Getting Started FeatureCAM 2010 Copyright © 1995-2009 Delcam plc All rights reserved Delcam plc has no control over the use made of the software described in this manual and cannot accept responsibility for any loss or damage howsoever caused as a result of using the software Users are advised that all the results from the software should be checked by a competent person, in accordance with good quality control procedures The functionality and user interface in this manual is subject to change without notice in future revisions of software The software described in this manual is furnished under licence agreement and may be used or copied in accordance with the terms of such licence Delcam plc grants permission for licensed users to print copies of this manual or portions of this manual for personal use only Schools that are licensed to use the software may make copies of this manual or portions of this manual for students currently registered for classes where the software is used Acknowledgements This documentation references a number of registered trademarks and these are the property of their respective owners For example, Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States FeatureCAM Version: 2010 Date: 10/08/2009 11:43 Contents Introduction How this guide is organized Special features in this guide Tell us what you think FeatureCAM overview Why creating toolpaths is so fast What's new in this release Installing FeatureCAM To install FeatureCAM PAF Installation Instructions Using a dongle .11 FeatureCAM maintenance releases .12 Evaluating FeatureCAM modules .13 Setting up Flex licensing .14 Website 35 Using FeatureCAM 36 Starting FeatureCAM for the first time .36 Opening a part 39 Closing the Stock wizard .41 Creating a simple part 42 Saving your work .44 Interface tour 45 Title bar 46 Menu bar 46 Toolbars .47 Graphics window 56 Steps panel 61 Part View panel 75 Browser 77 Results window 79 Assistance bar 80 Feature/Geometry Edit bar 80 Getting Started FeatureCAM 2010 Contents • i Status bar 80 Printing .81 Keyboard shortcuts 82 Getting help 84 Customizing FeatureCAM 86 Managing your settings 86 Controlling wizards 87 Setting up dynamic viewing options 88 Adjusting colors 89 Setting up snap and grid options 91 Customizing toolbars 92 Introduction to 2.5D milling 94 Creating a part file .94 Viewing 98 Toolpaths 99 Order of manufacturing operations 100 Part documentation 103 Controlling the automation 105 NC code 106 Tool mapping 106 Changing post processors 107 Saving NC code 108 Features from curves 109 Getting started 110 Setting the snaps 111 Building circles 111 Drawing lines 112 Chaining a curve 114 Creating a feature from a curve 115 Simulating the part 116 Modifying the boss feature to contour around the part 116 Changing the plunge point 117 Introduction to turning 120 Getting started 120 Create a part file 120 Making features 124 Viewing 128 ii • Contents Getting Started FeatureCAM 2010 Toolpaths 129 Ordering of operations 130 Part documentation 132 NC code 132 Changing post processors 133 Saving NC code 133 Advanced turning and machine simulation 135 Getting started 136 Setting up machine simulation 136 Adding a subspindle feature 139 Adding a bar feed feature 141 Running a subspindle simulation 141 Setting up the second turret 142 Synchronizing operations 143 Running synchronized multi-turret simulation 144 Introduction to turn/mill 145 Getting started 145 Creating a turn feature 146 Viewing 149 Creating a radial hole pattern on the face 150 Engraving on the face 152 Creating a pattern of wrapped slots 154 Simulating a turn/mill part 154 Creating features from 3D CAD models 156 Getting started 156 Importing the CAD model 157 Aligning the model 159 Shading the part 161 Automatic feature recognition 162 Recognizing holes 163 Recognizing pockets 165 Creating a slot feature 167 Creating a side feature 168 Simulating the entire part 170 Introduction to 3D milling 172 Getting started 172 Creating the bottle surface 175 Getting Started FeatureCAM 2010 Contents • iii Viewing 176 Creating a surface milling feature 178 Simulating the entire part 180 Advanced 3D milling 181 Importing the part 181 Selecting toolpath strategies 183 Simulating the toolpaths 185 Cleaning up the fillets 187 3D toolpath strategies 189 Introduction to 5-axis simultaneous 194 Getting started 194 Creating a surface milling feature 195 Importing geometry 198 Adding flowline operation 199 Recognizing holes 203 Recognizing side features 204 Solid modeling basics 207 Getting started 208 Creating the initial solid 208 Hidden line graphics 212 Creating the curved lower surface 214 Creating constant and variable radius fillets 219 Adding thickness 221 Creating a mold cavity 223 Introduction to FeatureWIRE 225 Getting started 225 Creating the profile 226 Creating a wire EDM feature 228 Simulating a wire EDM toolpath 229 Generating NC code 231 Adding a taper angle 231 Creating the second profile 234 Creating a 4-axis wire EDM feature 236 Modifying the start point 238 Matching the curves 239 Simulating the part 241 iv • Contents Getting Started FeatureCAM 2010 Index 243 Getting Started FeatureCAM 2010 Contents • v Introduction This guide is designed to quickly get you up to speed with FeatureCAM By the time you finish this book, you'll know enough about FeatureCAM to use it straight away You may also find this guide useful, if you have upgraded FeatureCAM, and want to learn the new modules FeatureCAM is very easy to use, and does not require any specialist computing knowledge However, you need to know how to use the mouse, the keyboard, and the Windows environment If you want to know more You can find answers to using specific features, in the online help system included with FeatureCAM How this guide is organized This guide contains two distinct parts: ƒ General overview of the FeatureCAM range, and common functions; ƒ Detailed step-by-step tutorials showing you how to program parts If you are familiar with the basic FeatureCAM features, you can skim through the introductory pages and go straight to the relevant tutorials If you are new to FeatureCAM, it's best to read this guide sequentially Getting Started FeatureCAM 2010 Introduction • Special features in this guide Names of dialogs, menus, toolbars, and the menu options appear in boldface The menu names are separated from the specific command on that menu with a '>' For example, a phrase 'select View > Simulation' instructs you to open the View menu and select the Simulation option Any text that you have to type in a dialog or a text box appears in blue boldface type Icons This icon draws your attention to something that may not work the way you think it should, and helps you to avoid common errors or hidden pitfalls This icon is here to save your time, and shows you a more efficient way of doing things in FeatureCAM This icon tells you how to avoid serious problems Tell us what you think Tell us what you think of this guide We need your opinion, and want to know what we are doing right, and what we could better Email your thoughts to documentation@featurecam.com Thank you for choosing FeatureCAM! • Introduction Getting Started FeatureCAM 2010 Change the taper type back to Left, and click OK to close the Properties dialog Select the Toolpaths Click the 3D Simulation button step from the Steps panel button, and then click the Play Since this is a die feature, it is assumed that the region inside of the curve will be discarded Click the Select button on the Standard toolbar Click the stock in the region inside of the curve FeatureCAM deletes that part of the stock 10.Click Eject 11.From the Show Show Stock Getting Started FeatureCAM 2010 menu on the Advanced toolbar, select Introduction to FeatureWIRE • 233 12.Open the Part View panel, right-click the die1 feature, and select the Hide Selected option Now the feature will not be displayed on the screen Creating the second profile Select the Top option from the Principal View Standard toolbar Select the Curves menu on the step from the Steps panel In the Curves Creation dialog, select the Curve Wizard button In the Curve wizard, select Other Methods as the construction method and Rectangle as the constructor, and click Next On the Rectangle page, select Use corner, width and height Set the corner point to 0.5, 0.5, 0.0 234 • Introduction to FeatureWIRE Getting Started FeatureCAM 2010 Set the Width and Height to 3.0, and click Finish Your part in the Graphics window should look something like this: Getting Started FeatureCAM 2010 Introduction to FeatureWIRE • 235 Creating a 4-axis wire EDM feature Select the Features step from the Steps panel In the New Feature wizard, select the Die radio button in the Axis frame, and click Next On the Upper Curve page, click the Pick Curve select the curve that you just created button and Click Next 236 • Introduction to FeatureWIRE Getting Started FeatureCAM 2010 On the Lower Curve page, click the Pick curve select the smaller curve that you created first button and Keep clicking Next until you get to the Dimensions page Enter 0.50 as the Thickness, click the triangle next to the Finish button, and select the Finish option Getting Started FeatureCAM 2010 Introduction to FeatureWIRE • 237 The feature is twisted because the start points were not set Modifying the start point Open the Part View panel, select the die4x1 feature from the Setup1 node, and click the Properties Feature/Geometry Edit bar button on the In the Properties dialog for die4x1, click the Start tab Click the Pick Location Start/End Point button for the Upper Curve In the Graphics window, click a point in the center of the stock, and then click on the bottom horizontal line of the outer curve You should notice a green line between the point and the edge of the curve 238 • Introduction to FeatureWIRE Getting Started FeatureCAM 2010 Click the Pick location Curve Start/End Point button this time for the Lower Click in the center of the stock and click the bottom horizontal line of the inner curve Click OK The feature now should no longer be twisted Matching the curves Open the Part View panel, select the die4x1 feature from the Setup1 node, and click the Properties Feature/Geometry Edit bar Getting Started FeatureCAM 2010 button on the Introduction to FeatureWIRE • 239 In the Properties dialog for die4x1, click the Dimensions tab and click the Match Curves button In the Match Curves dialog, click the Pick Lower Curve button Point In the Graphics window, select the top right point on the lower curve, and then select the right corner point on the upper curve You should see a green line between the two points 240 • Introduction to FeatureWIRE Getting Started FeatureCAM 2010 Hold down the Shift key and select the upper-right point on the lower curve, and then select again the right corner point at location Now you have matched both points on the lower curve to the single point on the upper curve Click Apply, and then click OK to close the Match Curves dialog Click OK in the Properties dialog The part in the Graphics window looks something like this: Simulating the part Open the Part View panel and deselect the check box next to the die1 feature to exclude it from the simulation Click the Isometric option from the Principal View on the Standard toolbar Getting Started FeatureCAM 2010 menu Introduction to FeatureWIRE • 241 Select the Toolpaths Click the 3D Simulation button Click the Select step from the Steps panel button, and then click the Play button on the Standard toolbar Click the stock in the region inside of the curve FeatureCAM deletes that part of the stock Click Eject You have completed this tutorial 242 • Introduction to FeatureWIRE Getting Started FeatureCAM 2010 Index Z-level finishing • 189 Z-level roughing • 189 2.5D Milling • 94 2D Simulation button • 52 2D spiral finishing • 189 2D turned profiles • 51 3D milling • 172 3D rapidcut simulation • 52 3D simulation • 52 3D spiral finishing • 189 3D toolpath strategies • 189 2D spiral finishing • 189 3D spiral finishing • 189 4-axis Rotary • 189 5-axis Trim • 189 Between Two Curves finishing • 189 Corner Remachining • 189 Flowline finishing • 189 Horizontal and Vertical strategy • 189 Isoline finishing • 189 Parallel finishing • 189 Pencil • 189 Plunging • 189 Radial finishing • 189 Swarf • 189 Getting Started FeatureCAM 2010 4-axis Rotary • 189 5-axis Trim • 189 A Advanced toolbar • 49 Arc menu • 52 Assistance bar • 45, 80 Automatic Feature Recognition • 162 B Bar feed • 141 Between Two Curves finishing • 189 C Chain menu • 52 Circle menu • 52 Colors • 86, 89 Context-sensitive help • 48, 82, 84 Corner Remachining • 189 Curves Index • 243 Curve from Curve menu • 50 Curve from Surface menu • 50 Curve menu • 50 Curve wizard • 49 Curves and Surfaces toolbar • 50 Curves step • 64 Features from curves (tutorial) • 109 Customising FeatureCAM • 92 Customize Manufacturing step • 69 D Databases Materials database • 73 Tools database • 72 Delete • 48, 60, 82 Details tab • 79 Dimension menu • 52 Display Mode toolbar • 51 2D turned profiles • 51 Draft hidden line mode • 51 Hidden line mode • 51, 212 Shade Selected button • 51 Show normals • 51 Unshade all • 51 Unshade selected • 51 Unshow normals • 51 Dongle • 11, 12 Draft hidden line mode • 51 Feature/Geometry Edit bar • 45, 80 Features from curves (tutorial) • 109 Features step • 65 FeatureTURN • 120, 135 FeatureTURN/MILL • 145 FeatureWIRE • 3, 225 Fillet menu • 52 Finishing • 189 2D spiral finishing • 189 3D spiral finishing • 189 Between Two Curves finishing • 189 Flowline finishing • 189 Isoline finishing • 189 Parallel finishing • 189 Radial finishing • 189 Z-level finishing • 189 Flex licensing • 14 Flowline finishing • 189 G Edit menu • 52 Eject button • 52 Engraving • 152 Evaluation • 12, 13 Geometry Feature/Geometry Edit bar • 45, 80 Geometry step • 63 Geometry toolbar • 49, 52 Arc menu • 52 Chain menu • 52 Circle menu • 52 Edit menu • 52 Fillet menu • 52 Line menu • 52 Point • 52 Importing geometry • 198 Graphics window • 45, 56 Grids • 91 F H Fast forward to end of simulation • 52 Feature/Geometry Edit bar • 45, 80 FeatureMILL3D • 172 Features • 49 Help • 48, 84 Context-sensitive help • 48, 82, 84 Hidden line mode • 51, 212 E 244 • Index Getting Started FeatureCAM 2010 Hide menu • 49 Horizontal and Vertical strategy • 189 I Importing geometry • 198 INITDB • 36, 156 Installing FeatureCAM • Interface • 45 Graphics window • 45, 56 Title bar • 45, 46 Toolbars • 45, 47, 92 Part View panel • 45, 75 Steps panel • 45, 61 Isoline finishing • 189 K keyboard shortcuts • 46, 82 L Licensing • 14 Line menu • 52 M Machine simulation • 52, 135, 136 Machining preferences • 69, 70 Maintenance releases • 12 Materials database • 73 Menus • 45, 46 Circle menu • 52 Dimension menu • 52 Fillet menu • 52 Hide menu • 49 Line menu • 52 Menu bar • 45, 46 Principle View menu • 48 Show menu • 49 View menu • 48 Metric • 156 Modules • 3, 13 More Simulation toolbar • 55 Getting Started FeatureCAM 2010 Mouse Mouse buttons • 56 Mouse cursor • 56 Mouse cursor • 56 N NC code • 69, 80 NC Code step • 69 NC Code tab • 80 New Feature • 49 New file • 39, 48 O Opening files • 39, 48 Operation list • 79 Options • 48 P Parallel finishing • 189 Part View panel • 45, 75 Pause simulation • 52 Pencil • 189 Play button • 52 Plunging • 189 Point • 52 Post options • 74 Principle View menu • 48 Printing • 81, 82 R Radial finishing • 189 Region of interest simulation • 52 Results window • 45, 79 Roughing • 189 Plunging • 189 Z-level roughing • 189 S Saving files • 44, 48, 82 Index • 245 Selecting • 48, 58, 82 Shading • 48, 51, 59 Draft hidden line mode • 51 Shade Selected button • 51 Unshade all • 51 Unshade selected • 51 Show menu • 49 Show normals • 51 Simulation More Simulation toolbar • 55 Region of interest simulation • 52 Simulation toolbar • 52 2D Simulation button • 52 3D rapidcut simulation • 52 3D simulation • 52 Eject button • 52 Fast forward to end of simulation • 52 Machine simulation • 52, 135, 136 Pause simulation • 52 Play button • 52 Region of interest simulation • 52 Simulation speed • 52 Single step simulation • 52 Stop simulation • 52, 82 Single step simulation • 52 Snap modes Snap Mode toolbar • 50 Snap Modes dialog • 49 Snapping options • 91, 111 Solids Solid toolbar • 55 Solid wizard • 49 Standard toolbar • 48 Status bar • 45, 80 Steps • 61 Curves step • 64 Customize Manufacturing step • 69 Features step • 65 Geometry step • 63 NC Code step • 69 246 • Index Steps panel • 45, 61 Steps toolbar • 55 Stock step • 62 Toolpaths step • 66 Stock • 41, 89 Stock step • 62 Stop simulation • 52, 82 Subspindle • 139, 141 Surfaces Curves and Surfaces toolbar • 50 Surface from Curve menu • 49 Surface from Surface menu • 50 Surface from Surfaces menu • 50 Surface Primitives menu • 50 Surface wizard • 49 Swarf • 189 T Text • See Engraving Title bar • 45, 46 Tool load • 52 Toolbars • 45, 47, 92 Curves and Surfaces toolbar • 50 Curve from Curve menu • 50 Curve from Surface menu • 50 Curve menu • 50 Surface from Curve menu • 49 Surface from Surface menu • 50 Surface from Surfaces menu • 50 Surface Primitives menu • 50 Display Mode toolbar • 51 Geometry toolbar • 49, 52 Arc menu • 52 Chain menu • 52 Circle menu • 52 Dimension menu • 52 Edit menu • 52 Fillet menu • 52 Line menu • 52 Point • 52 More Simulation toolbar • 55 Simulation toolbar • 52 Getting Started FeatureCAM 2010 3D rapidcut simulation • 52 3D simulation • 52 Eject button • 52 Fast forward to end of simulation • 52 Machine simulation • 52, 135, 136 Pause simulation • 52 Play button • 52 Region of interest simulation • 52 Simulation speed • 52 Single step simulation • 52 Stop simulation • 52, 82 Snap Mode toolbar • 50 Solid toolbar • 55 Standard toolbar • 48 Steps toolbar • 55 Toolbox • 45, 56 Part View panel • 45, 75 Steps panel • 45, 61 Toolpath strategies • 189 2D spiral finishing • 189 3D spiral finishing • 189 4-axis Rotary • 189 5-axis Trim • 189 Between Two Curves finishing • 189 Corner Remachining • 189 Flowline finishing • 189 Horizontal and Vertical strategy • 189 Isoline finishing • 189 Parallel finishing • 189 Pencil • 189 Plunging • 189 Radial finishing • 189 Z-level finishing • 189 Z-level roughing • 189 Toolpaths step • 66 Tools database • 72 Transform • 48, 214 Troubleshooting • 9, 12, 24 Getting Started FeatureCAM 2010 Turn/mill • 145 Turning • 120, 135 U UCS • 49 Undo • 48, 82 Units • 156 Unshading • 51 Unshade all • 51 Unshade selected • 51 Unshow normals • 51 V View menu • 48 Viewing • 59 Display Mode toolbar • 51 Hidden line mode • 51, 212 Shade Selected button • 51 Show normals • 51 Unshade all • 51 Unshade selected • 51 Unshow normals • 51 Graphics window • 45, 56 View menu • 48 W Wizards • 87 Curve wizard • 49 Solid wizard • 49 Surface wizard • 49 Z Z-level finishing • 189 Z-level roughing • 189 Index • 247