Pre form material made by welding foundry or other processes 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 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 f a Y P Pe r a A Ban AN 4 Fi y a F Fi F TLA Y Fa gt Fa i F 2 oe s F Fe a ri r ae r ra fa ra F T aan Fa F d ra Fa Y ff ff i w F Sr fF Y Y o a 5 F wren E ie ae E DE ra Fi Fa i 1 s F ii 5 F 7 se Pai ss Fi iai see a _ 4 F F F F in an a i F A a th ti F r te T Te F F i a j ty 7 Pi j A __ F Fe i i Fi Fi AUA f ANA fo 4 rs i al J rO k A r he r A F oF 2 7 F ra e N F oo i P ra So ka i F r i r r ka a if F w5 H Mess F Pa A war aai Gi W M
38. ormat file to be used in Super Verify software for NC program verification after CAM process is completed To save the file in STL format type in stlout in command line and press ENTER Follow the instruction 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 PCadCam International PCI 28 CAD 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 is 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 l Origin point for each design surface 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 if necessary Save the design and proceed to CAM operation 2 Save the design User sh
39. ould 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 Feature 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 PCadCam International PCI 29 CAD 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 is most effective when there is 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 dra
40. pe 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 shown 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 International PCI 45 CAD ome SD ee a E E Te Emm 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 Inter
41. wing 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 in the drawing before starting FR operation 2 7 2 Input the Drawing File into FR 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 ia te amp DXF Input FR Database fr Import PData Figure 2 14 Feature Recognition Toolbar PCadCam International PCI 30 drita BER CAD Look in 2000Manual z c E 3 Manual E 3 Manual J Files of type DMF def Cancel Open as read only ete tL M aB AER AS Figure 2 15 DXF file import dialog box ie alld dive ge if a OO oo 7 fa d Niii iL Posh rib l E i ee i li Ho Ji 2 G JLH i m ie Oo Oe Te ae zi l Sore Tce a T A TEO OLL E Cope ait fT U ei H Figure 2 16 Example drawing imported from DWG or DXF fil
42. wn in Figure 2 20 will appear PCadCam International PCI 34 CAD ETI o8 d 1 t ome es fe ees 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 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 is 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 PCadCam International PCI 35 CAD machining feature VISIBLE means for example a front view for plate type workpiece INVISIBLE means the feature designed to be recognized is on the back view a qT pHPI T
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