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1
INTRODUCTION
SURFCAM is a powerful and efficient CAD/CAM product that is very easy to learn. This booklet
provides some basic information on its hardware and memory requirements and its installation. It
also contains a detailed description of the SURFCAM user interface to enable you to more quickly
become familiar with operating SURFCAM.
The greater part of this booklet is devoted to the following activities that give you an overview of
some of SURFCAMs powerful features.
1. Using SURFCAM Help on page 17
2. Create a 2D Part Design on page 23
3. Machine the Design on page 27
4. Create Dimensions on page 34
5. Create a Cross Section Surface on page 37
6. Create a Drive Curve Surface on page 39
7. Create a Fillet Surface on page 41
8. Single Surface Machining on page 45
9. Multiple Surface Machining on page 47
10. Z Rough Machining on page 51
11. Multi-Surface Planar Scallop Cutting on page 55
12. NC Operations Manager Tools on page 58
13. Challenge: Create Double Clamp Design on page 63
14. Challenge: Create Fork Bracket Design on page 70
1.1
This Demo Tutorial booklet is normally accompanied by a copy of the demo version of SURFCAM,
which is used for evaluation and educational purposes. It creates, loads, and saves part files that
are neither compatible with, nor transferable to, the standard version of SURFCAM. Certain
functions have been de-activated. These include:
Creation of files used for post processing to your machine tool.
Output of the following types of files: DSN, CADL, IGES, VDA, FST, CSF, and DES.
Other differences between the demo version and the standard version of SURFCAM will be noted
in this tutorial as the occasion arises.
1.2
Online Manuals
All of the SURFCAM manuals, including this Demo Tutorial, are available on the SURFCAM CDROM in portable document format (PDF). They can be viewed on your screen or printed using the
Adobe Acrobat Reader. If you do not currently have this program installed, it will be installed
automatically when you install SURFCAM.
We refer to the manuals in this format as online documents or online manuals.
Manual Cross References
Blue text in an online document signals a cross reference. Click on the blue reference to jump
immediately to the location mentioned. If you want to read this Demo Tutorial online, refer to Online
Manuals on page 20.
Video Clips
Video clips are available on the SURFCAM CD-ROM to illustrate various features of SURFCAM.
Refer to Video Clips on page 19 for information on accessing them.
At installation of SURFCAM, you have the option to install manuals and video clips to your hard
drive.
1.3
SURFCAM requires an Intel computer system with a 80486 DX microprocessor (for the 2 Axis
product) or a Pentium/Pentium Pro microprocessor (recommended for 3 Axis and above) and
Windows 95, Windows NT 4.0, or later versions. The following are additional hardware
requirements/recommendations:
1. A fixed hard disk with at least 250 MB of storage.
2. A Windows compatible graphics card (OpenGL recommended) and software driver.
3. A Windows compatible pointing device (mouse) and software driver.
4. Recommended: Sound card and speakers for the video clips in the Help file.
5. RAM: Refer to Figure 1: Memory Requirement and Recommendations.
RAM
APPLICATION
MINIMUM
RECOMMENDED
32MB
64MB
64MB
128MB
128MB
256MB
Swap file size should be a minimum of three times memory (RAM) size
Figure 1: Memory Requirement and Recommendations
Copyright 2000 by Surfware, Inc. All Rights Reserved.
1.4
SURFCAM INSTALLATION
To install SURFCAM, insert the CD-ROM into your drive. Click Start, then Run. The Run dialog
box will be displayed. Type D:\SETUP.EXE or click Browse to search for the file. (If D is not your
CD-ROM drive, type the appropriate letter.) Click OK.
The installation program will begin. The Installation Wizard will guide you through the process.
At the bottom right corner of the screen is the Exit button. Click it to exit from the
installation program at any time.
The following is a partial list of the information you will need to supply during installation:
1. When you are asked which installation type you prefer, choose Full Installation.
2. The drive and the directory for your installation of SURFCAM.
3. Since this is the Demo version of SURFCAM, when you are given the choice to install a
licensed copy or a demonstration version of SURFCAM, you should choose the
demonstration version.
However, even if you choose to install the licensed copy, you will only be able to use the
features from the demonstration version. Refer to Section 1.1: Demo Differs from Standard Version
of SURFCAM on page 1.
4. By default, the Online Help Videos and the Online Manuals will be stored on your hard drive
in locations you indicate. The amount of space needed will be displayed on the screen. You
can choose to access them from the CD-ROM, instead of installing them on your hard drive.
5. The folder for your program files.
When the setup is complete, you may need to restart your system.
1.5
OPERATING INTERFACE
Interact with SURFCAM through the computers display screen using the keyboard, the mouse, or
another input device. By entering information into dialog boxes, you guide SURFCAM in its
operations.
This section will help you become familiar with some of the tools that you will use throughout a
SURFCAM session. Some portions may not be too clear at first glance, but come back to this
section and use it as a reference as you become more familiar with SURFCAM.
Run SURFCAM
Click Start, then navigate to Programs, then to SURFCAM 2000.1 Demo, then to
SURFCAM 2000.1 GL OFF (or ON if you have an OpenGl card installed). Then click
the left mouse button.
1.5.1
Display Screen
3. Windows Minimize/
Maximize/Close Buttons
5. Toolbar
6. Status bar
14. Pointer
Coordinates
15. OpenGL
Status
MENU
FILE
Manage files.
CREATE
EDIT
DISPLAY
NC
Create the toolpaths that NC machines will use to cut the parts drawn.
ANALYZE
Determine the size, location, and type of the objects on the screen.
OPTIONS
HELP
5. Toolbar
The SURFCAM Toolbar contains buttons used for file management, screen display, and the
Operations Manager. Refer to Section 1.5.2: SURFCAM Toolbar on page 6.
6. Status Bar
The Status bar, directly below the Toolbar, displays the status of the parameters SURFCAM
is currently using for construction of geometric objects. Click a Status command to quickly
change its setting. Refer to Section 1.5.3: Status Bar on page 11.
7. Secondary Menu Bar
Many commands on drop-down menus lead to the display of submenus or a Secondary
menu bar. Generally, the commands will be displayed at the beginning of the Secondary
menu bar, separated by the > symbol.
Use the Next and Previous buttons to view all of the commands.
8. Customize Display
Customize the display of the commands on the Toolbar, Status Bar,
and the Secondary Menu Bar by right-clicking on any of these bars
to display a dialog box.
You can change the size of the icons on all three bars. You can
display Secondary Menu Bar and Status bar commands without
text. You can re-arrange any one of these three bars.
Figure 5: Customize
Commands
9. Workspace
The workspace occupies the largest portion of the screen. Use this window to create, edit,
and analyze geometry and toolpaths. The background color can be changed.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
1.5.2
SURFCAM Toolbar
File Buttons
The first three buttons are the New, Open, and Save file
commands. These are standard Windows operations.
Use the shortcut, Ctrl + S, to save the file.
Figure 6: File
Display Buttons
Figure 7: Display
Figure 8: Delete
Shortcut: Ctrl + D
Transform Button
Figure 9: Transform
Click the last button to display the dialog box for the NC
Operations Manager. This is a utility that helps you
manage a numerical control machining project.
For some aspects of the Operations Manager, refer to
Section 2.10.3: Step 3 Use the NC Operations Manager on page
54 and to Section 2.12: NC Operations Manager Tools on page
58.
For the purpose of practicing with this example, the order of the toolbar buttons shown below
is not the same as the order on the toolbar.
Shrink the graphic image by half the current screen scale.
1.
Figure 13:
Zoom Out
Ctrl + U
Figure 14:
Zoom In
2. Move the pointer to a point above and to the left of the element(s) you
want to enlarge, and press the left mouse button. SURFCAM will anchor
one corner of a rubber-band box at the point you select.
Ctrl + Z
3. Drag the mouse to a point diagonally opposite the first point until all
elements to zoom are entirely within the rubber-band box. The rubberband box stretches in the direction the mouse is moved.
4. Press the left mouse button. SURFCAM enlarges the image so that the
area that was inside the rubber-band box now occupies the entire
display window.
Before Fit
4.
Figure 16:
Pan
Ctrl + P
Slide the graphic image using either mouse button. This command uses the
current screen scale.
1. Click the Zoom Out button to shrink the image.
2. Click the Pan button.
3. Press and hold a mouse button while moving the mouse. SURFCAM
pans the workspace to center a different portion of the image in the
window.
Before Pan
5.
Figure 17:
Rotate
Ctrl + R
After Fit
After Pan
10
Before Rotate
6.
Figure 18:
Last View
After Rotate
Display up to the 20 most recent screen displays. This includes view changes,
as well as any display command.
1. Click the Last View button. The Next View command can be used to
reverse this if you click Last View too many times. SURFCAM will display
the most recent previous view.
2. Repeat step 1 to show up to 20 previous views.
Display the previous 20 screen displays in the reverse order of Last view.
7.
Figure 19:
Next View
1. Click the Next View button. The Last View command can be used to
reverse this if you click Next View too many times. SURFCAM will display
the most recent previous view.
2. Repeat step 1 to show up to 20 next views.
11
Refresh the graphic viewing area. This is useful after deleting elements. The
Repaint command will display all active elements for the visible layers.
8.
Figure 20:
Repaint
Ctrl + Q
1.5.3
Status Bar
The Status bar, directly below the Toolbar, displays the status of the parameters SURFCAM
is currently using for construction of geometric objects. Click a Status bar button to quickly
change its setting.
Color
Ctrl + O
View
Ctrl + V
The box shows the color currently used to draw elements. The identifying
number of the color is also indicated.
To change the color for new entities, click the Color button. A dialog box
containing 16 colored squares will be displayed. Click a color. The box will
disappear and the new color and its number will be displayed. The colors
are numbered from zero (black) to 15 (white).
This is the number of the view or display view from which you are
currently observing a drawing. View represents your line of vision when
you observe the drawing.
There are eight predefined views. Use the shortcut keys to set the current
view to be one of these eight standard views: Ctrl + 1 through Ctrl + 8.
Another option is to click the View button to display the Views dialog box.
12
Layer
Ctrl + L
When you click the Layer button, the Layers dialog box will be displayed
showing the names, numbers, visibility status and selectability status of
the current layers. Various tasks related to layers can be accomplished
with this dialog box, including creating new layers.
Shade
Ctrl + A
Coord
13
Click the Shade button to toggle the shading of surfaces between ON and
OFF.
Mask
Ctrl + Alt + M *
toggles
Masking
ON and OFF.
Ctrl + M
displays the
Mask Selection
Settings
dialog box.
14
To change the depth value, click the Depth button. The Depth dialog box
will be displayed.
To change the setting, click the Scale button. The Display Scale dialog
box will be displayed for you to enter a value. After you click OK, the
screen will be redrawn accordingly.
1.5.4
Hot Keys
When two keys are indicated in the following tables, they should be pressed simultaneously
(or press the first key, hold it down, and press the second key).
KEY
F1
ALT + F4
Exit SURFCAM.
ALT + TAB
KEY
ARROWS
15
BACKSPACE
CTRL + 1 . . .
CTRL + 8
Set the current view to be one of the eight standard views. Refer to Figure
21: Views dialog box on page 12.
CTRL + ESC
CTRL + A
Shade the visible surfaces. To toggle ON/OFF, press Ctrl + A once again.
CTRL + B
CTRL + C
CTRL + D
CTRL + F
CTRL + L
CTRL + M
Note: If no element or color has been selected for masking, the Mask
Selection Settings dialog box will be displayed.
CTRL + N
CTRL + O
CTRL + P
CTRL + Q
CTRL + R
CTRL + U
CTRL + V
16
KEY
CTRL + Z
ENTER
ESC
KEYPAD + OR - If you click Rotate on the Display menu or the Display menu barnot the
The following table lists Hot Keys that are applicable when SURFCAM is drawing a toolpath
and the tool is being displayed. Refer to this in activities which draw toolpaths.
KEY
TAB
FUNCTION
1st press of tab key:
Display the tool holder holding the tool.
2nd press of tab key:
Turn off the display of the tool and the holder. (The toolpath will be
drawn most quickly when neither the tool nor the holder is visible.)
3rd press of tab key:
Turn on the display of the tool only.
Toggle between starting and stopping the tool motion if tool is visible.
SPACE BAR
Move tool one step at a time after the tool motion has been stopped.
Figure 27: Shortcut Keys used when SURFCAM is drawing a toolpath
ACTIVITIES
2.1
17
SURFCAM Help contains topic descriptions displayed in special Help windows. By clicking hot
spots you can jump to other windows or display pop-up windows.
Use the Table of Contents to access video clips and the online manuals. Use the Index to search
for specific information.
Whether you use help as a quick reference or for context-sensitive help, press <Esc> to exit.
2.1.1
Help as a Reference
Contents and
Index Tabs
Buttons: Help Topics, Back, Print, Browse, and Main Contents and Index
18
The right side of the screen gives some information about efficient use of the Help file.
Click the Help Topics button to toggle between viewing the help
window by itself and viewing a two-paned screen showing the help
window with either the Index or the Table of Contents.
If the Back button is available, click it to view the previous screen.
Click the Contents tab to show the Help File Table of Contents.
Click the Index tab to see the Help File Index.
Several files make up the SURFCAM help file. Click the Main
Contents and Index button if you are not able to find an item in the
current help file.
Throughout the Help File, move the mouse around the screen. If a
hand or an arrow appears over a graphic or over words, click the
mouse for more information.
More than 40 Video Clips are currently available as supplements
to various SURFCAM Help Topics. In a Help Topic, click a Video
Clip button to play the clip.
The Help windows topic area can contain hot spots that point to additional Help
windows. When the pointer passes over a hot spot, a picture of a hand or an arrow will
appear on the screen.
Some hot spots will be graphics. Other hot spots will be green colored words that are
underlined.
When you click on a hot spot, SURFCAM will jump to another Help window or will
display a pop-up window containing information.
2.1.1.1
Table of Contents
On the left side of the screen in Figure 29: SURFCAM Help Window there is a list of
topics, many preceded by a book icon. These are the major content areas into
which the Help file is currently organized. Double-click a book icon to open it to
its pages.
Pages of books have page icons. Click a page icon to jump to the page
containing information on the topic indicated.
Example
1. Double-click the book Tour of SURFCAM Menus to open it.
2. Then click the page SURFCAM 2000.1 Menus. SURFCAMs Main menu bar will
be displayed.
3. Move the pointer to the green, underlined words to see a hand appear.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
19
From the Help File display of SURFCAMs Main menu bar, you can navigate through
various other menus and dialog boxes.
Video Clips
A video clip is a screen capture of someone performing a series of steps in SURFCAM.
If your computer has a sound card and speakers, you can listen to these descriptions
as well as observe the steps being performed.
During installation of SURFCAM you had the opportunity to install the videos onto your
hard drive. If you chose not do so, you will need to use your CD-ROM to access them.
There are two common methods to
access a video clip:
1. Choose a video clip from the Table
of Contents.
Double-click Video Clips. The book
will open. You can choose:
A. A list of all video clips.
B. A video showing the Smart
Cursor.
C. A list containing more books.
20
Continue to open books and look through pages until you see the page with the
video clip you want to view. Then click on the page.
2. Click a video-clip button in a Help window.
Following is an example showing how to select a video clip from a Help window.
A. In the Help Contents, double-click the book Tour of SURFCAM Menus.
B. Click the page SURFCAM 2000.1 Menus. SURFCAMs Main menu bar will be
displayed.
C. Click the Edit hot spot. The Edit Menu will be displayed.
D. Scroll down to the Transform hot spot. Click it to display the Transform Menu.
E. Move the pointer to the Rotate button. In this case, when the pointer changes
to an arrow, the pointer will be on the video clip hot spot. In some cases in the
Help file, the arrow pointer will indicate a jump to the online manual. The
context of the Help file will make it clear which type of hot spot is available.
F. Click the Rotate button to run the video clip showing how to perform a rotation.
When the video clip is finished, you will be returned to the Help window.
Figure 32: Click the Rotate button on the Transform Help Window
Online Manuals
All of the SURFCAM manuals are available on the SURFCAM CD-ROM in portable
document format (PDF). They can be viewed on your screen or printed using the
Adobe Acrobat Reader. If you did not have this program installed, it was
automatically installed when you installed SURFCAM.
We refer to the manuals in this format as online documents or online manuals.
21
2.1.1.2
Index
To use the Help file index, click the Index tab on the upper left of the
SURFCAM Help window to display the index. Refer to Figure 29: SURFCAM
Help Window on page 17.
Type a word in the box above the index and click on the word in the index list, or just
click on any item in the index to display the screen with corresponding information. In
Figure 34: SURFCAM Help Window showing the Index on the left panel on page 22, Hot Keys was
clicked.
You can continue to choose index items and see the appropriate window displayed.
Note:
22
Figure 34: SURFCAM Help Window showing the Index on the left panel
2.1.2
Context-Sensitive Help
When you use Help as a context-sensitive reference, you will usually be in the middle of a
SURFCAM project and want to know about a feature that is currently displayed on the
screen.
To access Help in a context-sensitive mode, press the <F1> key on your keyboard
when the SURFCAM feature is visible on the screen.
Once the Help file is open, you can use all of the features discussed in Section 2.1.1: Help as a
Reference on page 17.
Press <Esc> to exit Help.
2.2
23
2.2.1
SURFCAM is a true three dimensional design environment and it is necessary to select the
correct construction view (CView) before you begin to create geometry.
A Top View, much like a plan view in a drawing, must be defined for this activity.
Double-click Top View, or type 1 in the box next to CView and click OK.
24
3. You can also select a working color from the Status bar. Click color, then click a color
on the chart that will be displayed. Every item drawn from this point on will be in the
color you chose.
2.2.2
Create a Rectangle
1. Click Create on the Main menu bar.
2. Click Line on the Create menu.
3. Click Rectangle on the Create > Line menu (on the Secondary menu bar).
Note
The shortcut format that is used throughout the tutorial for steps 1, 2, and 3 is
Click Create > Line > Rectangle.
25
You can toggle the display of the CView Indicatorthe smaller of the two displayed
coordinate systems, and you can change the background color of the workspace.
Click Options > Display. Modify the Show CView Indicator and the Color Scheme fields
of the Display Options dialog box. Refer to Figure 132: Display Options dialog box on page 59.
Create a Circle
Next, create a circle with its center on the lower left corner of the rectangle.
1. Click Create on the Main menu bar.
2. Click Circle on the Create menu.
26
2.2.3
After you have selected the five pairs of entities, your screen
should look like Figure 47: The 2D Part.
2.2.4
27
Then click Yes in the NCPOST dialog box that will be displayed.
In the Demo version of SURFCAM, any file you save will be saved with a DEM
extension, rather than a DSN extension. (Even if you type a DSN extension, when you
open the file again, you will see that the extension is DEM.)
Note that if you attempt to overwrite a DSN file, the Demo version of SURFCAM will
save your file with a DEM extension instead of overwriting the DSN file.
2.3
Follow the steps below to machine the 2D part you designed in the previous activity. In this activity
you will create a toolpath that will remove the interior of the part.
2.3.1
If the design in Figure 47: The 2D Part is still on your screen, skip to Section 2.3.2: Step 2 Select
the Appropriate Machining Mode on page 28. If not, follow this procedure:
1.
2. An Open dialog box will be displayed. If the Samples folder is not open, double-click on
it to display its contents.
28
3. Type the name of the file you saved from Section 2.2.4: Step 4 Save the File on page 27 and
click Open, or scroll through the list and double-click on the file name.
2.3.2
2.3.3
You need to specify the area on the part from which to remove material: the boundary that
defines the pocket. You do this with a process called chaining. There are a number of
different methods of chaining or identifying the geometry to pocket. The fastest is the
automatic chaining method.
SURFCAM will next display the 2 Axis Pocket dialog box that contains the machining
parameters used to cut a pocket.
29
30
2.3.4
The 2 Axis Pocket dialog box contains machining parameters that are displayed on four tabs.
The Tool Information tab contains parameters related to the cutting tool.
1. On the Tool Information tab, click the button after the description of the current Tool.
SURFCAM will display a Select Mill Tool dialog box. Refer to Figure 58: Select Mill Tool
dialog box on page 31.
Scroll through the visible tool library or click a tool button on the toolbar to display
another list of tools.
31
Tool buttons
3. Select tool #34 which is a 1/2 Inch HSS End mill tool.
4. Click OK on the Select Mill Tool dialog box.
Since you are creating a pocketing toolpath, you will need to define a depth in order for
SURFCAM to create the necessary passes. Click the Cut Control tab.
Near the middle of the tab there are two columns: On Sides and In Z. The first refers to
values applied to movements in the X and Y directions; the second to movements in the
Z direction.
In this activity we will use a pocket depth of 1.5 with equal passes of .75.
32
5. Enter the pocket depth and increment values from Figure 59: 2 Axis Pocket Cut Control tab.
6. Now click the Tool Information tab again.
7. Click the button after the description of the current Material.
8. SURFCAM will display the Select Material dialog box.
33
Scroll through the material library to see what is available, but select material #8 which
is a Tool Steel.
9. Click OK on the Select Material dialog box.
10. Click OK on the 2 Axis Pocket dialog box.
11. SURFCAM will generate the toolpath. Depending on certain settings, it may then
display the Keep Operation dialog box. Regardless of your response, remember that in
the Demo version of SURFCAM, toolpaths cannot be saved.
2.3.5
Figure 62: Toolpath in Top View shows what your screen should look like if you are in Top View.
In this case it is difficult to see the multiple passes in Z. To look at the image in a 3D view,
press Ctrl + 7. (Or click the View button on the Status bar and double-click Isometric View in
the dialog box that will be displayed).
It may be necessary to click the Fit button on the toolbar to fit the geometry into the
workspace.
This completes the machining for this activity. The next step of the procedurewhich we will not
cover in this tutorialwould be post processing to produce NC code for the machine that will cut
the pocket.
34
2.4
CREATE DIMENSIONS
2.4.1
In this activity you will display various dimensions on the screen along with the part.
1.
2. If you are not looking at the model from the Top View, change the view by pressing Ctrl
+ 1. (Or click the View button on the Status bar and double-click Top View.)
3. In order to provide enough room on your screen to place the dimensions, click
the Zoom Out button on the toolbar to reduce the image by half.
2.4.2
3. For this activity, if StyleText is visible (on the far right), click it to
toggle it to MouseText.
35
With the Center command you can select the center of an arc, the center of a circle or
the midpoint of a line.
6. Refer to Figure 71: Points to select for dimensions. Position the pointer near one of the circles
representing drilled holes and click the left mouse button.
7. Click another circle representing a drilled hole. The dimension will appear on the
screen.
8. Dont press the mouse button yet. First move the mouse to move the dimension to the
desired location, and anchor it there by pressing the left mouse button.
9. Continue to create additional dimensions by selecting more circles.
2.4.3
You will next use the Radius command on the Dimension menu to create a dimension for a
radius of an arc or a circle.
1. Click Back on the Select Point menu.
2. The Text/Dimension menu will re-appear. Click Radius.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
36
2.4.4
Refer to Figure 74: Various Dimensions on page 37 and create other dimensions (or text) by
clicking the Align, Diameter, Angular, Leader, or Text commands on the Dimension menu.
Follow the directions on the prompt line to select element(s).
Note:
If you choose to create a Radius, Diameter, or Angular dimension, when you finish,
the Text/Dimension menu will still be displayed. Otherwise, click Back to return to
the Dimension menu when you want a different type of dimension.
Note:
When the Text/Dimension menu is displayed, press the F1 key to get Help.
Note:
With the Align command, as well as with the Linear command, you need to indicate
on the Select Point menu whether you want to measure from the center or use
another method to select points.
Change Colors
To change the colors of the images and dimensions on your screen:
1. Click Edit > Color.
2. Click on a color.
3. The Select menu will be displayed. Click Visible. The colors will change. (Note: to
change the color of new entities created, use the Color button on the Status bar.)
Copyright 2000 by Surfware, Inc. All Rights Reserved.
37
2.5
In this activity you will use the Cross Section command on the Surface menu to create a surface
through multiple cross sections.
2.5.1
1.
38
2.5.2
3. Click Sections on the Create > Surface > Cross Section menu.
Figure 77:
Create > Surface
Figure 79: Create > Surface > Cross Section > Sections
4. The Select menu will be displayed. If Single is not highlighted, click Single.
5. SURFCAM will prompt you to select the contour(s) to be chained. Select each cross
section as shown in Figure 81: Select each cross section.
6. When you are finished, click Done. SURFCAM will generate a smooth surface through
the sections as shown in Figure 82: The Cross Section Surface.
Optional
Shade
Click the Shade button on the Status bar (or press the Hot Key shortcut: Ctrl
+ A) to toggle shading on and off.
Change Colors
Refer to Change Colors on page 36.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
39
The colors of the image will change, but if surface shading is on, the current
shade color will remain the same. (This can be changed using Display >
Shade > Options, but we will not do that in this tutorial.)
Note that to change the color of new entities that you will create, click Color
on the Status menu and choose a color.
Practice with Toolbar
Refer to Section 1.5.2: SURFCAM Toolbar on page 6.
7.
2.6
In this activity you will use the Drive Curve command to create a surface by driving a section
along a curve. This type of surface is often referred to as a swept surface.
2.6.1
1.
If you are NOT looking at the model in Isometric View, it is difficult to see the design
shape. Use the shortcut keys to change to Isometric View: Ctrl + 7.
2. It may be necessary to click the Fit button on the toolbar to fit the geometry into the
workspace.
2.6.2
40
3. A Select Chain menu will be displayed. If Chain is not highlighted, click Chain.
Click the Close button, which now appears on the menu, to let SURFCAM make the
selection automatically.
6. SURFCAM will then prompt you to Select beginning element of cross-section 1.
The Select Chain menu will be displayed. Click Single.
41
2.7
In this activity you will use the Fillet command on the Surface menu to create a constant radius
fillet surface and then a variable radius fillet surface between two surfaces.
2.7.1
1.
42
2.7.2
Figure 94:
Create > Surface
2.7.3
43
2. If you are NOT looking at the model in Isometric View, it is difficult to see the design
shape. Use the shortcut keys to change to Isometric View: Ctrl + 7.
3. Click Create > Surface > Fillet. (Note: Fillet on the Surface menu, not the Create menu.)
4. SURFCAM will again display the Fillet dialog box.
Set Variable Radius to Yes.
5. Click OK.
6. SURFCAM will display the prompt, Select first surface. Select the plane.
7. You will then be prompted to Select second surface. Select the cylinder.
8. SURFCAM will prompt you to Select the reference curve. Select the light blue curve.
9. The following Select Point menu will be displayed so you can define the locations of the
changes in radii. Click Point.
44
10. There are four points along this curve. Click one. A dialog box will be displayed. Enter
the corresponding radius value indicated on the following drawing and click OK. Repeat
the procedure with the other three points.
.125
.375
.375
.500
11. When you are finished, click Done on the Select Point menu.
12. SURFCAM will display the Variable Fillet Information dialog box.
For this activity, click OK to accept Blended for both Start and End, and Constant
Between Same Radius.
13. The resulting image is shown in Figure 102: Variable
Radius Fillet.
Optional
Shade the surface using either the Shade button
on the Status menu or the shortcut keys: Ctrl + A.
Optional
Use the toolbar to make various changes. Refer to
Section 1.5.2: SURFCAM Toolbar on page 6.
14.
2.8
45
SURFCAM has seven machining modes which can be seen by clicking NC on the Main menu bar.
The 3 Axis mode is often used to machine surfaces. There are two basic types of surface
machining. One machines a single surface at a time. The other machines a virtually unlimited
number in one step. The following activity shows how to machine a single surface.
2.8.1
1.
2. If you are NOT looking at the model in Isometric View, it is difficult to see the design
shape. Change to Isometric View.
3. It may be necessary to click the Fit button on the toolbar to fit the geometry into the
workspace.
Top View
Isometric View
Figure 103: Valve.dsn
2.8.2
In this activity you will cut a single surface with the 3 Axis Cut command.
Click NC > 3 Axis. The NC > 3 Axis menu will be displayed.
Click Cut.
2.8.3
46
47
8. SURFCAM will display a Select Material dialog box. Refer to Figure 60: Select Material
dialog box on page 32.
Scroll through the material library and select any material.
9. Click OK on the Select Material dialog box.
10. Optional: In the next step, you might want to try the hot keys used when a tool is
displayed and SURFCAM is drawing a toolpath. Refer to Figure 27: Shortcut Keys used
when SURFCAM is drawing a toolpath on page 16.
11. Click OK on the 3 Axis Cut dialog box to start the toolpath creation.
12. SURFCAM will generate the toolpath. If SURFCAM displays the Keep Operation dialog
box, click Accept to keep the operation. Regardless of your response, remember that in
the Demo version of SURFCAM, toolpaths cannot be saved.
2.9
2.9.1
1.
2. If you are NOT looking at the model in Isometric View, it is difficult to see the design
shape. Change to Isometric View.
48
It may be necessary to click the toolbar Fit button to fit the geometry into the workspace.
2.9.2
49
4. The 3 Axis Planar dialog box will be displayed with the Tool Information tab on top.
Click the button after the description of the current Tool.
5. SURFCAM will display a Select Mill Tool dialog box. Refer to Figure 58: Select Mill Tool
dialog box on page 31.
Scroll through the visible tool library or click a tool button on the toolbar to display
another list of tools.
6. For this activity:
If the mill ballnose tool library is not on your screen, click the first tool button on
the toolbar to choose the mill ballnose tool.
7. Select tool #6 which is a 1/2 Inch HSS Ballnose tool.
8. Click OK on the Select Mill Tool dialog box.
9. The Tool Information tab will again be visible on your screen.
Click the button after the description of the current Material.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
50
10. SURFCAM will display a Select Material dialog box. Refer to Figure 60: Select Material
dialog box on page 32.
Scroll through the material library and select any material.
11. Click OK on the Select Material dialog box.
12. Click OK on the 3 Axis Planar dialog box.
13. SURFCAM will then display the Select Point menu. Click End Point.
Offset Side
15. SURFCAM will then prompt you to Select offset side. You need to define which side
you wish to machine. Dont select the offset side until you read the following Optional
step.
Optional
After you select the offset side, you might want to try the hot keys used when the
tool is displayed and SURFCAM is drawing a toolpath. Refer to Figure 27: Shortcut
Keys used when SURFCAM is drawing a toolpath on page 16.
To select the offset side, place your pointer to the left of the part and click anywhere.
Refer to Figure 114: Selection Points and click on the side of the part that says Offset Side.
SURFCAM will highlight each surface and then begin to generate a toolpath to machine
all of them.
51
When this process is completed, your screen should look like Figure 115: Planar Toolpath.
16. Depending on certain settings, SURFCAM may then display the Keep Operation dialog
box. Regardless of your response, remember that in the Demo version of SURFCAM,
toolpaths cannot be saved.
2.10
Z ROUGH MACHINING
SURFCAM has an operation called Z Rough with which you can remove large amounts of material
from around multiple surfaces in preparation for finish cutting of those surfaces. In this activity you
will create a Z Rough toolpath and observe a tool traverse the path on the screen.
2.10.1
1.
52
2.10.2
2. The Select menu will be displayed and you will be prompted to Select surfaces to
rough. Click Visible.
Click the down arrow next to Material Type. There are six ways to describe the material
surrounding the part: Extents Box, Box, Bottom Profile, Top Profile, Surfaces, and No
Material. Select Bottom Profile.
4. You must now enter the height of the material above the bottom profile. Move the
pointer to the Material Height box and enter 3.5 and click OK.
5. A Select Chain menu will be displayed and you will be prompted to Select beginning
element. Click Chain.
53
54
14. SURFCAM will display a Select Material dialog box. Refer to Figure 60: Select Material
dialog box on page 32.
Click #2, Steel 18-26Rc.
15. Click OK on the Select Material dialog box.
16. Optional: In the next step, you might want to try the hot keys used when the tool is
displayed and SURFCAM is drawing a toolpath. Refer to Figure 27: Shortcut Keys used
when SURFCAM is drawing a toolpath on page 16.
17. Click OK on the 3 Axis Z Rough dialog box to start the toolpath creation.
When the toolpath has been drawn, depending on certain settings, SURFCAM may
display the Keep Operation dialog box giving you the opportunity to Accept or Reject
the toolpath.
For this Activity, click Accept so that the steps in the next section can be completed.
Remember that in the Demo version of SURFCAM, toolpaths cannot be saved.
2.10.3
The last icon in the operations tree3axis Z Roughis the icon for the Z Rough
operation you just performed.
With the NC Operations Manager dialog box open, you can perform many tasks that are
useful in managing an NC project.
2. Click the 3axis Z Rough icon you just created. Keep the left mouse button depressed.
Move the pointer so that the icon above is highlighted. Release the mouse button. You
should observe that the two icons have changed places.
55
With this method you can arrange NC operations in the order you want them performed
in the last stage of an NC project called post processing to NC code.
3. Not all of the buttons on the NC Operations Manager toolbar are available in the
demonstration mode. We will look at two that are: first, Hide Toolpath, then Delete.
Click the Hide Toolpath button.
The toolpath that was just drawn will be hidden.
4. You can use the Delete button to delete unwanted operations.
Highlight the 3axis Z Rough operation icon you just created.
5. Click the Delete button. The NC POST
dialog box will be displayed with a warning.
6. Click Yes to delete the toolpath data. (You
can do this activity over again to re-create
the operation you just deleted. Reminder:
You cannot save a toolpath in the Demo
version of SURFCAM.)
2.11
SURFCAM has a powerful feature by which you can cut multiple surfaces with dramatically
different slopes and maintain a constant scallop size. SURFCAM automatically adjusts the
distances between successive passes of the tool to maintain the constant scallop size.
In this activity you will create a 3 Axis Planar toolpath with a Scallop Step Type and observe the
tool traverse the path on the screen.
2.11.1
1.
2.11.2
1. Follow steps 1 through 5 in Section 2.9.2: Step 2 Create a Toolpath on page 48.
2. For this activity, select tool #5 which is a 3/8 Inch HSS Ballnose tool.
56
57
9. Refer to Figure 128: Starting Point, Direction, Offset Side to select the point that will define
the starting point of the toolpath. You will then be prompted to Select point in direction
of cut.
Offset Side
10. Optional: In the next step, you might want to try the hot keys used when the tool is
displayed and SURFCAM is drawing a toolpath. Refer to Figure 27: Shortcut Keys used
when SURFCAM is drawing a toolpath on page 16.
11. SURFCAM will then prompt you to Select offset side.
Refer to Figure 128: Starting Point, Direction, Offset Side and select a point to indicate the
offset side. SURFCAM will create the toolpath and may display the tool traversing the
path on the screen.
When the toolpath has been completed, you should be able to tell that in areas with
steep slopes, the tool passes are closer together than in areas where the surfaces are
flatter.
12. Depending on certain settings, SURFCAM may then display the Keep Operation dialog
box. Regardless of your response, remember that in the Demo version of SURFCAM,
toolpaths cannot be saved.
58
2.12
In this activity you will use the Backplot Toolpath and Hide Toolpath buttons on the NC Operations
Manager toolbar to display and study the parameters associated with several kinds of lathe
toolpaths that have already been created in SURFCAM.
2.12.1
1.
2.12.2
2.12.3
It is helpful to have the tool move slowly when observing a toolpath being drawn.
1. Click Display on the Options menu to see the Display Options dialog box. Refer to Figure
132: Display Options dialog box on page 59.
2. Change the 0 in the Tool animation wait box to a 9 to make the tool move at its slowest
speed.
3. If you want, you can also remove the display of the CView Indicator if it appears on your
drawing.
If the box after Show CView Indicator is checked, the CView Indicator will be visible.
Otherwise, it wont.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
4. Click OK.
2.12.4
1. Click the NC Operations Manager button on the SURFCAM toolbar to open the
NC Operations Manager dialog box.
59
60
2.12.5
1. In the NC Operations Manager dialog box, click on the Lathe Turn - Rough icon in the
operations tree.
2. Click the Backplot Toolpath button on the toolbar to draw the toolpath for this
operation.
Backplot is the name given to the process of showing the tool as it draws the toolpath.
If you click the similar looking Show Toolpath button, the toolpath will be drawn
without showing the tool.
The toolpath in this activity is for an outside diameter turning operation. It is a roughing
operation in that a large amount of material is removed from around the part. There is
one finishing pass made at the end of the operation.
61
2.12.6
When this toolpath was created, certain parameter settings were made in the tabs on the
Lathe Turn dialog box. These settings can be reviewed by opening the NC Operation
Information dialog box.
1. Click the NC Operations Manager button on the SURFCAM toolbar.
2. Right-click the Lathe Turn - Rough icon to open the NC Operation Information dialog
box.
62
5. You can view the parameter settings on each tab. In the standard version of SURFCAM,
these settings can be changed and the toolpath regenerated and saved.
6. Click Cancel to close the Lathe Turn dialog box.
7. Click Cancel to close the NC Operation Information dialog box.
2.12.7
From the NC Operations Manager dialog box you can also erase or hide the toolpath that you
just had SURFCAM draw for you.
1. Open the NC Operations Manager dialog box by clicking its button on the toolbar, if it is
not already open.
2. Click the Lathe Turn - Rough icon.
3. Click the Hide Toolpath button to hide the toolpath for the highlighted operation.
Hiding the toolpath that was just drawn will clear the drawing so you can
experiment with observing other toolpaths.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
2.12.8
63
Open the NC Operations Manager dialog box, if it is not still open, and use the other
operations in the operations tree for more practice backplotting and hiding toolpaths.
The Rough operations remove large amounts of material. The Finish operations make
several finishing passes over the final surface of the part.
2.12.9
When you have finished looking at the other toolpaths, you should set the tool speed back to
its fastest.
Repeat Step 3 but change the 9 in the Tool animation wait box back to 0. Refer to Section
2.12.3: Step 3 Change the Tool Motion Speed on page 58.
Note:
It would be good at this time to change back from lathe to milling operations. Refer to
Section 2.12.2: Step 2 Change View Indicator on page 58 to change the menu command on
the Options menu back to Mill Axis.
2.13
In this activity you will create the design shown in Figure 137: Double Clamp.
Click the New button.
This activity does not include detailed step-by-step instructions. It is
intended as a challenge to new users of SURFCAM. However, some guides
will be supplied.
As you are going through the Activity, be sure to pay attention to the prompt
line at the bottom of the screen.
2.13.1
Figure 137:
Double Clamp
5. The Select Point menu will still be displayed on the screen. Click Keyboard again.
6. Enter the center of the second circle in the World dialog box: X = 0, Y = -1.5, Z = 0.
7. At various times throughout this activity, you may have to click the Fit button.
64
2.13.2
Figure 139:
Offset Lines
7.
8. Click Back on the Select Point menu. The Create > Line menu will be displayed. Click
Offset.
9. If the Offset shown on the prompt line is not .5, click Change Offset and enter .5 in the
Offset dialog box.
10. Select one of the lines and click above it to indicate the offset side.
11. Select the same line and click below to indicate the offset side.
12. Repeat the previous two steps with the other line.
13. Click Edit > Delete. Then click Singleunless it is already highlighted.
14. Delete the two middle lines you created (in #2 through #5) for offset purposes.
15.
2.13.3
Figure 140:
Create Arcs
Copyright 2000 by Surfware, Inc. All Rights Reserved.
2.13.4
65
4. Select each of the four offset lines and offset each outwardly.
5. Click Create > Arc > 2 Points/Diameter > End Point.
6. Create an arc by selecting the right end points of one pair of
offset lines in counterclockwise direction.
7. Repeat the previous step to create the other arc.
2.13.5
Figure 141:
Offset Lines and Arcs
Youll notice that upper and lower sets of arcs and offsets do not line up vertically.
1. Click Edit > Trim/Break.
Top line
Extend
these
Figure 142:
Trim Lines to Extend
6. Select the left end point of the top line as the element to trim to. The lower line will be
extended.
7. With Trim 1 still highlighted, select the other line on the lower right. Click Location > End
Point and again select the left end point of the top line as the element to trim to. The
other lower line will be extended.
66
2.13.6
The next elements will be created with the intent of mirror-imaging them in a later step.
1. Click Create > Arc > Center/Radius.
2. The Create Arc dialog box will be displayed. Enter the following
values:
Radius: 4.75
Start Angle: 90
End Angle: 180
Direction: CCW
Click OK.
3. Click Keyboard on the Select Point menu that will be displayed.
4. Enter the center of the arc in the World dialog box:
X = 6.875, Y = 0, Z = 0 and click OK.
5. To create a vertical line, click Create > Line > Vertical > Keyboard.
6. The World dialog box will be displayed. Enter the coordinates of the point through which
the vertical line will be created: X = -0.875, Y = 0, Z = 0 and click OK.
7. Click Create > Circle > Offset > Change Offset.
8. Enter 0.5 in the Offset dialog box.
9. Select the upper circle only, as the element to offset.
10. Click on the left side of the line to indicate the offset side.
2.13.7
Figure 144:
Trim Vertical Line
7. With Trim 1 still highlighted, again select the vertical line as the element to trimbut this
time, select it near the bottom because we want to keep the bottom portion of the line.
8. Click Location on the Trim/Break menu.
9. Click Relative on the Select Point menu because we want a point that is a distance of
4.125 from the bottom of the line.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
67
10. Enter X = 0, Y = 4.125, Z = 0 in the World dialog box as the relative values, and click OK.
11. Click End Point on the Relative menu.
12. Select a point near the bottom of the vertical line as the relative point so that end point
will be selected.
2.13.8
Figure 146:
After Auto Trim
2.13.9
1. To create the top arc on the design, click Create > Arc
> Tangent 2.
2. Click Change Radius and set the radius to 20.
3. Click Location > End Point and select a point toward
the left end of the top line.
4. Click Location > End Point again and select a point
toward the top of the vertical line. You may need to
click other.
68
2.13.10 Step 10 Create Horizontal Line, Vertical Line, and Arc Offsets
1. Horizontal Line:
To begin to create the triangle-like portion on the
top left of the part, we draw a horizontal line.
Click Create > Line > Horizontal > Keyboard.
The World dialog box will be displayed. Enter the
coordinates of the point through which the
horizontal line will be created:
X = 0, Y = 3.125, Z = 0 and click OK.
2. Vertical Line:
Click Back > Offset > Change Offset and enter 1 for the offset value.
Select the top vertical line as the line to offset and click to the right to indicate the offset
side. Refer to Figure 150: Horizontal and Vertical Lines.
3. Arc Offsets:
Click Create > Arc > Offset.
Refer to Figure 151: Arcs to Offset and select one arc
to offset. For the offset side, select the inside.
Repeat with the other arc.
Figure 151: Arcs to Offset
69
70
2.14
In this activity you will create the design shown in Figure 155: Fork Bracket.
This activity does not include detailed step-by-step instructions. It is intended as a challenge to
new users of SURFCAM. However, some guides will be supplied.
2.14.1
3.
4. Click Back. Create two 0.5 diameter circles at positions relative to the 1 diameter
circle. Click Relative and enter X = -1.5, Y = -0.25, Z = 0 for the relative value for the
first circle. Click Center and select the 1 circle.
Click Relative again and enter X = 1.5, Y = -0.25, Z = 0 for the relative value for the
second circle. Click Center and again select the 1 circle.
5. Click Create > Circle > Offset and change the offset to 0.25 to create offset circles 0.25
larger than the 1 and the two 2 circles.
2.14.2
1. Use Create > Line > Tangent and select the circle that is
offset from the 1 circle. Then select the circle that is offset
from one of the 2 circles.
2. Now select the circle offset from the 1 circle again. Then
select the circle offset from the other 2 circle.
3. Click Horizontal > Keyboard to create a horizontal line through (0, -2.375, 0).
4. Click Back. Click Vertical > Keyboard to create a vertical line through (-3.5, 0, 0). Click
Keyboard again and create a vertical line through (3.5, 0, 0).
2.14.3
71
Step 3 Trim
2.14.4
1. Click Create > Line > Tangent. Select a circle offset from
one of the 2 circles.
Click Location > End Point.
Select the vertical line near that circle.
2. Repeat the process for the offset of the other 2 circle and
the vertical line near it.
2.14.5
1. Click Offset.
Change the offset to 1.5 and select each vertical line and
offset inside.
2. Change the offset to .75 and select each new vertical line
and again offset inside.
Figure 160: Offset Lines
3. Change the offset to 0.625 and select the horizontal line and offset up.
4. Change the offset to 0.25 and select the new horizontal line and offset up again.
2.14.6
Figure 161:
After Trims and Breaks
72
2. After you have extended the four vertical lines you will need to trim away the unneeded
segments in the drawing.
Click Auto Trim.
Make sure the Delete Segment button (to the left of the Auto Trim button) is showing. If
the Keep Segment button is showing, click it to change it back to the Delete Segment
button.
3. Notice the pointer is now an arrow and a pair of scissors. With Auto Trim you can now
modify your design to look like Figure 161: After Trims and Breaks.
With one click at a time, delete each of the unneeded segments.
4. If you delete the wrong thing click the Undo button to bring it back.
2.14.7
1. Use the shortcut, Ctrl + D, to display the Delete menu. Click Single and select the circle
that was offset from the 1 circle. (A fillet will be created here later.)
2. Click Create > Fillet. Change the radius to 0.25 and make two fillets as indicated in
Figure 164: Create Fillets.
73
3. Change the radius to 0.09 and create fillets where necessary. Youll need eleven of this
size. Dont forget the one at the top where the circle was deleted.
2.14.8
1. Click Create > Line > Vertical > Center. Select each of the
two horizontal lines at the bottom.
2. Click Back. Click Offset. Change the offset to 0.10 and
select one vertical line and offset it on one side. Then select
it again and offset it on the other side.
3. Repeat the process with the other vertical line.
4. Use the shortcut, Ctrl + D, to display the Delete menu. With
Single highlighted, delete the two center lines.
5.
2.14.9
The only thing left is to finish the slots so your design will look like Figure 166: Fork Bracket.
Save your file and try to do this on your own. If you have difficulty, open your saved file and
use the following guides. There are several ways the design can be finished.
1. With Trim 1 highlighted, select the offset of the left 2 circle at about the 9 oclock
position. As the element to trim to, select the tangent line at the top.
2. Again with Trim 1 highlighted, select the offset of the same 2 circle at about the 9
oclock position. As the element to trim to, select the tangent line at the bottom.
3. We have to treat the circle on the right in a slightly different manner since the 3 oclock
position is a break point.
4. With Trim 1 highlighted, select the offset of the right 2 circle at about the 2 oclock
position. As the element to trim to, select the tangent line at the top.
A portion of the circle was deleted. Well trim to extend it.
5. With Trim 1 highlighted, select the offset circle at about the 2 oclock position. As the
element to trim to, select the tangent line at the bottom. The arc will be extended.
6. Now use the Auto Trim operation on the Trim/Break menu to create the two slots in the
Fork Bracket.
With Auto Trim in the Delete Segment mode, trim away the unneeded parts of the four
vertical lines. Then trim the unneeded horizontal line segments and the unneeded arcs.
This completes the design. Your screen should look like Figure 166: Fork Bracket.
Copyright 2000 by Surfware, Inc. All Rights Reserved.
74
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