Lesson 3: Prismatic Milling: Objectives

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Lesson 3: Prismatic Milling

Objectives
Through completing the exercises in this lesson, you will be able to:
Section
Topic
Exercise
3.1 3.2
Create Stock Manufacturing Environment
Exercise 1 - Creating Stock Exercise 2 - Starting a New Machining Sequence Exercise 3 - Creating a New Tool Exercise 4 - Face Milling Operation
3.3 3.4
Select and Create Tools Face Milling Operation
3.5 3.6
Viewing the Toolpath Editing a CAM Instruction Exercise 5 - Editing a CAM Instruction Exercise 6 - Profiling Operation Exercise 7 - Roughing Operation Exercise 8 - Drill Cycle
3.7 3.8 3.9
Profiling Operation Roughing Operation Machining Holes Using the Drill Cycle Moving/Copying/ Inserting a Machining Instruction Flat Land Finishing
3.10
Exercise 9 - Moving and Inserting CAM Instructions Exercise 10 - Flat Land Finishing Operation
3.11
Use the right-hand column to tick off those lessons or exercises you have completed.
Before You Start

Before you begin work on the following exercises, make sure that you display the following toolbars on the screen:
Standard toolbar, Main toolbar. Tooling toolbar, Edit Toolbar. Input Options Toolbar, Browser window.
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Overview of the Lesson

In this lesson, you will learn the milling techniques required to machine the following component:
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Lesson 3.1 - Creating Stock

Before you can machine a component, you would typically create the stock to represent the material (or billet). The stock envelops the component outline and is used in EdgeCAMs Simulator to display the removal of material as the machining instructions are simulated.
Exercise 1 - Creating Stock

1. Open the component Packing Adapter_Metric.ppf''. The image should look like this:
2. 3.
Select the Stock/Fixture option from the Geometry menu. You see the Stock dialogue. Enter the following stock specifications:
automatic Stock checked X & Y Offsets 5mm Z Min offset 15mm Color White
Shape Box Z Max offset 5mm Layer Stock
4.
Save the Part as Packing Adapter_Metric.ppf to your X:\ drive.
Lesson 3.1 - Creating Stock
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Lesson 3.2 - Manufacturing Environment

EdgeCAM manufacture mode allows you to specify tooling and machining commands to manufacture components. The first time you enter manufacture mode, you must enter details on the type of machining you want to perform, for example milling or turning. The first dialogue is the Machining Sequence dialogue:
Exercise 2 - Starting a New Machining Sequence

1. 2. Ensure the part file Packing Adapter_metric.ppf is opened. Select the Manufacturing Icon.
3.
If this is the first time you have used the Manufacturing Environment - you will see the Machining Sequence dialogue box.
4.
Fill in the following parameters:

5. 6.
Sequence Name First Operation Discipline Mill Initial CPL Top Machine Tool pf-3x-mc.mcp All remaining modifiers can be ignored.
Dismiss the Dialogue box by selecting OK. You may edit any of the above information by clicking the right-hand mouse button over the Sequence Name in the Instructions Browser and select Edit.
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The Sequence Window displays a list of manufacturing commands. You can copy, move, edit and delete commands within this Window. 7. You will observe the following dialogue box:
8.
The above information can be altered at any time during the Manufacturing procedure.
Lesson 3.3 - Creating CAM Instructions

Essentially, you have two methods of creating machining instructions in EdgeCAM. Firstly you may adopt a Manual method which relies entirely on the users knowledge and skill of the software. Each individual CAM instruction will be created by the user. Alternatively, you can choose to work in a more Automated manner which allows the software to make more machining decisions for you and the physical creation of each CAM instructions are faster.
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Machining Process for Packing Adapter Component

Process CAM Instruction Work Content Tool Description Tool No.
Facemill Operation Profiling Operation Roughing Operation Hole Cycle
Face off component
40mm x 15 Approach Facemill
Rough-out external features Rough-out two Pockets Drill Through 2 x 8mm Dia. holes Counterbore the 2 8mm holes Finish and size both Pocket Features
40mm Dia. Endmill - Long Series
16mm Dia. Solid Carbide Endmill - Long Series 8mm dia. HSS Drill 16mm dia. Flat bottom peg drill or Slot drill 12mm dia. standard Endmill
Hole Cycle
Flatland Finishing Operation
Exercise 3 - Creating a New Tool

In this exercise, you will create a new tool, which will be used during the machining process, on the current component. Specifically, the tool is a 40mm dia. Face Mill. The tool will be used to remove surplus stock material from the component. 1. Before proceeding ask Mr. Carron to setup your TOOLSTORE DATABASE. 2. We wish to create a permanent record of this item within the ToolStore. Select the ToolStore icon.
3. Filter the current amount of tools on display by selecting Facemill.
4. Create a new 40mm Face mill - select Create.
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5. Enter the tool Description - 40mm Face Mill. 6. Enter the following values in the Geometry tab. Face Mill specifications:
Diameter 40mm Flute length 10mm Hand of Tool Right Included angle 15 teeth/flutes 5 Shank Length & Diameter 15mm
What happens by default if you do not enter a shank diameter?
4. Rotate and Pan the image of the Face Mill. Double click the left-hand mouse key in the Graphics port to Zoom Extents the image of the Tool. 5. The tool should now be displayed. Select Cancel to exit the ToolStore.
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Lesson 3.4 - Face Milling Operation

In this lesson, you will learn how to use the basic 2D milling CAM instructions to machine the component. Furthermore, you will learn how to Simulate the machining sequence- using EdgeCAM Simulator.
Process One
Facemill Operation
Face off component
40mm x 15 Approach Facemill
Exercise 4 - Face Milling Operation

The first step in milling the example part is to prepare the top surface of the component before using any other machining processes. You can facemill the top area of a component. Face mill can be performed manually by using Rapid & Feed movements. However, it is obviously better to employ EdgeCAMs commands - in this instance Facemill Operation.
1. Select the Face Mill Operation either form the menu, or from the toolbar.
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2. Observe the command prompt - Select Boundary Entities (Finish for None) Re-act
to the prompt by the chaining the 2D profile representing the stock.
3. You will now observe an interactive dialogue box, which runs a video of the tool
movements. As you tab through the various commands, the display will be altered in order to allow the user to visualize the influence of that particular command.
4. Digitize the ? symbol - EdgeCAM will display a miniature Help menu which will
allow the user to fully interpret the command.
5. Assign the following General Parameters:

Mill Type Climb Lead Length 25mm Angle 0 Stock Offset 0mm %Stepover 65
6. Assign the following Tooling Parameters:

Select Find and choose the 40mm Face Mill Position 1
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7. Assign the following Depth Parameters:

Clearance 20mm Depth -5mm Level 5mm Cut Increment 2.5mm
8. Dismiss the dialogue box by selecting OK.
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Lesson 3.5 - Editing a CAM Instruction

Exercise 5 - Editing a CAM Instruction
1. Observe the Sequence Window, containing the CAM Instructions. Select the + symbol alongside the Face Milling Operation.
Observe how the Operation contains individual CAM instructions.
Why do you think the Face Mill Operation has selected miscellaneous functions such as Coolant and Spindle commands? Investigate what influence does the Operation Preferences have over the Face Mill Operation.
2.
If you are not entirely satisfied with the toolpaths produced by the Face Mill Operation you may edit the operation. Position the cursor over the entry called Face Mill Operation and click the right mouse button - select Edit you will observe the following dialogue box.
3.
If you check the Coord Input box, you will be offered the opportunity to reselect CAD geometry. Ignoring the Coord Input box and selecting OK - you will be offered the opportunity of re-specifying the various information that was originally entered into the Face Mill Operation dialogue box. Try changing some of the original data:
4.
Mill Type Climb Angle 45 Lead Length 25mm
Stepover 25% Cut Increment 2mm
5. Select OK to dismiss the Dialogue Box and observe the alterations in the toolpaths.
Lesson 3.6 - Profiling Operation
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Viewing the Operation

6. Expand the Face Mill Operation by digitizing the + symbol. Place the cursor over the CAM instruction called Face Milling and click the right hand mouse button. Select Edit from the drop-down menu. You are now specifically editing the individual cycle.
7. Observe the numerous commands contained within the dialogue boxes - in particular look at the Lead parameters.
Do Not alter any of the information found within the Dialogue boxes.
8. If we had chosen to create our CAM instructions using the Manual method we would have used a Face Milling Cycle. 9. Dismiss the dialogue box by selecting CANCEL.
When viewing CAM Instructions and parameters born out of an Operation - you must dismiss the dialogue box by the Cancel command. Otherwise you will Collapse/Explode the Operation.
10. Select Preferences from the Operations Menu.
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11. Activate the Disable M-Functions command.
Operation Preferences influence the behavior of the CAM instructions (and its toolpaths) created from an Operation.
12.
Save the file. If you have already saved the file you will not be prompted for a file name nor Folder.
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13. Activate the Last option found in the Mode command (View Menu). This will have the effect of allowing EdgeCAM to only display the last toolpath and thus make the screen less cluttered.

Exercise 6 - Profiling Operation
Profiling Operation
Rough-out Outside Profile
40mm Dia. Endmill - Long Series
The next stage is to rough out the surplus material found on the outer regions of the component. There are obviously several methods that could execute this work - the Profiling Operation is one of several options.
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1.
Select Profiling Operation from the Operation Menu.
The characteristic of all Operations is determined by the Preferences settings. 2. Observe the command prompt Digitize Profiles - chain the outer profile of the component. Move through to the next command prompt by clicking the Right-hand mouse button. Observe the command prompt Digitize new Start Point for Profile Chain EdgeCAM is offering you the opportunity to determine the entry/exit point of the cutter in relationship to the profile. As you left-hand mouse key click around the profile, notice how the arrow symbol is positioned. Move through to the next command prompt by clicking the Right-hand mouse button.
3.
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4. 5.
You may ignore the final command prompt - Select Boundary Entities (Return for None) - by clicking the Right hand mouse button. You will now observe an interactive dialogue box, which runs a video of the tool movements. As you tab through the various commands, the display will be altered in order to allow the user to visualize the influence of that particular command.
6.
Digitize the ? symbol - EdgeCAM will display a miniature Help menu which will allow the user to fully interpret the command.
. Mill Type Climb Mill Tolerance 0.01mm Offset 0mm Compensation Geometry
None - no compensation G Codes are placed in the CNC program. The X & Y positional output within the program is based on the tools centerline. Centerline - as above expect compensation G Codes are placed in the CNC Program. Geometry - The X & Y positional output within the program is based on the geometry of the profile. Compensation G Codes are placed in the CNC Program.
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Lead Radius 4mm The tool will Roll into the sidewall of the profile as it enters the cut.
Lead Radius - radius compensation is applied along the Lead In section of the toolpath.
7.
Move onto the Tooling Tab.

8.
Position 2 Select the Find button and browse the ToolStore - selecting 40mm End Mill.
Move to the Depth Tab
Clearance 5mm Depth -33mm Cusp blank
Level 0mm Cut Increment 10mm
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9.
Dismiss the dialogue box by selecting OK.
10. Observe the resultant toolpath - referring to the previous exercise, use the Simulate Toolbar to play and view the toolpaths.
11.
Open the Simulator and observe the toolpaths.
When the Simulator is launched, select the Start icon from the toolbar:
You can change the speed by adjusting the speed slider bar:
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Quit the Simulator and return to EdgeCAM.
Refer to Lesson 4.2 - EdgeCAM Simulator section of this training guide for information about the Simulator software.
12. Observe the Sequence Window, containing the CAM Instructions. Select the + symbol alongside the Profiling Operation.
Observe how the Operation contains individual CAM instructions.
Why do you think that the Profiling Operation has selected the Tool Change command?
13. If you are not entirely satisfied with the toolpaths produced by the Profiling Operation you may edit the operation. Position the cursor over the entry called Profiling Operation and click the right mouse button. You will observe the following dialogue box.
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14. If you check the Coord Input box, you will be offered the opportunity to reselect another Feature or Profile. Ignoring the Coord Input box and selecting OK - you will be offered the opportunity of re-specifying the various information that was originally entered into the Profiling Operation dialogue box.
Viewing the Operation

15. Expand the Profiling Operation by digitizing the + symbol. Place the cursor over the CAM instruction called Profiling and click the right hand mouse button. Select Edit from the drop-down menu. You are now specifically editing the individual cycle.
16. Observe the numerous commands contained within the dialogue boxes - in particular look at the Start/End parameters.
Do Not alter any of the information found within the Dialogue boxes. 17. If we had chosen to create our CAM instructions using the Manual method we would have used a Profiling Cycle. 18. Dismiss the dialogue box by selecting CANCEL.
When viewing CAM Instructions and parameters born out of an Operation - you must dismiss the dialogue box by the Cancel command. Otherwise you will Collapse/Explode the Operation.
19. Re-Save the part.
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Lesson 3.7 - Roughing Operation

Roughing Operation
Rough-out two Pockets
16mm Dia. Solid Carbide Endmill - Long Series
Exercise 7 - Roughing Operation

Now that you have experienced setting up an Operation - you should find the next exercise slightly easier.
Remember, an Operation is creating the CAM instructions for you. You will be shown later on how to create these Instructions manually. 1. From the Operation menu, select Roughing. Observe the command prompt Digitize Geometry to machine - Chain both pocket profiles.
Think - what CAM instructions are created by the Roughing Operation?
2.
Observe the next command prompt Select Boundary Entities (Finish for None) You may ignore this prompt - a boundary is only used when you wish to restrict the positions of the toolpath. Observe the Video window and read the interactive Help. Set the following modifiers:
3.
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Mill Type Climb Offset 1mm Tolerance 0.1mm
%Stepover 50% Z Offset 0mm
The value inputted for Offset is 3D - applied to X,Y & Z axis. 4. Move into the Tooling tab and set the following.

5.
Tool Number 3 Tool Type 16mm Long Series End Mill
Move into the Depths tab and set the following:

6.
Clearance 5mm Depth -15mm
Level 0mm Cut Increment 5mm
Dismiss the dialogue box by selecting OK.
7. Observe the resultant toolpath - referring to the previous exercises, use the Simulate Toolbar to play and view the toolpaths.
8.
Open the Simulator and observe the toolpaths.
Refer to Lesson 4.2 - EdgeCAM Simulator section of this training guide for information about the Simulator software.
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9.
Observe the Sequence Window, containing the CAM Instructions. Select the + symbol alongside the Roughing Operation.
Consider why EdgeCAM has created a Move to Too Change .
10. Re-Save the Part.
Lesson 3.8 - Machining Holes Using the Hole Cycle

You can produce different drilled hole specifications by selecting the appropriate tool and specifying the relevant modifiers for the cycle. For example, you can create a main hole and its countersink by creating two hole cycles, each with different tool, depth and dimension specifications.
The method described herein represents the Manual method of creating CAM instructions. Therefore, unlike the previous exercises - you will not be using Operations.
Process Four
4 5
Hole Cycle Hole Cycle
Drill Through Counterbore the 2 8mm holes
8mm dia. HSS Drill 16mm dia. Flat bottom peg drill or Slot drill
4 5
Exercise 8 - Drilling the Holes

Complete machining of the drilled and counter bored holes.
You will now learn how to create a Hole cycle. For this particular component, you will have to produce two cycles to completely machine the drilled hole feature.
Drill - through the component with a 8mm dia. HSS Drill.
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Counterbore - 16mm Dia. X 5mm deep with a 16mm Slot Drill .
1. The Endmill from the previous machining instructions requires placing back in the tool carousel/turret. Execute a Toolchange command.
Consider why it wasnt necessary to use a Toolchange command during the previous machining transactions.
2. Define/select tool number four - 8mm diameter drill. 3. Open the Hole Cycle Command. You see the Hole Cycle dialogue:
Use Feature Name in order to lessen the amount of digitizing.
4. Set the following Parameters:

Subroutines Controller Feature Name Holes Clearance 10mm Depth -35mm Longhand No Optimize Path None Level 0mm
5. Set the Depth Parameters:
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Multilevel and Multi Depth are used where the same Drill is to be used on various holes features each possessing different Level and depth.
6. Step parameters are used when Peck Drill or Deep Hole Drilling Cycles are required. 7. Filtering can be used for refining the cycles. For instance where a drawing possesses
numerous arcs that represent hole positions, one can force the cycle to drill arc entities that match the drill diameter.
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8. 9. Dismiss the Dialogue box by selecting OK The command prompt will read
Digitize location for hole centre In the case of the component in hand, select the centre point(s) of the arc(s) you want to drill, then right-click to end the hole command.
Use Intellisnap to guarantee that you have selected the correct position. To select the centre of an arc, position the cursor over the arc centre and wait until the Entity Tooltip appears. Select the Centre-point option from the shortcut menu, then left hand click to select the required position.
Refer to Getting Started with EdgeCAM Lesson 2.5 Selecting Entities.
9. Having digitized the two positions, EdgeCAM creates and displays the toolpath(s) for
the hole cycle.
10. Move the Tool to the Tool change position. 11.

Save the file. If you have already saved the file you will not be prompted for a file name nor a Folder.
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Process Five
Process Cycle Work Content Tool Description Tool No.
Drill
Counterbore the 2 8mm holes
16mm dia. Flat bottom peg drill or Slot drill
12. Select or create a 16mm End Mill. 13. Create a second Hole Cycle - Pay special attention to the depth modifiers. 14. Remember to use Feature Name. EdgeCAM will remember the name used in the previous hole drilling cycle. On this occasion you will not have to digitize the hole centers:
15. Move the drill back to the toolchange.
position.
Lesson 3.9 - Moving/Copying/ Inserting a Machining Instruction

Exercise 9 - Moving and Inserting CAM Instructions
Moving a CAM Instruction
The following information will demonstrate how to create further CAM instructions AFTER a machining process has been completed. The method used to move and copy a CAM instruction is identical to that used in Microsoft. Windows Explorer for move Files and/or Folders. 1. Position the Cursor over the target CAM Instruction, click the left hand mouse button and hold the button down. Using the Drag and Drop method, slide the
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mouse/cursor up and down the CAM Browser. You will observe a black line appearing, this indicates the new position for the instruction. 2. Release the Left Hand mouse button the CAM Instruction is moved/Copied.
To Copy a CAM instruction, repeat the above procedure whilst holding down the Control Key.
Inserting a CAM Instruction

To Insert a CAM instruction: 3. Right-hand mouse key click over an Instruction and select Insert. 4. An arrow marker will appear next to the instruction. All new instructions will be placed Before the marked instruction. 5. Having created the new CAM Instructions - switch off Insert by right hand click over the CAM Instructions, and un-check Insert.
Lesson 3.10 - Flat Land Finishing Operation Process Six

Flatland Finishing Operation
Finish and size both Pocket Features
12mm dia. standard Endmill
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Exercise 10 - Flat Land Finishing Operation Flat Land Finishing Operation

The Flat Land Finish cycle is capable of finish machining the base and sides of the two pocket features. Without this cycle, one would have had to use a Roughing cycle (with the cut increment deactivated) plus a Profiling cycle.
The exercise herewith uses the automatic method of creating CAM instructions. Therefore, you will use the Flat Land Finishing Operation.
1. 2. 3.
Select Flat Land Finishing Operation from the Operations Menu. Observe the command prompt - Digitize Geometry to machine - chain the two profiles that represent the pockets. Ignore remaining prompts.
4. 5.
Set the Step-Over 35% and select a 12mm Dia. Endmill from the ToolStore Set the Depth parameters to: Clearance 5mm Level 0mm Depth -15mm
6. 7.
Observe how the tool machines the surplus material on the base of the pockets as well as the side walls. Re-Save the part as Packing Adapter.ppf.
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