CAMWorks 2006EX Wire EDM Tutorial

CAMWorks 2006EX Wire EDM Tutorial

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CAMWorks 2006EX Wire EDM Wire EDM Wire EDM Tutorial License Agreement In receiving a software product described herein, you are granted a nonexclusive license to use that software on one computer. TekSoft, Inc. retains full title to and ownership of the product. Use of the product constitutes acceptance of this agreement. Duplication of the software product for any purpose, other than backup protection, including duplication for any commercial purpose, is prohibited by law. TekSoft, Inc. reserves the right to revise and improve products as it sees fit, and to revise the specifications and information contained herein without prior notice. Due to continuing product development, specifications and capabilities described in this manual are subject to change without notice. Warranty TekSoft, Inc. will replace defective software for a period of 90 days from date of delivery, at no charge. TekSoft, Inc. makes no other warranty, either express or implied, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose, regarding any product described herein. In no event shall TekSoft, Inc. be liable to anyone for special, collateral, incidental, or consequential damages in connection with or arising out of the purchase or use of these products. The sole and exclusive liability of TekSoft, Inc., regardless of form of action, shall not exceed the purchase price of the materials ...

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CAMWorks 2006EX
Wire EDM Wire EDM Wire EDM
Tutorial









License Agreement
In receiving a software product described herein, you are granted a
nonexclusive license to use that software on one computer. TekSoft, Inc.
retains full title to and ownership of the product. Use of the product constitutes
acceptance of this agreement. Duplication of the software product for any
purpose, other than backup protection, including duplication for any
commercial purpose, is prohibited by law.
TekSoft, Inc. reserves the right to revise and improve products as it sees fit,
and to revise the specifications and information contained herein without prior
notice. Due to continuing product development, specifications and capabilities
described in this manual are subject to change without notice.
Warranty
TekSoft, Inc. will replace defective software for a period of 90 days from date
of delivery, at no charge. TekSoft, Inc. makes no other warranty, either express
or implied, including, but not limited to, any implied warranties of
merchantability or fitness for a particular purpose, regarding any product
described herein. In no event shall TekSoft, Inc. be liable to anyone for special,
collateral, incidental, or consequential damages in connection with or arising
out of the purchase or use of these products. The sole and exclusive liability of
TekSoft, Inc., regardless of form of action, shall not exceed the purchase price
of the materials described herein.
Trademarks
The following and other product names and corporate references herein are
registered or proprietary trademarks of their respective owners.
TekSoft™ is a trademark of TekSoft, Inc.
CAMWorks™ is a trademark of Geometric Software Solutions Co. Ltd.
SolidWorks® is a registered trademark and FeatureManager™ is a trademark
of SolidWorks Corporation.
Microsoft® Windows® is a registered trademark of Microsoft Corporation in
the United States and/or other countries.
All other brands and names are property of their respective owners.
Copyright ©2005 TekSoft, Inc. All Rights Reserved.

TekSoft is a subsidiary of Geometric Software Solutions Co. Ltd.

CW60g December 2005


Table of Contents
CHAPTER 1 LEARNING WIRE EDM BASICS 1-1
Wire EDM 1 .................................................................................................... 1-2
What You'll Learn...................................................................................... 1-2
Steps to Generate EDM Toolpaths and NC Code................................ 1-2
Step 1: Model Part in SolidWorks or Import Part............................... 1-2
Step 2: Change to CAMWorks Feature Tree ...................................... 1-3
Step 3: Define the Machine................................................................. 1-4
Step 4: Define the Stock...................................................................... 1-6
Step 5: Define Machinable Features ................................................... 1-7
Step 6: Generate Operation Plan/Adjust Operation Parameters ......... 1-8
Step 7: Generate Toolpaths ............................................................... 1-10
Step 8: Post Process Toolpaths.......................................................... 1-13
CHAPTER 2 LEARNING 2 AXIS CONTOUR CUTTING 2-1
2-Axis Contour 1 ............................................................................................. 2-2
What You'll Learn...................................................................................... 2-2
Extracting Machinable Features and Customizing AFR...................... 2-2
Generating a 2 Axis Contour Operation and Toolpaths....................... 2-4
Simulating and Post Processing Toolpaths .......................................... 2-5
2-Axis Contour 2 2-6
What You'll Learn 2-6
Inserting 2.5 Axis EDM Features......................................................... 2-6
Generating Operations and Toolpaths.................................................. 2-8
Changing the Machining Order and Post Processing........................... 2-9
2-Axis Contour 3 ........................................................................................... 2-10
What You'll Learn.................................................................................... 2-10
Inserting a Part Setup ......................................................................... 2-10
Inserting Vertical and Tapered Open Profile Features....................... 2-11
2 Axis Contour 4 2-14
What You'll Learn 2-14
Changing the Processing Order.......................................................... 2-14
CHAPTER 3 LEARNING 4 AXIS CONTOUR CUTTING 3-1
4-Axis Contour 1 ............................................................................................. 3-2
What You'll Learn...................................................................................... 3-2
Defining the Machine, Stock and Machining Direction ...................... 3-2
Defining a 4 Axis Die Feature Interactively ........................................ 3-3
Generating a 4 Axis Contour Operation and Toolpaths....................... 3-4
4-Axis Contour 2 3-6
What You'll Learn 3-6
Automatically Extracting Sync Curves to Define a 4 Axis Feature .... 3-6

i Table of Contents

Generating the 4 Axis Contour Operation and Toolpaths.................... 3-8
4-Axis Contour 3 ............................................................................................. 3-9
What You'll Learn...................................................................................... 3-9
Using Sketches to Define a 4 Axis EDM Feature................................ 3-9
Changing the Leadin Point................................................................. 3-11
4-Axis Contour 4 ........................................................................................... 3-12
What You'll Learn.................................................................................... 3-12
Picking Sync Curves to Define a 4 Axis EDM Feature..................... 3-12
INDEX






















ii

Chapter 1 Learning Wire EDM Basics
This chapter provides an opportunity to learn CAMWorks Wire EDM through a step-by-step
tour of the features and functions.
The exercises in this chapter are intended to show you how to use CAMWorks and may not
correspond to actual machining practices.









Learning Wire EDM Basics 1-1 Wire EDM 1

Wire EDM 1
What You'll Learn
Steps to Generate EDM Toolpaths and NC Code
The following steps are used to generate wire EDM toolpaths and NC code:
1. Model the part or open the part file in SolidWorks.
2. Change to the CAMWorks Feature tree.
3. Set the machine type and machine parameters.
4. Define the stock shape and material.
5. Define machinable features.
6. Generate the operation plan and adjust operation parameters.
7. Generate toolpaths.
8. Post process the toolpaths.

The next series of exercises show you how to generate toolpaths on a SolidWorks part
model. In order to give you a general understanding of how to use CAMWorks, you work
with a part that was previously modeled in SolidWorks. When you define the operations and
toolpaths, you will follow steps that are not explained in depth. This is done to show you the
basics of generating toolpaths from start to finish without getting into the details at this time.
Sample parts are provided for the exercises in this manual. When you install CAMWorks,
these files are installed automatically.
Step 1: Model Part in SolidWorks or Import Part
A part is a solid that is created with SolidWorks or imported into SolidWorks from another
CAD system via an IGES, Parasolid, SAT file, etc. This exercise uses an existing
SolidWorks part.
1. Open the part file EDM2AX_1.SLDPRT in the \Examples\EDM
folder inside the CAMWorks folder (e.g., \Program
Files\CAMWorksxxxx\Examples\EDM).
The FeatureManager design tree lists the features, sketches,
planes and axes in the part.
The tabs at the bottom or top are for moving between the
SolidWorks trees and the CAMWorks trees.
If the CAMWorks tabs are not visible, you can expand the size of
the tree. Position the cursor on the line that divides the tree from
the graphics area. When the cursor changes to a bar, drag the bar
to the right until the tabs display.


1-2 Learning Wire EDM Basics Wire EDM 1

Step 2: Change to CAMWorks Feature Tree
1. Click the CAMWorks Feature Tree tab.
The CAMWorks Feature tree displays.
The Machine item may indicate that a mill machine is currently selected. Step 3 on
page 1-4 explains how to change the machine to an EDM machine.


CAMWorks toolbar

CAMWorks menu Feature Tree tab

Operation Tree tab
Graphics area


CAMWorks
Feature tree



Part model





CAMWorks Machining Trees
The CAMWorks trees provide an outline view of the machining information for the model.
Initially, the CAMWorks Feature tree shows the NC Manager, Stock Manager, Machine and
Recycle Bin items. As you follow the steps to generate an NC program, this tree expands to
include Part Setups and machinable features. The tabs are for moving between the
SolidWorks trees and the CAMWorks trees.
• Stock Manager
The stock is the material from which the part will be machined. You can define the stock
as a rectangular bounding box or as an extruded sketch. You can also specify the type of
material.
• Machine
The Machine item defines the machine type that will be performed on the part (i.e., mill,
turn, mill-turn or EDM). For mill and turn machines, the tool definitions and the machine
controller (post processor) are also specified. The machines are set up in the Technology
Database.

Learning Wire EDM Basics 1-3 Wire EDM 1

• Recycle Bin
The Recycle Bin in the CAMWorks Feature tree is used to store machinable features that
you do not intend to machine.
CAMWorks Menu
1. Click CAMWorks on the SolidWorks menu bar. The CAMWorks menu lists the
CAMWorks commands. The commands are explained in the CAMWorks online Help.
2. Right click on the NC Manager in the tree. This is a shortcut menu. The right-click
shortcut menus provide access to a variety of commands.
CAMWorks Toolbar
The CAMWorks toolbar provides access to the main CAMWorks commands found on the
CAMWorks menu. Clicking a toolbar button is the same as selecting a command from the
NC Manager level, regardless of the active item in the tree.
1. Locate the CAMWorks toolbar and click the Options button.
2. In the Options dialog box, click each tab to view the options
and settings that you can change in CAMWorks.
3. Click the Help button at the bottom of the dialog box. Each tab is explained in the online
Help.
4. Click the Close button in the upper right corner of the Help window to close the window.
5. Click Cancel to close the Options dialog box.
Step 3: Define the Machine
The Machine item in the tree identifies the type of machine: mill, turn or wire EDM. The
machine type defines the machinable feature set that can be recognized automatically and
defined interactively.
The icons that display in the tree identify the current machine:
Mill Turn Mill-Turn Wire EDM
An alternative machine can be selected at any time to output different G-code programs for
alternative machine tools. If the machine type changes, then all features and operations will
be deleted.
Define the machine:
1. Right click the Machine item in the CAMWorks Feature tree.
The shortcut menu displays. Right-click shortcut menus
display commands that are appropriate for the item that is
highlighted in the tree.
2. Select Edit Definition on the shortcut menu.



1-4 Learning Wire EDM Basics Wire EDM 1

The Machine dialog box displays
the Machine tab. Milling is the
default machining type that is set
when CAMWorks is first
installed. The default machining
type is specified in the
Technology Database. Before
using CAMWorks for milling
and turning to machine your
parts, make sure you define the
machine tools available in your
facility. EDM machines are not
currently defined in the
Technology Database.
3. In the Available machines list,
highlight Wire EDM Mode–in
and click the Select button.
4. Click OK.

5. Right click Wire EDM
Mode–in in the tree and click Select Machine on the shortcut menu.
6. In the Machine Selection dialog box, select
TUTORIAL for the Make and TUTORIAL for
the Model, then click OK.
Use this selection for the exercises in this manual.
When you use CAMWorks to machine your own
parts, select your machine Make and Model from
the drop down list.

7. Right click Wire EDM Mode–in
and select Edit Settings on the shortcut menu. The EDM Settings dialog box displays.
On the Machine Setup tab, the path to the CTC Database is identified. This database has
been set up for the TUTORIAL machine. The cutting condition database sets machine-
specific parameters for
power settings, etc.
8. Click the EDM Setup
tab. This tab allows you
to set the wire diameter,
maximum taper angle,
etc.
9. Click the down arrow
next to the Wire diameter
and select 0.008.


Learning Wire EDM Basics 1-5 Wire EDM 1

10. Click the Posting tab.
The Posting page identifies the
post processor. This post
processor has been set up for
the TUTORIAL machine and
does not need to be changed.
The options on this page
provide information used to
generate the NC program,
including the processing order.
11. For the Die process order, use
By Complete Feature.
With this option, the NC
program will be generated in
the following processing order:
for each feature, cut the rough
pass, glue stop cut off, then all
skim passes.
Step 4: Define the Stock
The stock is the material from which the part will be machined. The default stock is the
smallest bounding box that the part will fit into. You can change the stock definition by
offsetting the bounding box from the part or by defining the stock from a sketch and a depth.
1. Double-click Stock
Manager in the Feature
tree. The Manage Stock
dialog box displays.
For this exercise, use the
default bounding box.
2. Click the Material
button.
3. In the Material Selection
dialog box, click the
down arrow to view the
materials. For this
exercise, use Tool Steel.
4. Click OK to close the
Material Selection dialog
box.
5.
Manage Stock dialog
box.

1-6 Learning Wire EDM Basics