EdgeCAM manufacturing basics

EdgeCAM Manufacture – User Guide

EdgeCAM Manufacture – User Guide Contents EdgeCAM Manufacture Mode.....................................................................................1 ENTERING MANUFACTURE MODE ........................................................................3 SELECTING TOOLS............................................................................................14 CHECKING THE PART ........................................................................................34 MOVING THE TOOL ...........................................................................................37 SELECTING A CYCLE .........................................................................................47 FINISHING A COMMAND .....................................................................................47 USING CUTTER COMPENSATION ........................................................................48 DISPLAYING TOOLPATHS ...................................................................................54 Editing Instructions in the Browser.........................................................................57 EDITING INSTRUCTIONS.....................................................................................57 COMBINING COMPONENTS AND SEQUENCES ......................................................59 INSERTING SEQUENCES ....................................................................................62 MERGING SEQUENCES......................................................................................63 RE-ORDERING THE MACHINING INSTRUCTIONS IN A SEQUENCE...........................64 MERGING HOLE CYCLES ...................................................................................71 USING INSTRUCTIONS MENU COMMANDS...........................................................75 Editing the Toolpath..................................................................................................79 DELETING A SECTION OF A TOOLPATH ...............................................................80 EDITING A SECTION OF A TOOLPATH ..................................................................80 SPLITTING A TOOLPATH ....................................................................................80 TRANSFORMING THE TOOLPATHS ......................................................................81 Generating CNC Code...............................................................................................87 PASSING JOB DATA TO THE NC FILE .................................................................89 ABOUT CNC FILENAMES...................................................................................89 CODE GENERATOR COMMANDS ........................................................................90 EDITING THE CNC CODE ..................................................................................92

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EdgeCAM Manufacture - User Guide

EdgeCAM Manufacture Mode

ENTERING MANUFACTURE MODE .......................................................................3 Browsing the Instruction List .......................................................................4 The Context Menu in the Instruction Browser .........................................................5

About Machining Sequences ......................................................................6 Defining a Machining Sequence .................................................................7 About the Initial CPL....................................................................................8 Passing Job Data to the NC File ...............................................................10 Selecting an Existing Machining Sequence ..............................................11 Building the Instruction List .......................................................................11 Changing the Machine Parameters...........................................................12 Conversion of Arcs to Lines ......................................................................13 SELECTING TOOLS ..........................................................................................14 Selecting from the ToolStore.....................................................................14 Selecting from the Tool Library .................................................................15 Defining New Tools Interactively...............................................................16 Selecting the Wire .................................................................................................17

Milling Cutter Parameters..........................................................................18 Turning Tool Parameters...........................................................................19 Specifying Insert Parameters ................................................................................20 Specifying Turret Parameters................................................................................22

Selecting a New Tool Datum.....................................................................23 Saving Tool Graphics ................................................................................24 Displaying the Tool....................................................................................24 Displaying the Tool Holder ........................................................................25 Setting Feeds and Speeds for Milling and Turning Tools .........................26 Setting Speeds and Feeds Manually.....................................................................26 Setting Speeds and Feeds Automatically..............................................................26

Viewing the Current Technology Values ...................................................28 Material Technology Table ....................................................................................29 Tool Technology Table..........................................................................................29 Defining New Material Technology Tables ............................................................29

Selecting a Safe Distance for the Tool......................................................30 Selecting a Safe Distance for the Turning Tool ........................................31 USING MISCELLANEOUS (M-) FUNCTIONS ........................................................32 Checking the Miscellaneous Functions .................................................................33

CHECKING THE PART .......................................................................................34 Verifying the Machining Parameters .........................................................34 Viewing the Machine Datum Co-ordinates................................................35 MOVING THE TOOL ..........................................................................................37 Moving at the Rapid Rate (Milling and Turning environment)...................37 Moving the Wire at the Rapid Rate .......................................................................38

Moving at the Feed Rate ...........................................................................38 Editing Co-ordinates of Rapid and Feed Moves .......................................39 Moving the Tool in an Arc at the Feedrate ................................................41 Moving the Tool around a Co-ordinate Axis..............................................41 Moving the Tool to the Toolchange Position .............................................41 Moving the Tool to the Home Position ......................................................42 Moving to the Initial Plane .........................................................................43 Freehand Milling........................................................................................43 Exact Tool Positioning in Turning..............................................................44 Moving Relative to an Entity......................................................................45 Moving Constrained by Entities.................................................................46 Moving Relative to Two Entities ................................................................46 1

Manufacturing Basics

SELECTING A CYCLE........................................................................................47 FINISHING A COMMAND ....................................................................................47 USING CUTTER COMPENSATION.......................................................................48 Using Cutter Compensation in Milling Cycles ...........................................48 Using Wire Compensation.........................................................................49 Using No Compensation ...........................................................................50 Using Controller Compensation ................................................................50 Using Pathtrace Compensation.................................................................51 Using Cutter Compensation in Turning Cycles .........................................52 DISPLAYING TOOLPATHS .................................................................................54 Controlling the Toolpath Mode ..................................................................54 Simulating Tool Movement........................................................................54 Displaying Solid Models ............................................................................55

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Entering Manufacture Mode EdgeCAM starts up in Design mode, as it assumes that you want to begin by creating a part. If you have already created a part, or have loaded an existing part, you will now want to start the machining process. To use the EdgeCAM system, you should be experienced in CAD/CAM methods and the appropriate equipment and terminology. You also need to have some experience of the Microsoft™ Windows NT™ graphical user environments. Most of the commands you require are not present in Design mode (to make the number of commands available to you more manageable). To access the commands for machining a part, you must enter the Manufacture mode. Select Manufacture (Options menu) or press the Manufacture button to switch into Manufacture mode.

If you need to switch back into Design mode at any time, click on the Design button or select Design (Options menu). If this is the first time you have entered Manufacture mode since starting EdgeCAM, you are prompted for details on what type of machining you want to use. This information defines a new “machining sequence” or machining worksession. You also specify which Code Generator file you want to use. A Code Generator provides appropriate manufacturing commands and contains the data on converting an EdgeCAM machining sequence into CNC code for a specific machine tool type. You may enter Manufacture mode with a new executable file (for example, a PDI) or a new Code Generator file. If you do, you are prompted to enter the text for the machine-specific commands that appear under the M-Functions menu.

About Creating Wire Toolpaths Before you try to create wire toolpaths, you should already have created a Wire Profile. Whichever method you used to create the profile, simply select the command Machine Design (Cycles menu). This command uses whatever information is stored in the profile to generate the appropriate toolpaths. Also see Creating the Design Intent.

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Browsing the Instruction List The Instruction List is, simply, the list of all machining commands for the current part. Each time a new machining command is used on the part, it is added to the bottom of the list of the current machining sequence. Commands that cannot be converted into CNC code (for example, viewing and editing commands) do not appear on the list. The browser on the left of the screen shows all machining sequences and instructions associated with the current part.

You can also view the EdgeCAM Instruction list associated with a job from within the Job Manager or the web-based Job Reports. If an associated instruction list exists for a particular job, the instructions will be displayed on the Instructions tab of the Job Manager or through a link on the job reports page. The icon for the current machining sequence is shown with a green background.Note that the machine sequence description is followed by the code generator file (‘Machine Tool’ in dialogs defining the sequence) used by the sequence. ‘Sequence 1’ is used by default if you do not specify a description. By default, as the mouse is moved over an instruction in the browser window, the relevant toolpath is automatically highlighted in the graphics area. Uncheck the Highlight Instructions option on the Toolpaths tab of the Preferences (Options menu) dialog to disable this functionality. Clicking on a plus sign expands the view to show all instructions under that machining sequence, including toolchange descriptions with turret position.

To collapse part of the view, click on the minus sign. You can use the mouse to drag instructions to a new position in the list if necessary. You can also copy instructions to a new position in the list by holding down the 'Ctrl' key while dragging the instructions.

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By default, the instructions in the Browser window are numbered as this can be useful when a part has a large number of similar instructions. To display the instructions without numbers, please ensure that the Number Instructions option on the Toolpath tab of the Preferences (Options menu) dialog is unchecked. Displaying the individual co-ordinates in feed and rapid moves can slow down EdgeCAM when working with a part containing a large number of instructions. Uncheck the Display Co-ordinates option on the Toolpaths tab of the Preferences (Options menu) dialog if you do not wish to display the co-ordinates. Note that you may edit instructions within an operation, but this will break the operation down into its component instructions. You can also group instructions together as operations using Operation (Instructions menu). This means that when editing the instruction list you could edit individual commands or entire operations. Do not confuse these with the integrated machining commands provided under the Operations menu.

The Context Menu in the Instruction Browser A right-hand mouse click on an instruction opens the context menu with the options Edit, Delete, Simulate, PCI Template, Swathe, Text File, Refresh and Regenerate. The first three options are self-explanatory. The Text File option allows you to export the contents of the sequence to a text file for subsequent printing. Different levels of information can be exported to the text file. The PCI Template command allows you to generate a PCI from selected instructions in the browser If you make changes to the instruction list, the display is not updated. In this case, use the Refresh option to ensure that the instruction list is displayed correctly in the browser window. The Regenerate option will regenerate the sequence from the selected instructions. The Swathe option (supported in both milling and turning) allows you to activate/deactivate the Swathe mode in GLView.

Note that this functionality will only display a planar 'slice' at each level of cut. 5


The Output Process option is used to select one or more EdgeCAM instructions to be passed to Strategy Manager. EdgeCAM Strategy Manager is a product introducing rules based machining to the Solid Machinist user that combines logic and flow chart methodology to capture working practices and define a machining strategy, which can then be applied to EdgeCAM hole cycles and operations in the first development phase in version 7.00. EdgeCAM Strategy Manager is a separate licensed application. Please contact your EdgeCAM reseller for further information on Strategy Manager.

About Machining Sequences A machining sequence is a set of machining information for an EdgeCAM part. Depending on the environment, it specifies the: •

machine tool (the Code Generator to be used to provide machining commands and to create CNC code from the instruction list)

•

machine datum for the machine tool

•

axis system being used

•

turret configurations

•

machine tool specific functions available (added to the M-Functions menu)

•

units to be used in the CNC output

•

sequential list of machining instructions and/or operations.

If a part has been saved, the default sequence is the sequence in use when the part was saved. This sequence is used for the part at the start of a new Manufacture session. A new sequence can be defined at any time in Manufacture using the command New Sequence (File menu). An existing sequence can be selected using the command Select Sequence (File menu). Parts can contain multiple sequences, for example two milling operations on the same model. Also, more than one discipline (mill, inspection, turning, and so on) can be used with the same model. If you have to physically move the workpiece from one setup to another, you should consider using separate sequences, as the output will be for machine tools used in that setup. If the part is complex, the redraw time may get quite long, so you may want to break it down. However, you must then merge the files together with an editor (the EdgeCAM Editor is recommended).

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Defining a Machining Sequence When you enter the Manufacture module for the first time, or as a result of selecting the command New Sequence (File menu), you are asked to create a new machining sequence. The parameters for the sequence are: Billet - (Turning environment only) Check this box to define the geometry of the billet (bar stock).After you click on OK to dismiss the sequence parameters, you can digitise the entities that define the initial material profile or billet. Alternatively you can specify two opposite corners of the billet using the mouse or by inputting the actual co-ordinates using the

button.

The first point is the outer corner of the billet:

Mirror View - (Turning environment only) Check this box to create a mirrored profile about the Z axis that you can use for Four Axis cycles. EdgeCAM only needs the upper side of the turned profile to be drawn. After you click on OK to dismiss the sequence parameters, you can digitise the profile that you want to mirror. Perform a Finish and the mirrored profile is created. Machine Datum – (Milling and turning environment only) Specifies the effective machine origin. This defaults to CPL Top (in milling) or the Initial CPL (in turning), but you may select any desired location. You may specify a point on the graphics screen using co-ordinates or a digitise. A CPL will be generated at this location, with the same orientation as the Initial CPL. To help visualise the Machine Datum, you can display the Primary and Secondary axes by selecting the Machine Datum box in the Drawing, Configure (View menu) command. Sequence Name – Type in a (descriptive) name for the new machining sequence (eg. 'OP1'). Please note that each machining sequence must have a unique name. Job Name – Select a job be entering the appropriate name or use the Browse button to call up the Job Manager and select a job from the list. Also see Passing Job Data to the NC File.

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Discipline – Select the appropriate machining discipline. This then filters the available Code Generator files that appear under Machine Tool. When selecting a sequence for combined turning and milling operations on a single component, and all operations are to carried out on a turning centre, select the Turn discipline. If the same combination of operations is to be performed on a milling centre and a separate turning centre, then two separate machining sequences should be used. Machine Tool – Select the appropriate Code Generator file from those available. This generates the CNC code for a particular machine tool or other device. It also defines which commands and options are appropriate for the desired manufacturing discipline and type of machine tool. Initial CPL – Select the CPL in which to begin machining. For wire erosion this must always be set to TOP. Also see Initial CPL in the Milling and Turning environment. Datum Type – (Milling environment only) Specify the type of coordinate shift from the World Co-ordinate System origin (Absolute or Incremental). Absolute typically invokes a co-ordinate shift on the machine tool similar to a G50 (the co-ordinate system can be reinstated from any other co-ordinate system). This must be supported by the code generator and machine tool. Incremental typically invokes a co-ordinate system shift similar to a G92 (reselection is not easy from another co-ordinate system).

About the Initial CPL On initialising a new machining sequence, you select an Initial CPL. This is used to define the initial orientation of the tool (for example, A0.0 B0.0), and an absolute point of reference for setting up the machine tool (for NC program co-ordinates). The Initial CPL defaults to the CPL in use when you entered Manufacture from the Design module. The choice of available CPLs depends on which environment was in use when you entered Manufacture. The Initial CPL is where the machine’s programmed “zero” is to be located. Because of this, when you import or create a model that is not in a convenient position for manufacture, use Create CPL (Geometry menu) in Design mode to set up a more useful origin. Alternatively, use the Translate Transpose (Edit menu) command to move the geometry so that CPL Top is the program zero.

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There are two commands for altering the datum point in the current machining sequence: • Datum Shift (M-Functions menu) – Allows you to move the program zero to a new location in the current part. This is useful if you want to machine several separate components in the same model within the same machining sequence. You could instead translate the toolpath from one component onto the other component. For more information, see Transforming Commands (Copy Machining). • Index (Move menu) – Also allows you to move the datum. For more information, see Multiplane Milling and Rotary Milling. For a turning sequence, this must be a standard CPL or user defined CPL that has a base co-ordinate system of Turn (ZX). If the datum point of the geometry is unsuitable, translate the geometry to the appropriate position using the Design command Transform Translate (Edit menu).

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Passing Job Data to the NC File When a job record is selected for a machining sequence the specified modifiers will be loaded into EdgeCAM and the values displayed in the appropriate field on the Job Data tab. This information along with Material, Machine and Description will be passed through to the Code Generator, bringing the Job Manager, EdgeCAM machining sequences and the NC file closer together. You can also set these modifiers on the New Machining Sequence and Machine Parameters dialog. The relevant fields in the Job Manager will be updated when an NC file is generated. Comment – Add any relevant notes. Family – All jobs defined in the database can be grouped into families which form the tabs on the job panel of the ToolKit Assistant dialog. Customer – Enter the customer name for the job. Programmer – Enter the name of the programmer. Job Revision – Enter the current revision identifier for change control purposes. Please note that the text string must not exceed 39 characters. Note that the job record will contain only a text field holding the current revision. If you wish to keep a complete change history or other audit trail information this can be done by making appropriate entries on the Notes page.

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Code Generator Variable

Token Name

Token Description

JOBDESC

JM-DESC

Job Manager Description

JOBCOM

JM-COM

Job Manager Comment

JOBFAM

JM-FAM

Job Manager Family

JOBMACH

JM-MACH

Job Manager Machine

JOBCUST

JM-CUST

Job Manager Customer

JOBPROG

JM-PROG

Job Manager Programmer

JOBMATL

JM-MATL

Job Manager Material

JOBREV

JM-REV

Job Manager Revision


Selecting an Existing Machining Sequence To use a machining sequence other than the current one, pick the command Select Sequence from the Files menu. You are presented with a list of available sequences. Select one of the sequences. If you want to use a new sequence, select the New Sequence (File menu) command. See Defining a Machining Sequence. You can remove a machining sequence in a similar manner using the Delete Sequence command. If you delete the current sequence, you are prompted to pick an existing sequence. If there are no existing machining sequences, the New Sequence dialog is displayed, allowing you to define one.

Building the Instruction List The Instruction List is, simply, the list of all machining commands for the current part. Each time a new machining command is used on the part, it is added to the bottom of the list. Commands that cannot be converted into CNC code (for example, viewing and editing commands) do not appear on the list. Example Instruction List:

You can also group instructions together as operations using Operation (Instructions menu). This means that when editing the instruction list you could edit individual commands or entire operations. Do not confuse these with the integrated machining commands provided under the Operations menu.

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Changing the Machine Parameters To check the values for the current machining sequence, use the Machine Parameters (Verify menu) command. This displays a dialog box showing all current machining parameters. You can alter the conditions of the machining sequence at any time using the Machine Parameters (M-Functions menu) command: Depending on the manufacturing environment, some or all of the following parameters can be altered: Rapid 3D – Click in this box to allow the tool to rapid move in all three axes. Each axis may accelerate to rapid at differing rates. There is therefore a risk of collision as the resulting move is not easily predictable. Refer to your machine tool documentation. Sequence Name – Enter a new name for the current machining sequence. Job Name – Select a job be entering the appropriate name or use the Browse button to call up the Job Manager and select a job from the list. Initial Plane* – Set the absolute height of the Initial Plane. Note that while toolchange and home positions are defined in world co-ordinates the initial plane is defined from the intial CPL of the sequence. These two datum points may be different. You must ensure that this height is clear of any obstruction including holding devices and material. Use this plane to move around the part at the rapid rate. See also Moving to the Initial Plane. Output Tolerance – Specifies the smallest distance that the Code Generator can output in the final CNC file of the machining sequence. Also see Conversion of Arcs to Lines. Machine Tool – Select a Code Generator file for the machining sequence. This file defines which machining commands are available and controls the output of the CNC code. To be able to successfully reselect a machine tool, the two machine tools should have the same capability. For example, moving C axis operations to a turning centre not equipped with a C axis control would result in an incomplete machining instruction list. Units* – Select the units that the final CNC code is to use. Any differing units used in the model are automatically converted. The default units are specified in the Code Generator file. You can select between mm (millimetres) and inches. Home* – Set the tool home position by entering the X, Y and Z world coordinates. Toolchange* – Set the toolchange position by entering the X, Y and Z world co-ordinates. *The marked parameters have default values that are set in the Code Generator file. For more information on the parameters on the Job Data tab, please refer to Passing Job Data to the NC File.

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Conversion of Arcs to Lines EdgeCAM converts an arc move to a linear move when the chord height of the arc is less than the output tolerance of the machining sequence. The output tolerance is normally set to the same precision as the controller's decimal point format. For example 0.001mm or 0.0001 inch. EdgeCAM performs this conversion to inhibit the output of potentially invalid arc moves which could cause an error on the controller where •

arcs have a radius greater than the control can interpret. This can be encountered in smoothed surface toolpaths.

•

the arc start and end positions are so close that when formatted they are the same position. This can result in the controller interpreting it as a complete circle move.

•

the arc start or end positions in one axis are close enough to become the same position when formatted. This can result in the controller reporting an error that the point does not lie on the arc.

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Selecting Tools Before you can begin machining a part, EdgeCAM expects you to load a tool of some description. This is so that the correct tool offsets and positioning from the work can be calculated. Until you load a tool in the turret, you are only allowed to position the turret and select M-Functions commands. Once you have loaded a tool, all cycles appropriate to that tool type can be used. EdgeCAM provides these methods of loading tools: •

Loading pre-defined tools from the ToolStore or Tool Library. Note that you can set up where to find the ToolStore and the Tool Library using the Tool Libraries tab of the Preferences (Options menu) command.

•

Entering the parameters defining a completely new tool.

•

Loading tools from an AutoTAS database.

Selecting from the ToolStore To access the ToolStore: •

Select ToolStore from the Tooling menu.

•

Click on the ToolStore

•

Click Find on the General tab of the Milling Cutter dialog.

button.

For further information on using the ToolStore, please refer to the context sensitive help in the ToolStore application or the ToolStore chapter in this manual.

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Selecting from the Tool Library Before proceeding, you should be familiar with the Tool Library. See Using the Tool Library, and Searching for Records. To load a tool from your default tool kit See Defining a Machining Sequence for details on specifying the default tool kit. button. This 1. Select Load From Kit (Tooling menu) or click on the dialog appears, listing the tools already saved to the default tool kit:

2. Select the appropriate tool. 3. Click on OK. To load a tool from the Tool Library 1. Select from Turn, Thread, Bore, Groove, Parting Off or Milling Cutter (Tooling menu) or click on a tool button:

EdgeCAM displays the parameter input window for that tool type. 2. Click on the Library button. The Library window appears:

3. Click on the OK button to search the source database. 4. Select an appropriate tool from the list.

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To save a tool in the Tool Library You must have selected a tool type from the Tooling menu or have clicked on a tool button. This displays a parameter input window for that type of tool. Once you have specified the parameters of a particular tool, you may want to save it so that you can use the same tool later. To save a tool 1. When you are satisfied with the values of each parameter, select the Library... button. The Library window is displayed. 2. Select the Tool Library database using the Source parameter. You can only select Cutting Tools as you cannot save an Assembly or a Tool Kit with this method. 3. Specify a reference Tool Name for the tool. 4. Click on the Save Tool box. 5. Click on OK.

Defining New Tools Interactively Rather than load the tool information from a database, you can specify a completely new tool, purely for use with the next cycles you select in the current machining sequence. All tools can be selected from the Tooling menu or from the toolbar.

Milling Cutters

Turning Tools Turn, Thread, Bore, Groove and Parting Off are considered to be fixed tooling, while Milling Cutters can be either driven (powered tooling) or fixed. You could also use a fixed drilling tool for making holes on the spindle centreline.

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Selecting the Wire Use the Select Wire (Cycles menu) command to set the parameters for the Wire Machine. This command lets you define the wire thickness and height of the upper and lower guide to be used when you machine the part. Diameter - Specifies the diameter of the wire. Colour - Specifies the colour of the wire and any positional moves. Upper Guide* - Specifies the height of the upper guide above the workplane. Lower Guide* - Specifies the height of the lower guide above the workplane. These guide height values will only be used if the Code Generator is set to output at guide height. * Guide height values are only applied to langhand output. Code Generators working at guide heights should have taper mode disabled and 4-axis circular moves should be converted to linear moves.

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Milling Cutter Parameters The parameters concerning the dimensions of the milling cutter can be seen from these diagrams:

Number of Teeth – Specify the number of cutting teeth on the tool. Comment – Enter any short notes here regarding the tool – these will appear in the instruction list and in the NC output for the machining sequence. Layer – Specify the layer on which the associated toolpath will be drawn. Units – Specify the units in which the tool is defined. Depth Type – Specify whether the setting point of the tool is taken to be at the Point of the tool, or at the beginning of the Full Diameter of the tool. Colour – Select the colour of the tool and the associated toolpath. Turret Tab Position – Specify the tool’s position number on the turret. Zgauge – Specify the distance between the tool setting point and the tool loading point. Please note that the gauge length is specified in part units (not tool units).

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Turning Tool Parameters You may have more or fewer parameters than are given here. This is because you are using a customised Code Generator file which alters those commands and parameters that are displayed within EdgeCAM. Comment - Enter a text string that is placed in the CNC file as a comment when you generate code from the machining sequence. Layer - Select the layer on which the tool is drawn. Hand of Tool - Select which side of the rotary spindle axis the tool cuts on:

Left Hand

Neutral

Right Hand

Gauge Point - Defines the Gauge Point of the insert, in relation to the long (Z) axis of the tool. The Gauge Point can be set to the Primary, Secondary, Centre (of the Primary or Secondary tip radius) and Orthogonal points of an insert, and is usually positioned as follows:

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These insert types use different Gauge Point locations: Primary

Centre Primary

Centre Primary

Primary

Centre Primary

Centre Secondary

Centre Secondary

Centre Secondary

Secondary

Orthogonal

Orthogonal Orthogonal Secondary

Secondary

Primary

Specifying Insert Parameters The insert's orientation is defined relative to the tool axis. This diagram is based on a right handed turning tool: Edge Length

Inscribed Circle

End Angle

Tool Axis Included Angle

Side Angle

End Angle - Define the angle between the tool axis and the end of the insert. Side Angle - Define the angle between the tool axis normal and the side of the insert.

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End/Side Clearance Angle - Specify the clearance in degrees between the End/Side Angle and the actual End/Side Angle to be used. These values are measured relative to (and are deducted from) the End and Side Angles, and should always be (small) positive values. Here is an example insert and some example parameters: End Clearance Angle=3

End Angle =120 Side Clearance Angle=2

Side Angle=120

Included Angle - Define the angle between the end and side of the insert. Edge Length - Define the length of the cutting edge of the insert. Inscribed Circle - Define the diameter of an imaginary circle that could just fit inside the outline of the insert. Nose Radius - Define the radius of the corner at the cutting end of the insert. Reach - Defines the depth that the insert can cut before the shank makes contact with the material. This is only for Thread, Parting Off and Groove tools.

Reach

Style - Select the position of the insert to be at the End or Side of the tool. This example shows a Grooving or Parting Off tool with Style = End.

Corner Radius Width

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Corner Radius - Define the radius of the corner at the cutting end of the insert. Width - Define the width of the cutting edge of the insert, ignoring corner radii. Symbol - Select from a list of ISO insert symbol types.

Specifying Turret Parameters These parameters define the orientation of the tool to the Machine Tool Coordinate System: Position - Specify the position that the tool occupies on the turret (this defaults to the last-used turret position). Xgauge, Ygauge, Zgauge - Enter the distance of the Gauge Point from the mounting point of the tool in the X, Y and Z axes.

Tool Mounting Point

Xgauge

Gauge Point

Zgauge

Ygauge is only used on Driven tooling and when Y axis mode is enabled to allow for the tool to have a distance defined off the centreline of the spindle. Please note that the gauge length is specified in part units (not tool units). Orientation – Select from Axial, Radial and Reverse Axial to define the position of the tool axis relative to the Machine Tool Co-ordinate System:

Reverse Axial

Axial

X axis

Radial

Z axis

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Angle - Specifies the angle the tool makes with the Machine Tool Coordinate System's Z axis. This is used for finer control over the tool than by using the orientation. To activate the field, set the Orientation parameter (General tab) to . Reverse – Mark this box to use the tool rotated 180° about its own axis:

Right Hand tool, Radial orientation with Reverse off Radial orientation with Reverse selected

X axis

Z axis

Whether you reverse the tool or not depends on the direction of the machine spindle's rotation.

Selecting a New Tool Datum Use the Tool Datum (Tooling menu) command to select a gauge point and offset for the insert of a fixed tool.

Offset - Select the offset register for the tool, as specified by the machine tool controller. This is only valid if you are using controller compensation. Usually, the turret number is used to determine the offset register. However, you may want to use multiple registers, for example when turning a part with different diameters, using different offsets to compensate for tool deflection. For more details on the gauge point of a tool, see Specifying Turning Tool Parameters.

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Saving Tool Graphics Saving tool graphics in the ToolStore command on the Tool Graphics toolbar The Save Tooling Graphics allows you to save a tool/holder graphic as a .csv file. The parameters for the command are: Tool Graphics – Saves current tool graphics data to a .csv file. Click Browse to look for an existing file. Holder Graphics – Saves current holder graphics data to a .csv file. Click Browse to look for an existing file. Saving tool graphics in the Tool Library The Save Tooling Graphics (File menu) command allows you to save a drawing of a tool as a .gra Tooling Database graphics file. Once you have set the parameters, click on OK. For further information on individual parameters, please refer to the context sensitive help. You must then digitise the required datum point for the tool, the first and second points on the z axis of the tool, entities to define the tool graphics image, and any entities to de-select. Note that you can use the Run Executable (Custom menu) command to run the toolgra.exe PDI program, which generates entities from any on-screen tool simulation graphics. You can then select these entities with the Save Tooling Graphics command, and store them in the Tool Library.

Displaying the Tool By default, EdgeCAM displays the tool at its last position. The Toggle Tool icon on the Display toolbar allows you to specify how tools are displayed on the graphics screen:

Check the Hide Tool option if you do not want to display the tool. Please note that this option is unchecked by default.

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Alternatively, right click on the view status bar and select Properties.

On the Properties dialog, choose between the Wireframe, Solid or Translucent options from the Display parameter on the Tool tab. Check the Hide option if you do not wish to display the tool.

Displaying the Tool Holder By default, EdgeCAM displays the tool and the tool holder at its last position. The Toggle Tool icon on the Display toolbar allows you to specify how tools are displayed on the graphics screen:

Check the Hide Tool Holder option if you do not want to display the tool. Please note that this option is unchecked by default.

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Setting Feeds and Speeds for Milling and Turning Tools Setting Speeds and Feeds Manually You can specify the tool spindle speed and movement rates in the parameter input dialog box for any machining cycle. These speeds and feeds can be input manually for each cycle or you can use automatic defaults derived from material and tool technology tables. The common parameters are: Feedrate – Specifies the feed rate in the workplane in units per revolution (for a Boring tool, for example) or in units per minute. You can select the type of feed using the Feed Type (M-Functions menu) command. Plunge Feed – Specifies the vertical feed rate. Speed – Specifies the rotational speed of the tool on a milling centre in revolutions per minute. On a turning centre, this refers to the spindle speed, measured in units per revolution. This is overridden if you have selected constant surface speed using the CSS (M-Functions menu) command. CSS is normally only used with turning centres with fixed tooling (but not drills and taps). If you select another cycle, these speeds and feeds are carried over and used again as the default values. These can be overridden or accepted.

Setting Speeds and Feeds Automatically You can specify the tool spindle speed and movement rates for any machining cycle. However, EdgeCAM automatically calculates “speeds and feeds” for the tool based upon data previously specified. Using the technology database in the ToolStore Material and Insert records are held in the Technology database and can be accessed through the Technology tab of all tools in the ToolStore. Values loaded from the Technology database are shown "greyed out" as they cannot be directly edited. These values are used by the system and are passed to EdgeCAM operations and cycles. For further information on using material and insert data, please refer to the help in the ToolStore application.

26


To select material technology values in the Tool Library Material technology tables are held in the Material Technology database in the Tool Library, but you can access them through the Model (Options menu) command in Design mode. For more information on using the Tool Library databases, see Searching for Records. 1. Select the Model (Options menu) command in Design mode. Specify a Rigidity factor. If the material is weak or the clamping system exerts low holding forces, then you need to adjust this downwards. For example, a factor of 50% halves the theoretical speeds and feeds. This applies to all tools used for the part. 2. Search the database. All records matching your search are displayed. 3. Select the material data table you want to use. To select tool technology values 1. Use the Technology (Tooling menu) command in Manufacture mode if you want to select any tool or material technology data for the current tool. 2. Use the Cut Type parameter to determine which set of material technology values you want to use from the current Material Technology table. Select from None, Rough, Medium or Fine. The default Cut Type is Medium. Select None to manually specify feed and speed parameters when the parameter input box for each cycle that you select for the current tool. 3. You can also specify a percentage Factor by which to multiply the values in the material technology tables. This is used to adjust the theoretical speeds and feeds for this tool only. For example, a long series endmill needs to be driven slower than a short series endmill. 4. Click on OK.

27


Viewing the Current Technology Values Select the Technology (Verify menu) command. A window displays the current technology values, as in this example: Technology

(Mild Steel)

Rigidity

100%

Technology Factor

100% DEPTH

SPEED

FEEDRATE

(mm)

(rev/min)

(mm/rev/tooth)

4.00

250.00

0.25

0.25

tooling

100%

50%

100%

100%

(Final values)

4.00

125.00

0.25

0.25

MEDIUM

PLUNGE FEED

(Cut Type)

The Rigidity and Technology Factor are multiplied with the values from the Material Technology table to produce the corrected values. The tool’s Technology values (measured in percentages) are now multiplied with the Material Technology values. This increases or decreases the feeds and speeds, depending on the grade of insert and the toughness of the material. The material speed and feed values are based upon the material being cut with a certain tool grade. If a tool has been selected where the grade of insert is inferior, the tooling percentages would therefore be lower to reflect the lower cutting performance of the tool. The final values are what EdgeCAM uses as the default feeds and speeds for all cycles.

Material Technology table

X

Rigidity factor

X

Technology factor

= Calculated Speeds and Feeds

28

X

Tool Technology table


Material Technology Table This defines the speeds and feeds to be used for different materials. Material speeds and feeds are based on machining data using a standard tool grade.

Tool Technology Table This defines the modification to the Material Technology Table in percentage terms. For example, the tool used for the standard grade would use a factor of 100%, but a tool of a higher standard may use 130%, thus increasing the Material Technology Table values by 30%. You can select the: •

Rigidity – Specified using the Rigidity parameter (a percentage) in the Model (Options menu) command.

•

Technology Factor – Specified using the Factor parameter (a percentage) in the Technology (Tooling menu) command.

•

Cut Type – Sets the column of the Material Technology table to be used. Specified using the Cut Type parameter in the Technology (Tooling menu) command.

Defining New Material Technology Tables You may find that you need to create a completely new material technology table for your typical machining tasks. In this case you must define a new table record in the Material Technology database in the Tool Library.

You can enter data into these tables based either on data from tool manufacturers’ handbooks or from your own experience. Remember which units you are working in – millimetres or inches. You cannot mix values within a single record, but you can have two records however, one for inches and one for millimetres. These records can have the same name (as long as they are using different units). Rough, Medium or Fine values can be selected for a cycle. The values for Surface Speed are in either metres per minute or feet per minute. The values for Feed 1 and Feed 2 are in “chip per tooth” (millimetres or inches per tooth). The values for Depth are in millimetres or inches.

29


To create a new record in the Material Technology database Before proceeding, you should be familiar with the Tool Library. See Using the Tool Library, and Searching for Records. 1. Switch to the Program Manager by holding down the Alt key and repeatedly pressing the Tab key, releasing the Alt key when the box labelled Program Manager is displayed. 2. Select the Tool Library icon

in the EdgeCAM program group.

The Tool Library window appears. 3. Select Material from the Technology menu. The Material search window appears. 4. Enter search parameters for the new table. 5. Click on OK. The Tool Library searches for and displays a list of any matching records. 6. Select the Insert operation control. The Insert Record window appears. 7. Enter the parameters of the new record. 8. Click on OK to save the record.

Selecting a Safe Distance for the Tool Use the Safe Distance (M-Functions menu) command to specify a safe distance for the tool in each of three dimensions. EdgeCAM ensures that the tool maintains these distances from the component between machining passes. The default values are: 1mm (if you are using metric part units) .05” (if you are using imperial part units) In some circumstances, the safe distance must be a vector instead of X, Y and Z distances. In these cases, the vector sum of the safe distances is used:

30


Selecting a Safe Distance for the Turning Tool Use the Safe Distance (M-Functions menu) command to specify a safe distance for the tool in each of two dimensions (or three dimensions if using Y Axis machining). EdgeCAM ensures that the tool maintains these distances from the component between machining passes. The default values are: 1mm - (if you are using metric part units) .05" - (if you are using imperial part units) In some circumstances, the safe distance must be a vector instead of Z, X and Y distances. In these cases, the vector sum of the safe distances is used:

For Rough Turning cycles, a Safe Distance move is added to the end of a pass:

31


Using Miscellaneous (M-) Functions The M-Functions menu contains several standard commands, but it also contains commands which EdgeCAM takes from the Code Generator file. These commands are specific to the machine tool corresponding to the Code Generator. You can find out which miscellaneous functions are available by using the MFunctions (Verify menu) command. Which parameters appear in the dialog depend on the machining discipline and the Code Generator you are currently using. The list of available MFunctions includes: Program Stop/Optional Stop This command from the M-Functions menu is used to insert a program stop (for example, M0) or optional stop (for example, M01) into the instruction list. It is usually used where the machine tool cannot automatically change tools, and the machine tool must be stopped so that the operator can manually change the tool. It can also be used in process inspection, when clearing swarf, moving clamps and so on. Coolant Mist/Flood/Off These M-Functions menu commands control the state of the machine tool’s coolant system. The Code Generator file controls the machine tool’s default coolant state. Inserting a Dwell Use the Dwell (M-Functions menu) command to dwell or pause the currently selected turret. Changing the Feed Type You can change the feedrate type of the tool from feed per minute to feed per revolution using the Feed Type (M-Functions menu) command. Selecting the Input Mode You may want to switch between co-ordinate systems before entering positional data for creating geometry or specifying machining cycles. Using the Input Mode (M-Functions menu) command, you can choose between: Tool Local - Specifies the Z axis as equivalent at all times to the tool axis. This allows you to easily specify distances relative to the tool's current position. Machine Tool - (Default) Any co-ordinate data input is in terms of the Machine Tool Co-ordinate System.

32


Selecting Constant Surface Speed As a fixed tool cuts down towards the spindle of a turning centre, the cutting speed decreases as the circumference of the turned part decreases. To ensure that the speed of the tool over the surface of the material stays constant (a condition known as Constant Surface Speed, or CSS), use the CSS (M-Functions menu) command. If you mark the CSS box, EdgeCAM uses constant surface speed (as the tool approaches the centreline, the spindle speed increases). If you want to return to using the default condition of fixed spindle speed, use this command again but make sure that the CSS box is blank. Update Fixtures This command allows you to select and update fixtures for a machining sequence at anytime during the sequence. At the start of the machining sequence it is possible to nominate the initial fixture setup. Machining will then be carried out as usual. If the fixture setup then changes midway through a machining sequence (for instance when clamps are moved) you can use the command to update the fixture setup. Fixture entities must be predefined using the Stock/Fixture (Geometry menu) command prior to using this function. The initially nominated fixtures will be taken through into the Simulator. The Simulator will subsequently update the fixture display during its runtime when an Update Fixtures command is encountered.

Checking the Miscellaneous Functions You can check the selections that have been made using M-Functions menu commands using the M-Functions (Verify menu) command. A window should appear similar to this:

The actual items that appear depend upon your current Code Generator file. Each Code Generator can add extra functions to the M-Functions menu. These functions can be switches (for example, Coolant On/Off) or values (for example, New Offset). The Code Generator assumes one of the options as a default (Coolant is assumed to be on unless otherwise specified). Therefore, if the function has not been used, the machine status reports -DEFAULT as shown above.

33


Checking the Part Verifying the Machining Parameters Use the Machine Parameters (Verify menu) command to see the current selections for the current machining sequence. A window appears similar to this:

The actual items that appear depends upon your current Code Generator file. This is listed here as the Machine Tool.

34


Viewing the Machine Datum Co-ordinates You can view the Machine Co-ordinates by switching on the Status Bars, Machine Datum Co-ordinates option from the View menu. While you are in Manufacture mode, a window shows the current co-ordinates of your tool:

The column on the left shows the co-ordinates of the tool with respect to the active CPL (and can be displayed on its own by using the Status Bars, CPL Co-ordinates option). The column on the right shows the co-ordinates of the tool with respect to the Machine Datum (which you set by checking the Machine Datum box when defining a new Machining Sequence). The machine (MC) co-ordinates update at the end of each cycle. Turning Example

The top two sets of co-ordinates are for the Upper Turret, while the bottom two are for the Lower Turret. The column on the left shows the co-ordinates of the tool(s) with respect to the active CPL (and can be displayed on its own by using the Status Bars, CPL Co-ordinates option). The column on the right shows the co-ordinates of the tool(s) with respect to the Machine Datum (which you set by checking the Machine Datum box when defining a new Machining Sequence). The machine (MC) co-ordinates update at the end of each cycle. Wire Erosion Example

The column on the left shows the co-ordinates of the wire as it passes through the XY plane, with respect to the active CPL (and can be displayed on its own by using the Status Bars, CPL Co-ordinates option). The column on the right shows the co-ordinates of the wire with respect to the Machine Datum (which you set by checking the Machine Datum box when defining a new Machining Sequence). The machine (MC) co-ordinates update at the end of each cycle. 35


Viewing Information on the Part You can view information on the current part by switching on the Status Bars, Part Information option from the View menu. Milling Example

Turning Example

If Override Angles have been specified for the tool, these are shown in place of the clearance angles, in { } brackets:

Wire Example

The numbers in brackets are the Upper and Lower Guide heights (see Selecting the Wire for details).

36


Moving the Tool The type of tool movement available depends the machining discipline used. In the Milling environment, the type of movement also depends on whether the 2D Snap button is selected. The default is for this button to be selected. If the 2D Snap button is selected, the tool can only move in the workplane at the current height.

Moving at the Rapid Rate (Milling and Turning environment) Use the Rapid (Move menu) command to move the tool in a straight line at the rapid rate. The command is usually used to place the tool in a position to begin a new machining operation or toolchange. You can change the tool movement at the rapid rate to be in all three axes. To do this, select the Machine Parameters (M-Functions menu) and click on the Rapid 3D parameter to put a cross in its box. Important Note Machine tools can move from point to point in two ways (see example): •

Resolved – When moving from point to point the toolpath is linear. This means that one axis may move slower than the other, so that a straight line is achieved between points.

•

Unresolved – When moving from point to point both axes accelerate at the same rate until one axis has reached its position. The other axis then completes its move, thereby producing a ‘dog-leg’ move.

The Code Generator has a parameter that sets the rapid type for your machine. It is important that the correct display is shown so that you can see if the toolpath has inadvertently collided with the part. Please refer to your machine tool manual for details.

37


In the Milling environment, if Rapid 3D is not selected, the default method depends on whether the tool is moving: a. Out of the work- the tool moves in the Z+ direction first, then in the workplane. b. Into the work – the tool moves in the workplane first, then in the Zdirection. Note that some machine tool controllers can override the programmed rapid in three dimensions, in a similar manner to cases a and b described above. Please consult your machine tool manual for details. You can also specify a different colour for your rapid moves. Select the Colours (Options menu) command and set the Rapids & Normals parameter. Also see Editing Co-ordinates of Rapid and Feed Moves

Moving the Wire at the Rapid Rate Use the Rapid (Move menu) command to generate a toolpath for a move in a straight line at the rapid rate. Warning: Do not use this command while a wire is threaded. Note that the Code Generator may already be configured to cut the wire and re-thread at the new location. Also see Editing Co-ordinates of Rapid and Feed Moves

Moving at the Feed Rate Use the Feed (Move menu) command to move the tool or wire to a position at the feedrate. It should be used when the tool may come into contact with the material. Feed moves can also be used as “freehand” machining commands where more complex machining cycles are unnecessary. In the milling environment, if 2D Snap is off, the feed move ignores all Z information (for example, from an entity digitise). Also see Editing Co-ordinates of Rapid and Feed Moves

38


Editing Co-ordinates of Rapid and Feed Moves All rapid and feed moves are listed on the Instructions tab in the EdgeCAM browser window on the left-hand side of the screen.

The entries can be expanded by clicking on the

sign.

Note that displaying the individual co-ordinates in feed and rapid moves can slow down EdgeCAM when working with a part containing a large number of instructions. Uncheck the Display Co-ordinates option on the Toolpaths tab of the Preferences (Options menu) dialog if you do not wish to display the co-ordinates. As you select co-ordinates in the browser, the node (a single position) in the toolpath is highlighted in the graphics area. A right click on a co-ordinate in the browser calls up the context menu which allows you to edit or delete individual existing co-ordinates or to insert new co-ordinates:

39


Editing co-ordinates Right click on an existing co-ordinate in the browser and select Edit from the context menu. You can now specify new co-ordinates for this position by a using a free digitise, snapping to an entity or using co-ordinate input and/or construction tools. Note that ‘modal’ values inherited from the previous line are shown as blank. Inserting new co-ordinates Right click on an existing co-ordinate in the browser and select Insert from the context menu. You can now specify a new co-ordinate position by a using a free digitise, snapping to an entity or using co-ordinate input and/or construction tools. The new position is inserted before the selected node. If incremental values are input or if only some of the required co-ordinates are given, the inserted node will be based on the position given in the previous node. If a co-ordinate value which has dependants in subsequent co-ordinate nodes or move instructions is changed then those dependent values (incremental or blank) will also update automatically. (Milling only) Use of the 2D Snap option when creating co-ordinates will result in Z values being modal, based on the last specified Z height. Deleting co-ordinates Right click on an existing co-ordinate in the browser and select Delete from the context menu. Multiple nodes can be deleted by holding down the “shift” or “control” key when selecting a range or multiple individual co-ordinates. If you select all of the co-ordinates of a rapid or feed move for deletion, the whole instruction will be removed. If you make changes to the instruction list, the display is not updated automatically. Use the Refresh option to ensure that the instruction list is displayed correctly in the browser window. Note:

40

•

Double clicking on an a move or individual co-ordinate calls up the rapid/feed move dialog. Checking the Coord Input box allows you to change the position of the toolpath(s) by using free digitises, entity digitises and/or explicit co-ordinates. However, when this option is selected the original toolpath is deleted and you need to re-specify all positions for the toolpath without reference to the originals.

•

If reference co-ordinates are used, the browser shows both the reference point and the required offset from it, e.g. (X 0.000 Y 50.000 Z 0.000) + X10.


Moving the Tool in an Arc at the Feedrate Milling and Turning environment only Use the Arc (Move menu) command to move the tool in a circular motion in the workplane at the specified feedrate. Arc moves can also be used as “freehand” machining commands where more complex machining cycles are unnecessary. 2 Point – This parameter controls how the arc move is defined. •

If you check the box, you are prompted to digitise a midpoint and an endpoint for the arc move.

•

If you leave the box unchecked, you are prompted to digitise the endpoint of the arc. The arc leaves the last move at a tangent and finishes at the endpoint.

Moving the Tool around a Co-ordinate Axis Milling environment only Use the Angular (Move menu) command to move the tool with reference to one or more co-ordinate axes. These parameters specify the direction of motion: X, Y, Z Co-ordinate – Specifies the movement along the X, Y or Z axis in part units. A, B, C Co-ordinate – Specifies the movement around the X, Y or Z axis in degrees. Your Code Generator must be capable of supporting these movements for these to be displayed. You may also specify the feeds, speeds and whether the move is to be at the Rapid or Feed rate.

Moving the Tool to the Toolchange Position Milling and Turning environment only The default toolchange position is defined in the Code Generator file, and is specified relative to the Machine Datum and in the orientation of the Initial CPL. To move the tool to the toolchange position Use the Toolchange (Move menu) toolchange position.

command to return the tool to its

If you use the button, the tool moves to the three dimensional location specified in the Code Generator and machine parameters.

41


If you select the command, you can specify these parameters: Milling

Turning

You might want to simply move the tool up in Z to the toolchange position rather than moving the tool to its default XYZ position. To do this, lock the X and Y positions by marking the X Fixed and Y Fixed boxes.

You might want to simply move the tool up in X to the toolchange position rather than moving the tool to its default ZX position. To do this, lock the Z position by checking the Z Fixed box.

You can also specify the First axis to move the tool in.

You can also specify the First axis to move the tool in. This is useful when retracting tools from features such as bores and grooves, where the tool can collide with the component.

The default toolchange position may be changed using the Toolchange button in the Machine Parameters (M-Functions menu) command.

Moving the Tool to the Home Position The default home position is defined in the Code Generator file, and is specified relative to the Machine Datum and in the orientation of the Initial CPL. command to move the tool to its home Use the Home (Move menu) position. In Milling and Turning, the parameters are similar to those of the Toolchange move. The home position may be changed using the Tool Home button in the Machine Parameters (M-Functions menu) command.

42


Moving to the Initial Plane Milling environment only Use the Initial Plane (Move menu) Initial Plane.

command to move the tool to the

The Initial Plane is a height at which the tool is safe to move without any risk of colliding with any part of the workpiece, clamps or fixtures. The default value is taken from the Code Generator file. You can set the height of the Initial Plane by specifying a value for the Initial Plane parameter in the Machine Parameters (M-Functions menu) command. Note that while toolchange and home positions are defined in world coordinates the initial plane is defined from the intial CPL of the sequence. These two datum points may be different.

Freehand Milling Rather than use specific commands listed under the Cycles menu, for simple machining tasks you may find it easier to use commands for moving the tool at the feed rate. You can use the Feed, Arc and Relative commands under the Move menu. In this example, feed moves have been used to facemill a part:

As an alternative to the Profile (Cycles menu) command automatically positioning the tool, you may want to manually move the tool to the required position. To do this, use the Relative (Move menu) cycle. Use an offset value to distance the tool from the profile, select the entity to offset from, and select feed as the type of move. This generates an offset feed move running parallel to an existing profile section.

43


In this example, a tool is moved relative to a piece of geometry:

As the tool moves relative to the geometry, the angle of the geometry does not matter.

Exact Tool Positioning in Turning If you are, for example, moving into position for a profiling operation, you must allow a safe distance: •

if the face is rough (sawn, or generally rough)

•

if using Constant Surface Speed, to allow the spindle to adjust its speed

•

if the exact position of the component is variable

•

to avoid leaving marks on the final component.

You may encounter a problem when cutting a chamfer with a radiused tool. Normally the Gauge Point of the tool insert is driven along the geometry and therefore the tool does not cut the correct profile.

44


This example shows that a toolpath based on the Gauge Point misses the profile geometry:

The solution is to use the Move menu commands Relative, Relative Two or Constrained with Pathtrace Compensation selected. These cycles calculate the real position for the tool and place the tool correctly.

Moving Relative to an Entity Milling and Turning environment only Use the Relative (Move menu) command to position the tool with respect to a selected entity. In this example a tool has been moved at the Feedrate relative to a line entity, with the parameters Distance and Offset specified, and the Side parameter = Left.

45


Moving Constrained by Entities Milling and Turning environment only Use the Constrained (Move menu) command to move to a destination point, choosing from a variety of ways to constrain this motion using another selected entity. This milling example shows a Constrained feed move, using the parameters Method=Parallel to Entity and To X=10.

When using the Constrained command, the move type can be set to either Feed or Rapid. Note, however, that for non-linear moves the output will always be in Feed mode. Rapid moves will be subject to the same “dog leg” restrictions that apply to all other rapid moves, depending on the characteristics of the selected machine tool.

Moving Relative to Two Entities Milling and Turning environment only Use the Relative Two (Move menu) command to move the tool relative to two other selected entities. The First and Second tabs display the movement parameters relative to the first and second entities respectively. Otherwise, Relative Two uses the same parameters as the other move commands, but with an important exception – the side of an entity nearest to the tool is defined by which side you digitised the entity.

46


Selecting a Cycle Once you have selected a tool and possibly used a rapid move to bring the tool closer to the work, you are ready to select a machining cycle. You can find all machining cycles permitted by the Code Generator file selected for the machining sequence, and the current tool, under the Cycles menu. Individual buttons provide another method of selecting the appropriate cycle (which of these are displayed on the toolbar is also determined by the machining sequence and the current tool).

Finishing a Command The help refers to the action ‘Perform a Finish’ when describing how to use certain commands. In EdgeCAM, selecting the right hand mouse button will finish a command. Alternatively, selecting the Enter/Return key will also finish the command. There is also an icon that can be added to your Toolbars. To add the icon, select Toolbars (View menu), and select the Input Options Toolbar from the list displayed on the Commands Tab. icon can be added to any Toolbar by selecting it with the left hand The mouse button and dragging it on to a Toolbar.

47


Using Cutter Compensation Using Cutter Compensation in Milling Cycles EdgeCAM provides a powerful tool radius offset calculation. Many machine tool controllers also have a tool radius compensation facility, so when using the Profile (Cycles menu) command you need to consider which method will work best for you. The Radius Compensation (Tooling menu) command or buttons:

allow you to select the offset facility (the Tooling toolbar must be selected using Toolbars (View menu) to see these buttons). If the Left or Right compensation buttons have been selected, compensation remains on until the Off or the other compensation button is selected. The compensation is further modified by the choice made in the Compensation parameter for a cycle. This can be either Pathtrace or Controller compensation. If no compensation is applied, the CNC output is based purely on the centreline toolpath. This button also switches off the current compensation setting.

Note in using radius compensation in profile cycles If mill type, profile side and radius compensation side are incompatible, a warning message is displayed. When regenerating parts from previous versions of EdgeCAM that were defined incorrectly, compensation side overrides the other parameters. This may cause the profile side to be reversed. See Also Using No Compensation Using Controller Compensation Using Pathtrace Compensation.

48


Using Wire Compensation EdgeCAM provides a powerful wire radius offset calculation. Many machine tool controllers also have a wire radius compensation facility, so when using the Machine Design (Cycles menu) command you need to consider which method will work best for you. The combination of the Radius Compensation and Compensation parameters in the Machine Design and 2D Profile (Cycles menu) cycles determines what information is to be output when you generate the CNC code from your machining sequence: Radius Compensation

Compensation Pathtrace

None

Left/Right

Controller

Toolpath co-ordinates are Design Intent co-ordinates to to be output. be output. Recommended.

Not recommended.

Toolpath co-ordinates are to be output, but the tool is instructed to use the contents of an offset store.

Design Intent co-ordinates are to be output, but the tool is instructed to use the contents of an offset store.

Not recommended, as this Recommended, especially changes the actual size of where many different wire the final component. diameters may be used. Note that Radius Compensation is also available as a command from the Cycles menu. See Also Using No Compensation Using Controller Compensation Using Pathtrace Compensation

49


Using No Compensation Radius Compensation None Compensation

Pathtrace

CNC output path

Tool/wire centreline

If no compensation is applied, the CNC output is based purely on the centreline toolpath.

The advantages of this method of output are: •

The tool/wire does not need a run-in onto the profile.

•

The toolpath displayed on screen is an accurate representation of the output.

•

Corner Type parameters are supported.

The disadvantages of this method are: •

The milling tool cannot be compensated for wear, therefore the part could be cut over- or under-size.

•

CNC code is not as readable as it represents the centre of the cutter rather than the geometry.

Using Controller Compensation Radius Compensation Left/Right Compensation

Controller

CNC output path

Geometry or Design Intent

The CNC output is based on the geometry of the profile or the design intent. The controller compensates for the radius of the milling cutter/wire by using an offset store within the control.

50


Notes in Using Controller Compensation in Milling •

When the radius of the corner equals the tool radius, the shape of the output corner is the same as the Corner Type parameter selected in the cycle.

•

Profile cycles create a "back offset" NC path allowing for the tool radius. The compensated toolpath is only displayed in Manufacture and resides on the same layer as the toolpath.

Please note that compensation should only ever be applied in Profile cycles.

The advantages of controller compensation are: •

CNC code can be read more easily as the code represents the part.

•

The milling tool’s size can be altered to allow for tool wear.

The disadvantages of this method are: •

Most controllers require the compensation code to be applied under strict rules. These rules can vary between controllers. See your controller handbook for details.

•

Controllers normally need a run-in of at least the radius of the cutter/wire, but you may not have sufficient room around the part.

•

EdgeCAM’s Pathtrace compensation is superior to most controllers.

•

On external corners, if the Corner Type parameter is set to Round, this will be ignored as it is not part of the geometry (milling environment).

•

The toolpath displayed on screen is not an accurate representation of the output.

Using Pathtrace Compensation Radius Compensation Left/Right Compensation

Pathtrace

CNC output path

Tool/wire centreline

The CNC output is based on the tool/wire centreline.

The controller compensates for the radius of the cutter/wire by using an offset store within the control. The operator must set this offset store to zero prior to running the program. 51


To adjust for tool wear in the milling environment, the operator must change the offset store value by the difference between the true tool diameter and the programmed tool diameter. The advantages of this method of output are: •

The milling tool’s size can be altered to allow for tool wear.

•

EdgeCAM’s Pathtrace compensation is superior to most controllers.

•

The toolpath displayed on screen is an accurate representation of the output.

•

The controller does not need a run-in (as the radius of the cutter in the offset store is set to zero), therefore the controller does not need a compensation move.

•

Corner Type parameters are supported.

The disadvantage of this method is: •

CNC code is not as readable as it represents the centre of the cutter rather than the geometry.

Using Cutter Compensation in Turning Cycles EdgeCAM contains a powerful tool offset calculation facility for Turning cycles. Many machine tool controllers also have a tool nose radius compensation facility, so consider which method will work best for you. The Radius Compensation (Tooling menu) command or buttons allow you to select the offset facility (the Tooling toolbar must be selected using Toolbars (View menu) to see these buttons). Why use compensation at all? In this example the set point of a tool nose is taken from the two edges of the radius. This means that the tool is driven by the bottom left hand corner of the nose. If this point is programmed round a profile, material can be left on or undercut when the tool travels at an angle, producing an inaccurate part. Using Pathtrace Compensation This is applied using the Radius Compensation (Tooling menu) command:

Pathcomp Turning Centres are usually limited to simple forms of compensation for turning tools. EdgeCAM provides an extensive facility to compensate for the tool geometry. Selecting Pathcomp causes the output tool path to be readjusted to cater for tool geometry. This is in effect until cancelled.

52


Using Controller Compensation The tool radius compensation facility on machine tool controls gives the considerable advantage of allowing the operator to adjust for tool wear and component deflection (caused by cutting forces). Controller compensation is applied with using the Radius Compensation (Tooling menu) or

buttons:

Left & Right Applies controller compensation. In the case of Fanuc-like controllers, G41 & G42 are inserted into the CNC code. When controller compensation is applied, the programmed tool path is output with respect to the tool set point, and it is assumed that the CNC controller is compensating for the Tool Nose Radius. This mode requires that that controller offset registers and tool types are defined correctly. Refer to your controller manual for details. None Cancels controller compensation. In the case of Fanuc-like controllers, G40 is inserted into the CNC code. This is the default condition.

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Displaying Toolpaths You can use these methods to control how toolpaths appear on the graphics screen: •

Set the Colour parameter when selecting a tool. This determines the colour of the tool/wire and all toolpaths created using it.*

•

Use the Mode (View menu)

•

Switch on the Simulation toolbar.

command.

*You can also specify a different colour for your rapid moves. Select the Colours (Options menu) command and set the Rapids & Normals parameter.

Controlling the Toolpath Mode The Mode (View menu) command controls how tool motion is displayed on the screen. You can restrict the simulation to only cover specific instructions in the instruction list and control the speed of tool/wire motion.

Simulating Tool Movement Once a cycle that moves the tool/wire has been fully defined, the system displays a simulated tool/wire in the graphics screen area, moving along the toolpath generated by the cycle. This is controlled using the Simulation toolbar:

The top slider shows the progress of the simulation throughout the instruction list. The current cycle or command is displayed (‘Areaclear Milling’ in this example). You can narrow the selection to a smaller portion off the instruction list by dragging the slider while holding down the Shift key, then click Zoom. Click Zoom again to return to the entire instruction list. Control the simulation using these buttons:

You can control the speed of the simulation by moving the bottom slider, left to slow down and right to speed up.

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Check the Constant box to set the simulated tool/wire to move at a fixed rate. Otherwise it will move at a rate proportional to the rates generated for the cycle. Please note that the simulation of toolpaths in Four Axis Turning cycles is only correct when Constant is OFF. Using the Stop button halts the simulation for the current tool only.

To switch on the Simulation toolbar

•

Select Simulation from the Status Bar (View menu) command, OR

•

Click on the

Simulation button on the Display toolbar.

Displaying Solid Models A simple way of displaying solid models is to make sure you have checked the GLview option under the View menu. 1. Right click on the view status bar and select Properties.

2. Choose the Rendered option from the Display parameter on the General tab.

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56


Editing Instructions in the Browser

EDITING INSTRUCTIONS ...................................................................................57 COMBINING COMPONENTS AND SEQUENCES ....................................................59 Preparation of Base Parts .........................................................................60 Insert and Merge in Use ............................................................................60 Notes on Inserting and Merging Sequences .............................................61 INSERTING SEQUENCES ...................................................................................62 MERGING SEQUENCES ....................................................................................63 RE-ORDERING THE MACHINING INSTRUCTIONS IN A SEQUENCE .........................64 Merging Hole Cycles .................................................................................64 Rationalising by Tool .................................................................................65 Rationalising by Priority.............................................................................66 Rationalising by CPL/Index .......................................................................67 Example 1 – Rationalise by Tool Position .............................................................68 Example 2 – Rationalise by CPL...........................................................................69 Example 3 – Rationalise by Tool Position and then CPL ......................................70

MERGING HOLE CYCLES..................................................................................71 Setting Parameters before Merging Hole Cycles ......................................71 Depth Parameters in Merged Cycles ....................................................................72

Using the Merge Hole Cycles Command ..................................................72 Merging Hole Cycles - Example................................................................73 Merging into Multiple Cycles - Example ....................................................74 USING INSTRUCTIONS MENU COMMANDS .........................................................75 Choosing the Editing Options....................................................................76 Selecting from the Instruction List .............................................................77 Respecifying Co-ordinate Input.................................................................77

Editing Instructions The browser window on the left-hand side of the EdgeCAM screen shows all associated machining sequences and instructions related to the current part. By default, the instructions in the Browser window are numbered as this can be useful when a part has a large number of similar instructions. To display the instructions without numbers, please ensure that the Number Instructions option on the Toolpath tab of the Preferences (Options menu) dialog is unchecked. If a Sort Priority has been assigned to a toolchange this priority will be displayed in the Instructions Browser to the right of the instruction number.

57

Editing Instructions

As explained under Browsing the Instruction List, you can use this window to edit the current instruction list.

Notes

58

•

Only commands that are included in the instruction list can be edited, moved or deleted.

•

Editing one or more sub-instructions within an Operation breaks the Operation down into its constituent cycles.

•

If you edit an Index (Move menu) command, all subsequent commands may be invalidated.

•

Once the instruction list has been changed, EdgeCAM recalculates the toolpath according to the new geometry.

•

In the milling and turning environment, the Merge Sequences (Instructions menu) command allows you to merge two or more sequences into one by appending the instructions in the second and subsequent sequences to those in the current sequence. See Merging Sequences.

•

In the milling environment, the Rationalise (Instructions menu) command allows you to re-order the instructions in a single sequence to rationalise the NC file by one or more criteria. See Re-ordering the Machining Instructions in a Sequence


Combining Components and Sequences It is possible to, optionally, insert sequences when inserting a part as a component into another part. It is also possible to then merge the separate sequences into a single sequence and to rationalise that sequence by tool, index angle or CPL. Whilst these three functions have been designed to work together, primarily in a multiplane milling environment, they may also be used separately and also in 3 axis milling or in turning. When merging sequences in multiplane milling the Profile cycle is liable to corruption. To ensure that inserting and merging function correctly, profiles must be created in a defined view, not in "dynamic". The most common use for these features is in loading components onto a machine with rotary axes so that a combination of parts or multiples of the same part can be machined. This use of Insert and Merge is the most complex and is described below in some detail. The principles laid down here, and the techniques suggested, can also be applied in other circumstances such as multiple parts laid on a flat machine bed or sub-programs merged into a single final program for a turning application. Please note that since datum shifting is not supported in turning only sequences utilizing common initial and machine datum points can be successfully merged. The use of both Insert and Merge offers considerable flexibility in approach but for maximum ease of use it is suggested that you follow a few simple guidelines: 1. For each machine tool, a "Base Part" containing the machine's basic set up and configuration should be created. Common use fixtures such as a machined cube should be incorporated. This part should contain a single sequence with the Code Generator reference and with home/toolchange positions, initial plane, initial CPL and machine datum points correctly configured. When you merge sequences, the current sequence is copied to form the new sequence. For this reason it is important that your current sequence has been created correctly for your machine tool, especially with regard to the machine datum and initial CPL. 2. Suitable location or mounting positions should be created as CPLs on the cube faces. 3. Parts to be inserted as components should always be created with a "location" CPL in position to enable easy placement on the machine. If fixtures are used they may be incorporated into the component with the "location" CPL on the back face of the fixture. 4. When components are inserted the target part will, inevitably, build up a large number of CPLs. Whilst EdgeCAM will ensure that there are no name clashes, you may find it helpful to use the "Name Prefix" field in the Insert Component dialog. This enables all CPLs and layers relating to a particular component to be identified. It is strongly recommended to use the following suggested method for use of Insert and Merge in a multiplane environment. In other environments these procedures can be adapted accordingly.

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Preparation of Base Parts 1. Create a base part for each machine tool with cube or tombstone etc. in place and with the machine datum (centre of primary rotation) marked. 2. If common location points on the faces of the cube are to be used, create CPLs at those positions. 3. Create an empty sequence with the required code generator, initial CPL and machine tool datum (centre of rotation). Check that home/toolchanges and initial plane entries are correct. 4. Save this as a "Base Part" for that machine. Make a backup copy as a guard against accidental over-writing. 5. When creating component parts to be used on this machine always create a CPL that matches the position of the location points. Giving this CPL a common name in all such parts makes life easier, e.g. "Location". 6. If fixtures are to be used as separate .ppf files give each a CPL for location of the component and a CPL for positioning the fixture on the cube. Standardise the CPL names but remember they will be modified on insertion. When you merge sequences, the current sequence is copied to form the new sequence. For this reason it is important that your current sequence has been created correctly for your machine tool, especially with regard to the machine datum and initial CPL.

Insert and Merge in Use 1. Load base part and save as required combined part name. 2. Insert component(s) as required, placing location CPL on mounting CPLs. 3. Switch to manufacture. 4. If necessary, edit sequences to change to the correct Code Generator. 5. Select base sequence and pick "Merge Sequences" from browser menu or Instructions menu. 6. Select sequences required by moving them from left panel to right. Fill in new sequence name etc. and click OK. 7. Check through the newly created sequence and remove any unwanted instructions. Carefully check all clearances etc, especially when indexing.

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Notes on Inserting and Merging Sequences Realignment of Toolpaths Where regeneration of a sequence results in realignment of the toolpath to suit machine tool axes, any angles and free digitise positions used in the instructions will also be realigned and measured from the machine tool axes. This means that such angles and positions may move relative to the component. This is most likely to occur when components are inserted at an angle to the target CPL. If a rapid or feed move position is considered critical and it is intended to rotate the part in this way then you should create a geometric point in the required position and make an entity digitise for the move. If angles, such as lace cycle angle or thread mill start/end angles, are critical then they must be re-adjusted after the realignment. Post Processors All sequences must use the same code generator when merging. The success of insert and merge operations is utterly dependent on the compatibility of the code generator files in use and the machine tool requirements. You must ensure that you have set your Code Generator files correctly for all possible instances of Index and Datum Shift commands. Inserted sequences retain their machine datum. When sequences are merged the current or base sequence machine datum is used. Safe Indexing It is vital that all index moves be performed with the tool at a safe height. You must ensure that individual parts are programmed with this in mind and that any merged sequences are thoroughly checked in an appropriate view to ensure safety. The toolchange heights and initial plane value should reflect actual machine tool requirements. All index commands in parts to be inserted as components should be to named CPLs (Position To Name). The way in which indexing by angle handles datum positions may not give the required result. Component Prefixes When inserting multiple components into a part, EdgeCAM will rename CPLs, layers, sequences etc. with an appended number to ensure that the integrity of each component is maintained. This can become confusing and it is recommended to specify a name prefix for each component inserted so that the CPLs and layers relevant to individual components are easily identifiable. Rotary Milling The Insert Component and Merge Sequence commands are not supported in rotary milling. Wire Erosion Merging Sequences is restricted to the milling and turning environment and will not appear in the wire manufacture mode. PCI PCI command recording and playback is not supported for merge sequences. Turning Datum shift is not supported by EdgeCAM for turning parts. For this reason all inserted components with sequences must use the same target CPL. 61


Inserting Sequences Requires the Multiplane Machining licence The Insert, Component (File menu) command allows you to insert a component and its machining sequences into the active part. Please note that sequences are not inserted if their part units are different. When merging sequences in multiplane milling the Profile cycle is liable to corruption. To ensure that inserting and merging function correctly, profiles must be created in a defined view, not in "dynamic".

To insert a component with machining sequences 1. Select the Insert, Component (File menu) command. The dialog offers the following commands:

2. Check the Segregate Layers option if you want all entities to remain on their existing layers. The layers will be renamed, with the name consisting of the inserted part name followed by the original layer and a number representing the instance of insertion of that part (1,2,3 etc.). If this box has not been checked, part name and incremental numbering will not be used and all entities from a particular layer in the source part will be placed on the same layer in the target part. 3. Check the Insert Sequences option. 4. Enter or Browse for the Name of the .ppf part file to be inserted. 5. Specify the Target and Source CPLs. CPL Source – Nominate the CPL in the named part.This determines how the geometry is to be inserted into the current part. Select from Named List or Digitise a user-defined CPL. CPL Target – Nominate the CPL onto which to insert the component. Select from Digitise or a list of available CPLs in the current environment. If you choose Digitise, you are prompted to digitise the appropriate CPL marker. Datum shift is not supported by EdgeCAM for turning parts. All inserted components with sequences must use the same target CPL.

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6. When components are inserted the target part will build up a large number of CPLs. The Name Prefix option enables you to easily identify all CPLs and layers relating to a particular component. 7. Enter any required Rotation about the Z axis of the target CPL. Centre of rotation will be that of the target part not that of the source part(s). 8. Click OK. Note: The 'Undo' functionality is not supported when inserting components with sequences.

Merging Sequences Only available in the milling and turning environment. Please note that this function is not supported by rotary milling. The Merge Sequences command allows you to merge two or more sequences into one by appending the instructions in the second and subsequent sequences to those in the current sequence. For more detailed information on common use and recommended methods, please refer to Combining Components and Sequences. All sequences to be merged must use the same Code Generator. When merging sequences in multiplane milling the Profile cycle is liable to corruption. To ensure that inserting and merging function correctly, profiles must be created in a defined view, not in "dynamic". When you merge sequences, the current sequence is copied to form the new sequence. For this reason it is important that your current sequence has been created correctly for your machine tool, especially with regard to the machine datum and initial CPL. To merge sequences 1. Highlight a base sequence in the browser and call up the Merge Sequences command, either via the context menu (right-hand mouse click) or the Instructions menu. This will open the Merge Sequence dialog. 2. The Current Sequence field specifies the name of the base sequence. When merging, the current sequence is copied to a new name and all other selected sequences are appended in order. 3. Specify the name for the new (merged) sequence in the Description field. By default, the name of the new sequence is created by appending .1, .2 etc to the name of the current sequence. 4. Job file names allocated to the sequences being merged will not be carried over to the new (merged) sequence. If you want to allocate a job file to this sequence you must enter the required name in the Job Name field. 5. Select sequences required by moving them from the list of Available Sequences on the left to the list of Selected Sequences on the right. You can do this by simply highlighting the required sequence(s) and pressing the single arrow. The double arrow allows you to move all sequences to the right panel. To change the order in which sequences are merged, select one or more in the right-hand panel and use the arrows on the extreme right to change their relative positions. Sequences will be merged in the order shown when the command is executed. 63


6. Specify the required Datum Type. You must take into account the requirements of your machine tool when making this choice. Also bear in mind any limit on the number of definable datum points when planning a merged sequence. 7. Check the Remove Tool Positions option to set all tool positions to blank in the merged sequence. You will need to re-specify these parameters for all toolchanges by editing the appropriate toolchange dialog. If this option is not checked, it is assumed that you are happy with the sequences and no changes will be made. Please note that option is only offered once for each merge commend and there will be no further checks for compatibility. 8. Click OK. Note: The 'Undo' functionality is not supported when merging sequences.

Re-ordering the Machining Instructions in a Sequence Only available in the milling environment. The Rationalise (Instructions menu) command allows you to re-order the instructions in a single sequence to rationalise the NC file by one or more criteria. You can choose between sorting the instructions by Tool (default setting), CPL or Index. •

Rationalisation will always be applied to the currently selected sequence.

•

When re-ordering by several criteria sorting must be done in the reverse order. Also see Example 3.

•

The Undo command is not supported by this function. The sorted sequence is created as a new sequence and can easily be deleted, if not required. The new ‘duplicate’ machining sequence will automatically be renamed by appending ‘.1’.The original sequence will not be changed by the rationalisation process. Once you are satisfied with the re-ordered sequence you can delete the original sequence.

•

Sequences containing instructions in “Matrix Mode” cannot be rationalised.

Merging Hole Cycles When sequences are rationalised, a number of cycles are frequently grouped together for machining by a single tool. In the case of hole cycles this gives rise to a canned cycle (G81 etc) in the NC file for each EdgeCAM cycle instruction. The Merge Hole Cycle option on the Rationalise Sequence (Instructions menu) dialog enables you to group such instructions into a single cycle so that multiple, identical holes may be drilled with one G81 canned cycle. Please note that this option is only available when rationalise is by tool. Also see Merging Hole Cycles. Ensure that you have carefully checked the re-ordered sequence before deleting the old one and using the new one.

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Rationalising by Tool Instructions will be selected by turret position ONLY. If different tools have been assigned to the same position the one assigned first will be used. A warning will be given if a different tool type, diameter(s), corner radius, angle or description is encountered on a previously used turret position. The sorting mechanism will work through the sequence sorting by tool as the first instance of use is found. If a tool is required to be exempted from sorting you will have to edit it to another turret position number and then reset it after the sorting is complete. A check will be made to ensure that a turret position has been specified for all tools. If not, a warning will be given and the faulty toolchange indicated in the browser. Changes to Tlo offset register for a given tool position will be maintained. If this situation is encountered a toolchange command will be used to change the value. No other tool parameters will be changed and there will be a retract to safe height before the toolchange instead of a return to toolchange position. All instructions using the tool will be moved with it. Any necessary index or datum shift instructions to give correct orientation from the preceding instructions will be inserted. Where groups of instructions are brought together by the rationalisation process a move to safe Z will always be inserted. This will prevent the creation of 3D rapid moves that could scrap the part or be a safety hazard. If required, you can remove such moves afterwards. Rationalise will insert retract moves to the Z of the toolchange position before inserted index and datum shift instructions. Index commands will be inserted with the “shortest” direction modifier set. There are circumstances when sorting by tool in order of first use does not give you the desired results. In this case, an alternative method of sorting by tool can be used. See Rationalising by Priority. When sequences are rationalised, a number of cycles are frequently grouped together for machining by a single tool. In the case of hole cycles this gives rise to a canned cycle (G81 etc) in the NC file for each EdgeCAM cycle instruction. The Merge Hole Cycle option on the Rationalise Sequence (Instructions menu) dialog enables you to group such instructions into a single cycle so that multiple, identical holes may be drilled with one G81 canned cycle. Please note that this option is only available when rationalise is by tool.

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Rationalising by Priority There are circumstances when sorting by tool in order of first use does not give you the desired results. For some combinations of cycles this can, for example, reverse the order of roughing and finishing, with dangerous results. To overcome this scenario, you can assign a sort priority to each toolchange by specifying a Sort Priority modifier on the More tab of the toolchange dialog. Sorting will then be performed by order of first use within each priority group. All tools with the same priority will be sorted by order of first use, followed by those with the next priority and so on in ascending numerical order. If a Sort Priority has been assigned to a toolchange this priority will be displayed in the Instructions Browser to the right of the instruction number. Usage Tips: It is much easier to set the priority of tools in the individual part files when developing the machining sequence before rationalising the merged sequence. We would suggest that types of tools are given a pre-defined number that relates to a type of operation. For example: 100 = Roughing 200 = Semi roughing 300 = Semi finishing 400 = Finishing 500 = Centre Drill / Spot face 600 = Drilling 700 = Tapping / Reaming / Boring When the merged sequence is rationalised the priority order will ensure that all roughing is carried out before any semi-roughing and semi-roughing is performed before any semi-finishing etc. Any final changes to the tooling order can be achieved by adjusting the Sort Priority after rationalisation. For example you may wish to change the order of two roughing tools (both have Priority 100) by changing the sort priority for one of them to 101 or 99. Once all the final changes have been made run Rationalise by Tool again to re-order the sequence.

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Rationalising by CPL/Index Sort by Index is ordering by resultant rotary axis positions. If two or more CPLs result in the same rotary axis positions then the instructions associated with them will be combined, e.g. the front face of a component on a cube might be machined at the same time as side faces of components mounted on adjacent sides. Datum changes will be retained by insertion of a datum shift command. Sort by CPL works on CPL name only. Identical (rotary angle and datum position) CPLs will be combined but CPLs having the same rotation but a different datum will not. When sorting by Index or CPL additional toolchanges with safe moves to the toolchange position will be inserted as required. The data for these toolchanges will be copied from that associated with the instructions in the original sequence (including both turret position and Tlo number). For the purpose of this operation, a “toolchange” is taken to mean the relevant toolchange instruction together with its move to toolchange position and any M-Functions that precede the toolchange (back to the preceding cycle command or feed move). For repeats of the first toolchange, the preceding M-Functions and move to toolchange position will be taken from the next toolchange instruction. Where groups of instructions are brought together by the rationalisation process a move to safe Z will always be inserted. This will prevent the creation of 3D rapid moves that could scrap the part or be a safety hazard. If required, you can remove such moves afterwards. Sort by Index or CPL will take account of both primary and secondary rotation axes where both exist.

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Example 1 – Rationalise by Tool Position Original Sequence Initial CPL 1

Sort by Tool Position Initial CPL 1

Tool 1

Tool 1

Instructions A

Instructions A

Z Safe

Z Safe

Index to CPL 2

Index to CPL 2

Instructions B

Instructions B

Move to ToolChange

Move to ToolChange

Tool 4

Tool 4

Instructions C

Instructions C

Move to ToolChange

Move to ToolChange

Tool 3

Tool 3

Instructions D

Instructions D

Z Safe

Z Safe

Index to CPL 1

Index to CPL 1

Instructions E

Instructions E

Z Safe

Z Safe

Index to CPL 2A (Same index position as CPL2)

Index to CPL 2

Instructions F

Instructions F

Move to ToolChange

Move to ToolChange

Tool 2

Tool 2

Instructions G

Instructions G

Move to ToolChange

Z Safe

Tool 7

Index to CPL 1

Instructions H

Instructions J

Z Safe

Move to ToolChange

Index to CPL1

Index to CPL 2

Instructions I

Tool 7

Move to ToolChange

Instructions H

Tool 2

Z Safe

Instructions J

Index to CPL1

Return to Home

Instructions I Return to Home

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Example 2 – Rationalise by CPL Original Sequence Initial CPL 1

Sort by CPL Initial CPL 1

Tool 1

Tool 1

Instructions A

Instructions A

Z Safe

Move to ToolChange

Index to CPL 2

Tool 3

Instructions B

Instructions E

Move to ToolChange

Move to ToolChange

Tool 4

Tool 7

Instructions C

Instructions I

Move to ToolChange

Move to ToolChange

Tool 3

Tool 2

Instructions D

Instructions J

Z Safe

Move to ToolChange

Index to CPL 1

Tool 1

Instructions E

Index to CPL 2

Z Safe

Instructions B


Move to ToolChange

Instructions F

Tool 4

Move to ToolChange

Instructions C

Tool 2

Move to ToolChange

Instructions G

Tool 3

Move to ToolChange

Instructions D

Tool 7

Z Safe

Instructions H

Instructions F

Z Safe

Move to ToolChange

Index to CPL1

Tool 2

Instructions I

Instructions G

Move to ToolChange

Move to ToolChange

Tool 2

Tool 7

Instructions J

Instructions H

Return to Home

Return to Home

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Example 3 – Rationalise by Tool Position and then CPL Original Sequence Initial CPL 1

Sort by Tool Position and then CPL* Initial CPL 1

Tool 1

Tool 1

Instructions A

Instructions A

Z Safe

Move to ToolChange

Index to CPL 2

Tool 3

Instructions B

Instructions E

Move to ToolChange

Move to ToolChange

Tool 4

Tool 2

Instructions C

Instructions J

Move to ToolChange

Move to ToolChange

Tool 3

Tool 7

Instructions D

Instructions I

Z Safe

Move to ToolChange

Index to CPL 1

Tool 1

Instructions E

Index to CPL 2

Z Safe

Instructions B


Tool 4

Instructions F

Instructions C

Move to ToolChange

Move to ToolChange

Tool 2

Tool 3

Instructions G

Instructions D

Move to ToolChange

Z Safe

Tool 7

Instructions F

Instructions H

Move to ToolChange

Z Safe

Tool 2

Index to CPL1

Instructions G

Instructions I

Move to ToolChange

Move to ToolChange

Tool 7

Tool 2

Instructions H

Instructions J

Return to Home

Return to Home

* Note that the sorting criteria were applied in reverse order, i.e. Sort by CPL (the “primary” criterion) was the second on applied.

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Merging Hole Cycles When sequences are rationalised, a number of cycles are frequently grouped together for machining by a single tool. In the case of hole cycles this gives rise to a canned cycle (G81 etc) in the NC file for each EdgeCAM cycle instruction. The Merge Hole Cycle option on the Rationalise Sequence (Instructions menu) dialog enables you to group such instructions into a single cycle so that multiple, identical holes may be drilled with one G81 canned cycle and not many individual canned cycles each drilling one hole. You can merge hole cycles if the following conditions are met: •

the cycle parameters are equal or compatible (see Setting Parameters before Merging Hole Cycles)

•

the cycles are adjacent except for rapid Z moves, repeat modal functions (such as instruction 9 in the example) and self-cancelling pairs of modal functions (e.g. Coolant Off followed by Coolant Flood)*

* Self-cancelling pairs of spindle and coolant instructions will be removed from between cycles that are being merged. This action is controlled by the instruction number (Code Generator macro number) and custom posts using different macro numbers may produce unexpected results. Where a number of cycles are to be merged and there are some intermediate instructions that prevent merging into one cycle, the cycles will be merged into multiple cycles separated by the appropriate commands (see example). The Merge Hole Cycle command is only available for Code Generators that support multilevel/multidepth drilling. When using the Merge Hole Cycle command compatible cycles with different Feature Name settings are not merged. For this reason, the Feature Name modifier should be left blank if the hole cycles are to be merged. You must ensure that merged cycles act in the required way and that the toolpaths produced are safe and clear of any obstacles such as fixtures etc.

Setting Parameters before Merging Hole Cycles The following parameters must be identical in all affected cycles to allow a merge of those cycles: General tab* - Strategy, Plunge Feed, Speed, Dwell Time, Tap Cycle, Longhand Step tab - Cut Increment, Degression, Safe Distance Entry tab - Tool Diameter, Entry Depth, Entry Feed Filtering parameters will be ignored as they are used for data input control rather than processing of the cycle. * If all of the cycles to be merged have the same Optimisation setting then the new cycle will be optimised by that method. If cycles have different optimisation the combined cycle is set to and is not optimised. The order of drilling will be as if cycles had never been optimised and thus the toolpath may change.

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Depth Parameters in Merged Cycles •

If Level/Depth is constant for all merged cycles the Level/Depth field will be set to that value. If the cycles contain coordinates at different levels or require drilling to different depths the Multi Level and/or Multi Depth checkboxes will be set automatically for the combined cycle. The Depth and Level parameters will be stored for each hole in the cycle.

•

The clearance plane will be set at the highest Clearance value specified in the merged cycles and intermediate retracts (except retracts to toolchange Z).

•

Retract will be set to the highest Retract value within the merged cycles.

Using the Merge Hole Cycles Command Before merging your hole cycles it is suggested that you follow a few simple guidelines: 1. Ensure that the parameters for the cycles that are to be merged are equal or compatible (see Setting Parameters before Merging Hole Cycles). 2. When specifying the Optimisation setting for your hole cycles you will need to consider the following points. If all of the cycles to be merged have the same Optimisation setting then the new cycle will be optimised by that method. If cycles have different optimisation the combined cycle is set to and is not optimised. The order of drilling will be as if cycles had never been optimised and thus the toolpath may change. 3. Self-cancelling pairs of spindle and coolant instructions (e.g. Coolant Off followed by Coolant Flood) will be removed from between cycles that are being merged. This action is controlled by the instruction number (Code Generator macro number) and custom posts using different macro numbers may produce unexpected results. 4. You must ensure that merged cycles act in the required way and that the toolpaths produced are safe and clear of any obstacles such as fixtures etc. 5. Ensure that the Feature Name modifier for the hole cycles to merged has been left blank as otherwise compatible cycles with different Feature Name settings are not merged. 6. Once you are satisfied that all these points have been considered, select the Rationalise (Instructions menu) command and ensure that the default option By Tool is selected. 7. Check the Merge Hole Cycles option and click OK.

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Merging Hole Cycles - Example Rationalising a cycle without intermediate functions will give the following result: 1

T1 milling Cutter: CDRILL

2

Spindle CLW

3

Hole-Cycle Drill

4

Rapid Z Clear

5

Hole Cycle Drill

6

Return to Toolchange

Rationalising an operation will give the following result: 1

Coolant Off

2

Milling Cutter: Drill

3

Coolant Flood

4

Spindle CLW

5

Hole-Cycle Drill

6

Coolant Off

7

Rapid Z Clear

8

Coolant Flood

9

Spindle CLW

10

Hole-Cycle Drill

11


In both cases, if the cycle clearance height is equal to the toolchange height, the Rapid Z Clear is omitted. If you check the Merge Hole Cycles option both examples would appear like this: 1

T1 milling Cutter: CDRILL

2

Spindle CLW

3

Hole-Cycle Drill

4


Note that the self-cancelling instructions from between the cycles have been removed.

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Merging into Multiple Cycles - Example Where a number of cycles are to be merged and there are some intermediate instructions that prevent merging into one cycle, the cycles will be merged into multiple cycles separated by the appropriate commands. Using the Merge Hole Cycles command when rationalising this sequence Tool: 1 Hole-Cycle, positions 1, 2, 3 Hole-Cycle, position 4 Optional Stop Spindle CLW Coolant Flood Hole-Cycle, positions 5, 6 Coolant Off Rapid Z to Clearance Spindle CLW Coolant Flood Hole-Cycle positions 7, 8, 9 Return to Tool Change would produce the following result Tool: 1 Hole-Cycle, positions 1, 2, 3, 4 Optional Stop Coolant Flood Hole-Cycle, positions 5, 6, 7, 8, 9 Return to Tool Change

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Using Instructions Menu Commands Several commands in the Instructions menu allow you to alter existing commands in the current instruction list. Notes •

Only commands that are included in the instruction list can be edited, moved or deleted.

•

If you edit an Index (Move menu) command, all subsequent commands may be invalidated.

•

Editing one or more sub-instructions within an Operation breaks the Operation down into its constituent cycles.

•

Once the instruction list has been changed, EdgeCAM recalculates the toolpath according to the new geometry.

The Instructions menu commands are: Edit – Change a command’s parameters and any related co-ordinate input. If you have deleted any entities, you must respecify the entities required by the machining cycle. You can select more than one command at the same time. Aborting or Escaping at this stage deletes the cycle. Edit Screensnap – Change a command’s parameters and any related co-ordinate input by digitising the appropriate toolpath. Insert – On/off toggle. When on, it allows a new instruction(s) to be inserted. Move – Move a command’s position within the list. You may have to create commands out of sequence, but Move allows you to correct the order of events. You can select more than one command at the same time. An example of this is when drilling a start hole for pocketing - you don’t know where to drill the hole until after the Areaclear cycle has finished. Copy – Duplicate a command at another location in the instruction list. Delete – Remove a command from the instruction list. You can select more than one command at the same time. Regenerate – Regenerates the machining sequence from the selected instruction onwards. Regenerate Screensnap – Regenerates the machining sequence from the digitised toolpath onwards. Synchronise – (Only used for Four Axis Turning) Inserts a turret synchronisation command into the instruction list.

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View – Displays the machining sequence from the selected instruction onwards, including parameter input and screen digitises. View Screensnap – Displays the machining sequence from the digitised toolpath onwards, including parameter input and screen digitises. Simulate - Displays a tool simulation from the selected instruction onwards. Simulate Screensnap – Displays a tool simulation from the digitised toolpath onwards. Operation – All subsequent instructions are grouped under an Operation name, until you select the Operation command again. Rationalise – (Milling environment only) Enables you to re-order the instructions in a single sequence to rationalise the NC file by one or more criteria. Choose between sorting by Tool, CPL or Index. Also see Re-ordering the Machining Instructions in a Sequence.

Choosing the Editing Options If you have selected a command using the Instructions menu, you can then choose your editing options: Screen Snap – Check this box to select the command by digitising the appropriate toolpath, rather than by selecting the command from the instruction list. Operations – Check this box to list only those operations defined in the current machining sequence, rather than all commands in the instruction list. Operations can be defined with the Operation (Instructions menu) command. Global – Check this box to alter the Feeds, Speeds and Depth... parameters for all selected commands. Redraw – Check this box to redraw the screen after you have edited the instruction list. Disable Automatic Regeneration – Check this box to only regenerate the selected instructions. EdgeCAM defaults to regenerating all subsequent instructions, which you might consider unnecessary and time-consuming if you were simply changing the colour of the toolpath. Caution – To avoid invalid results you should regenerate the toolpath before saving or generating CNC code. Click OK when you want to proceed.

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Selecting from the Instruction List Unless you previously chose the Screen Snap option, you are now presented with this box showing all the available commands in the current instruction list that may be edited, moved or deleted. 1. Click on one or more commands from the list.

2. Click OK to continue.

Respecifying Co-ordinate Input Once you have selected all the instructions that you want to edit, you are presented with the dialog box for each command in turn. •

If a command needs you to input co-ordinate information, a new parameter is shown on the dialog - Coord Input.

Select one or more of the options. You can re-specify the co-ordinate information for each of these aspects of the cycle after you click OK for the cycle parameter input dialog box. •

Coord Input may appear instead as follows:

Check this box to respecify the co-ordinates required by EdgeCAM. Once you click on the OK button you are promted to enter this information in the usual manner for the particular command.

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78


Editing the Toolpath

DELETING A SECTION OF A TOOLPATH ....................................................................80 EDITING A SECTION OF A TOOLPATH.......................................................................80 SPLITTING A TOOLPATH .........................................................................................80 TRANSFORMING THE TOOLPATHS ...........................................................................81 Notes on Translate Command ........................................................................83 Using Matrix Mode ..........................................................................................84

Please note that these options are only available in the milling and turning environment Several commands allow you to edit the toolpath itself. These can be selected from Toolpath (Edit menu): Section - Changes a toolpath section. Split - Breaks up a toolpath. Delete - Deletes a toolpath section. Note that once a toolpath has been edited using one of these commands, it is no longer a normal machining instruction and cannot be edited or regenerated. Toolpaths that have been edited will be shown with an appropriate comment after the command name in the instruction list.

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Deleting a Section of a Toolpath The command Toolpath Delete (Edit menu) lets you remove part of a toolpath between two selected points. The system then creates a linear tool move to link the two parts of the toolpath. Link Control – (Milling only) Specifies how the link moves are to be created. Select Shortest to create a single linear move. Select Retract to create a vertical move to the Retract plane (defined below) before adding a link move. Depth Parameters – (MIlling only) Specifies the Clearance and Retract depth levels used by the system to generate the link moves. Screen Snap – Check this box to select a toolpath from the screen rather than a command from the instruction list.

Editing a Section of a Toolpath The command Toolpath Section (Edit menu) lets you change part of a toolpath between two selected points. Location – Check this box to move a node on the toolpath. If you reposition an arc move, it will change into a linear move. Feedrate – Specify the tool feedrate in the workplane for the selected part of the toolpath. Plunge Feed – (Milling only) Specify the vertical tool feedrate (into and out of the workplane) for the selected part of the toolpath. Speed – Specify the spindle speed to be used during the selected part of the toolpath. Rapid – Check this box to change the selected part of the toolpath to all rapid moves. Screen Snap – Check this box to select the toolpath from the screen rather than from the instruction list.

Splitting a Toolpath The command Toolpath Split (Edit menu) lets you break a toolpath at a selected point to produce two separate toolpaths. This lets you insert new commands between the two toolpaths. Screen Snap – Check this box to select a toolpath from the screen rather than a command from the instruction list. The toolpath will then be broken at the point nearest to the digitised point on the screen.

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Transforming the Toolpaths Several commands are available to copy or alter one or more machining operations from the instruction list. Note that only the toolpaths are altered by these commands – there is no alteration of the original design geometry. These commands copy and transform the calculated toolpath. They do not regenerate the path in its new position. This means that fixed points such as home or toolchange positions and moves to Z clearance may not give the desired output. Such moves should not be included in the instructions to be transformed. Subroutines used for repeating the hole cycle positions may also be invalidated as they will no longer have unique identifying numbers. These are the Edit menu commands: Transform Mirror – (Milling and Wire only) Mirrors a series of operations about a selected plane:

Transform Repeat – (Milling only) Copies the toolpath at successive depths:

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Do not set the Finish At parameter to Clearance or Retract for any cycles transformed by this command. Otherwise Z moves will be output into the subroutine which may invalidate the toolpath. Transform Rotate – (Milling and Wire only) Rotates or copies a series of operations one or more times about a selected point. This is used where the same feature appears several times about a central point:

Transform Translate – Moves or copies a series of operations one or more times. This is used where the same feature appears more than once in a component. Also see Notes on Translate Command.

In Wire Erosion, you may only translate the toolpath in the X and Y directions.

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Notes on Translate Command Changes have been made in EdgeCAM 7.00 to the way in which the Translate command works, particularly for controller subroutines. These changes result in a better correlation between the moves shown by EdgeCAM graphics and the toolpath on the machine tool. Translated moves EdgeCAM translates the toolpath as represented by move end points within the designated labels. From a machine tool point of view the "Start" of a sub-routine is, therefore, the End of the move leading to that first endpoint. Slightly different results will be seen depending on the type of move. A direct rapid or feed move will result in its end point being the subroutine start and the move will effectively be "lost" in repeats of the subroutine. A 2D rapid, doglegged, move (e.g. XY and then Z) will give the dogleg point as subroutine start and only the first segment of the move will be lost. Note that the graphics often show an apparent dogleg when resolved rapids are not used. This intermediate point does not exist on the NC data - it is purely for visualisation purposes - and will not be used as a start point. Some previous changes in this area have been removed from EdgeCAM. This means that in some cases the graphical representation will change, compared to previous versions, to more closely represent what happens on the machine tool. Good practice For safety reasons, subroutines should always start and finish at a safe clearance height. If this practice is followed then the link moves between subroutines can be expected to also be at the safe height. The subroutine should always include the liftout move at the end of a cut. A specific move to a point near to the required start of the subroutine before defining the subroutine is recommended. This is generally preferable to making a move direct from, say, toolchange and relying on the 2D rapid's dogleg to be the start point. If the machine tool movements are not exactly as represented on screen then this will minimise the discrepancy. Code Generators Some additional system variables have been added to the Code Generator to pass the subroutine start point. •

In macros TRANSLATE and RESET, the variables XEND, YEND, ZEND now represent the end of any approach move and thus the start of the subroutine.

•

In macros SUBSTART and SUBCALL, the existing variables NEXTXMOVE, NEXTYMOVE, NEXTZMOVE can be used.

•

The TRANSLATE Macro (No. 32) should now use XEND etc. as subroutine start point instead of XSUB etc. Rapid approach moves to this point should be output.

•

The SUBSTART Macro (No. 55 ) should use NEXTXMOVE etc. as a "HOLD" point for calculation of incremental moves.

•

The SUBCALL Macro (No. ) should include a rapid approach move to NEXTXMOVE etc.

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Existing code generator files will continue to work as before since no existing variables have been changed. It may be, however, that their actions are not correctly represented on screen by EdgeCAM graphics. The Code Wizard templates for milling and turning have been updated to match the graphics. Template based code generators should be updated to the version 7.00 templates to take advantage of these changes. The templates have also been updated to make the switch between incremental and absolute subroutines easier. The logic within the template will now determine whether to use the Rapid or Translate code constructors and G90/91 blocks will only be output by subroutine start and end if they are required. This last change is within the default sequence of the code constructors. It will not be applied automatically to updated CGD files but will be available for newly created files. It should always be remembered that the exact action of a machine tool when using controller cycles is beyond the control of EdgeCAM. It is the user's reponsibility to ensure that his code generators are correctly configured and that the on-screen representation closely matches the actions of his controllers.

Using Matrix Mode Only available in the milling environment Matrix Mode lets you repeat an operation or series of operations at regular intervals, specifying the number of rows and columns you need in your grid or matrix. EdgeCAM always displays the selected geometry in the bottom left hand corner of the Matrix. The various elements of the matrix are machined starting from the bottom left hand corner by default. However, when you select a tool, the Quadrant list box lets you start from the other corners of the Matrix. (Note that the Quadrant parameter must have been enabled in your code generator for this to work.) Matrix Mode Start (Edit menu) is used before the sequence of machining commands that are to be matrixed. You now perform a normal sequence of toolchanges and machining cycles on the geometry as a single part. Matrix Mode Finish (Edit menu) is used after you have finished entering the sequence of commands that are to be matrixed. Each Matrix Mode Start must be completed with a Matrix Mode Finish command. Note that the Mode (View menu) command contains a ‘Matrix’ check box that allows you to display or hide the Matrixed toolpath.

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In the example below, a Lacing area clearance toolpath has been created after a Matrix Mode Start:

On selecting the Matrix Mode Finish command, the Lacing toolpath is repeated in a grid according to the parameters specified in the Matrix Mode Start command.In this case, the parameters used were: X Repeats = 3

X Length = 50

X Border = 5

Y Repeats = 2

Y Length = 50

Y Border = 5

The default double fret border spacing is used here, so the total spacing between repeats of the toolpath is 50+5+5=60 as shown above. Repeats – Specify the number of cells in the matrix in the X and Y direction. Fret – Specify the number of Border widths (Double or Single) separating each cell in the matrix. Border – Specify the border spacing in part units in X and Y. Length – Specify the distance between each cell in the matrix in X and Y. Dead Zones – Allows you to specify areas that can be used by clamps or fixturing. Define the dead zones by nominating two sides of the matrix rectangle and a distance in from the edge.

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This example has X Repeats=5 and Y Repeats=4, and a Dead Zone along the bottom right of the matrix:

Direction – Specifies which cell is to be machined after the first cell. Select between Row or Column. Column forces the tool to move to a cell in the Y direction and Row (the default) forces the tool to move to a cell in the X direction. Lace Cut – Deselect to move the tool in the same direction along each row or column. The default setting of the checked box moves the tool to the next cell with the shortest possible movement. Subroutines – Select Pathtrace to avoid using subroutines when generating CNC code from this matrixed toolpath. The default setting of Controller will use subroutines where available. Define Layout – Select to ignore the Direction modifier and specify exactly in which order the individual cells are to be machined. The system displays a diagram of the cells in the matrix. Select each cell in the order you want the cells machined in. As each cell is selected, it is given a number to show its position in the sequence.

86


Generating CNC Code

PASSING JOB DATA TO THE NC FILE ................................................................89 ABOUT CNC FILENAMES .................................................................................89 CODE GENERATOR COMMANDS .......................................................................90 File Menu Commands in the Code Generator ..........................................90 View Menu Commands in the Code Generator ........................................91 Options Menu Commands in the Code Generator....................................91 EDITING THE CNC CODE .................................................................................92 Modifying a Code Generator File ..............................................................92

At some stage you will want to produce CNC code from your EdgeCAM machining sequence information. To do this, you must use the Code Generator application. This converts toolpath data generated within an EdgeCAM machining sequence into files containing CNC code. To generate the code from the active machining sequence 1. Select the Generate Code (File menu)

command.

2. Specify the following parameters: CNC Name – Enter a name for the CNC file (the default file extension is .nc). You can specify the file extension using the Default NC File Extension option on the Toolpaths tab of the Preferences (Options menu) dialog. To save CNC file names in upper case check the Force Upper Case option on the Toolpaths tab of the Preferences (Options menu) dialog. Click on the Browse... button to select an existing file name to write over. Job – Type in the name of the job file or press the Browse button to select from a list of existing files. Also see Passing Job Data to the NC File. Operation Names – Check the box to add operation names as comments to the CNC file. PDI Name – You can also name a category-run PDI file to execute before NC code generation begins. This is provided for users who have written their own PDIs and want to execute them before NC code generation. Open Editor – Check to automatically start the Editor and open the *.nc file after code generation. Please note that this option is checked by default. 3. Click on OK. The Code Generator main window is now displayed.

87

Generating CNC Code

If the Code Generator has been configured to ask for input before generating the CNC code, then it displays a dialog box for each option for example.

You need to enter or accept the settings for each dialog box. Once you have input this information, the Code Generator begins to generate code for the active machining sequence. If your system can compile Code Generator source files and you have modified the source file, the system compiles a new Code Generator file before compiling any CNC code. The generation process can be paused, continued and stopped using the controls. When the code generation process finishes and if your Code Generator is set up to list the NC code, EdgeCAM displays a dialog box.

Click on OK to dismiss this dialog box and return to EdgeCAM. If you did not choose to list the NC code, you will be returned to EdgeCAM automatically when the compilation ends.

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Passing Job Data to the NC File When a job record is selected for a machining sequence the Comment, Family, Customer, Programmer and Job Revision modifiers will be loaded into EdgeCAM (if specified for the job record) and the values displayed in the appropriate field on the Job Data tab. This information along with Material, Machine and Description will be passed through to the Code Generator, bringing the Job Manager, EdgeCAM machining sequences and the NC file closer together. You can also set these modifiers on the New Machining Sequence or Machine Parameters dialog. The relevant fields in the Job Manager will be updated when an NC file is generated. Code Generator Variable

Token Name

Token Description

JOBDESC

JM-DESC

Job Manager Description

JOBCOM

JM-COM

Job Manager Comment

JOBFAM

JM-FAM

Job Manager Family

JOBMACH

JM-MACH

Job Manager Machine

JOBCUST

JM-CUST

Job Manager Customer

JOBPROG

JM-PROG

Job Manager Programmer

JOBMATL

JM-MATL

Job Manager Material

JOBREV

JM-REV

Job Manager Revision

About CNC Filenames When a milling or single turret turning sequence is generated, the CNC filename is generated to the following format: CNC file

- example.nc

Setup file (optional)

- example-set.nc

When a single .nc file is generated, there is no ‘-1’ included in the name. This clarifies that the file is for a single turret machine. You can specify an extension other than ‘.nc’. When a multiple turret turning sequence is generated, the CNC filename is generated to the following format: 1st CNC file

- example-1.nc

2nd CNC file

- example-2.nc

Setup file (optional)

- example-set.nc

89

Generating CNC Code

The EdgeCAM Editor and Communications modules interpret and use long filenames generated from EdgeCAM (or any application) when running on a Windows NT installation. Note, however, that long filenames are truncated when viewed from Windows 3.1 and Novell networks. For example, the file 1234567890abc.nc will be truncated to 123456~.nc. The name assigned to the ‘setup’ file is configurable in the Code Generator source file, for example, instead of including -SETUP in the filename, it may be specified as -HEADER. Any CNC file generated using an existing Code Generator that specifies a ‘setup’ file name should be ignored and .set appended to the filename in its place.

Code Generator Commands File Menu Commands in the Code Generator Select Code Generator - Selects the Code Generator source file to be compiled. Print - Sends the current file to the printer. Print Preview - Shows how the current file would appear if sent to the printer. Print Setup - Configures the printer setup. Compile - Displays a dialog box containing the file compilation options. An input file is selected and the filenames for all other options are automatically entered. These filenames default to the same name as the input filename followed by the appropriate extension. The name can be re-specified by the user if required. This option is applicable to the Code Generator Compiler only, and will be “greyed out” if you do not have a licence. Exit - Returns to the previous application.

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View Menu Commands in the Code Generator Toolbar - Shows/hides the Toolbar. Status Bar - Shows/hides the Status bar. Large Icons - Uses the larger of the two icon sets for the Code Generator's buttons. Tool Tips - Allows command names to be displayed if you hold the cursor over a button.

Options Menu Commands in the Code Generator Re-run - Regenerates the CNC code using the data files for the last code generation. This forces a re-compilation of the Code Generator file if the date and time of the source is later that that of the Code Generator. Pause - Pauses\continues the active process. This lets you inspect the information displayed in the text box. Use the horizontal and vertical scroll bars to move up and down the file. Stop - Aborts the process. Remove Unused Variables - Instructs the compiler to remove any duplicate or unused variables from the source file (*.?xt) Quick Compile - Forces a quicker compilation by displaying the minimum amount of feedback in the viewing window. Specify Output Filename - Selecting this Code Generator Compiler-only option displays a dialog box similar to this after you click on the Compile button:

Enter a different name for the compiled Code Generator file. If this option is not selected, the source filename will be used by default.

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Generating CNC Code

Editing the CNC Code Once the Code Generator has created a file containing CNC code for a machining sequence, you can load the file into the Editor and make any changes directly to the code, should they be required. To enter the Editor, select the

icon from the EdgeCAM Program Group.

For more details, please refer to the Editor documentation.

Modifying a Code Generator File One way to alter the CNC code produced for a machining sequence is to edit the Code Generator itself. The recommended method for modifying Code Generators is to load the files into the Code Wizard

.

You must know how Code Generator source files work before trying this! For more details, please refer to the Code Wizard online user guide.

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EdgeCAM manufacturing basics

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