Using Surfcam to Produce a Numeric Control (NC) Program. Production of Wheel Blanks for the Wooden Toy Project An Introduction to the CAD/CAM Process Instructions for 3 Axis Programming Using the D&M CNC Milling Machine and Cyclone Router.
Using Surfcam to Produce a Numeric Control (NC) Program
Production of Wheel Blanks for the Wooden Toy Project
An Introduction to the CAD/CAM Process
Instructions for 3 Axis Programming Using the
D&M CNC Milling Machine and Cyclone Router
To produce the program for the wheel blanks for this exercise you will need to follow these general procedures:
Create a 2d drawing using SolidWorks.
Draw the wheels with a diameter greater than the wheel required (compensation for the bit diameter).
Include the material perimeter in the drawing keeping any wheel circumference at least 1/8 from the material perimeter and each other
Save the drawing as a .DXF file.
Save the .DXF file on a flash drive.
Open the file on a computer running the Surfcam software.
Follow the steps listed on the following pages.
Open Surfcam from the desktop on the laptop computer.
Insert the flash drive into the laptop.
Open the file that you need to have converted to G-code by selecting the location, file and file type.
Be sure to have
AutoCAD DXF Files(*DXF) selected as Files of type:.
The following settings need to be made for
converting the 2d .DXF data to Surfcam data.
The converted DXF data will appear as shown below.
Select Zoom Out multiple times until the axis orientation marker, the origin point and the drawing data is shown on the screen together.
You will need to delete the extraneous data that has
been placed on the diagram.
To do this, select Edit, Delete, Within and use the cursor to surround the excess lines/text. Select Cancel when finished.
The drawing data will now need to be attached to the program origin.
To move the drawing data, select; Edit, Transform & Move.
Next, select Location.
Then, select Within.
Click, drag and surround the drawing data.
Select Sketch, click on the lower left-hand corner of the
drawing data and then click directly on the origin point.
The drawing data will now be attached to the origin and the diagram will need to be resized to fit the screen. To do this select Display & Fit.
Points for indicating where holes are to be drilled will need to be located on the diagram.
To do this select Create, Point and Center.
Touch the cursor to each of the circles to produce the center points.
Select Cancel when finished.
To begin producing the tool paths:
Select NC 2-axis contour auto visible done
Center points in place.
The holes will need to be drilled first in the sequence of cuts that are to be made.
To program the drilling of the holes, select NC, 2-Axis and Drill.
Have Single highlighted and then touch off on each of the center points.
Select Done when the center points are highlighted.
The Hole Processing dialogue box will appear.
Change Coolant to Off.
Select Select Tool.
Select Drill from the drill bit icons.
Scroll through the list and select the HSS drill (#151).
Select Cycle Control and set the Hole Depth to
THE DEPTH REQUIRED BY YOUR PROJECT DESIGN.
Use .55 to drill all the way through .
Use .375 to drill of the way through the wheel blank.
The diagram will now show the Tool Path in green.
To see the depth of cut, select View and double click on Isometric view.
The view can later be changed back to a top view by selecting View and double clicking on TOP view.
The contour cutting of the wheel outline will now need to be completed.
Select NC from the menu and then, 2 Axis and Contour .
Select Single and highlight each of the circles.
Select Done when the circles are highlighted.
Choose Select Tool and set the cutter as a 2-flute, 1/4 End Mill.
Choose Select Material and set the material as Mahogany.
Set the Feed Rate at 50 and the Plunge Rate at 10.
Select Cut Control.
In the Cut Control dialogue box, set the Amount to Remove at .55
Set the Rough Spacing to 0 and .2 . Select OK twice.
The contouring tool paths are now complete.
The next steps will produce the G-Code for the machine to run.
Once you have the NC process data in place,
Save your file to the flash drive.
Exit from the Surfcam software.
Up until now you have been running the
the demonstration mode.
At this point you will need to insert the
software key so that you may continue your
work using the full capabilities of the software.
Open Surfcam again.
Open your file.
Go to the operations manager, right click on the NC project
And select regenerate all.
The Operations Manager should now appear as shown below.
The material size data will now need to be entered.
Right click on NC Project in the Operations Manager outline.
In the sub-menu that appears select Edit Setup Information.
In the Section Information dialogue box select Stock.
Corner 1 is the lower, front, left corner of the material.
Corner 2 is the top, back, right corner of the material.
Enter the data shown to the right for this project.
Be sure to indicate the Z data for Corner 1 as a negative number.
Once the data is entered, select Add and then OK.
Save the program at this point.
Select Toolpath Verification to inspect the program that has been created.
The Toolpath Verification screen will appear.
Move the speed control slider to the left (slow)and then select Play to verify the accuracy of your program. If it appears correct, exit the screen and save your program. If there are errors, see the instructor.
Exit the Toolpath Verification screen and return to the Operations Manager .
The next step will be to run the Post to create the G- code. Set the axis type and the post as shown below.
Be sure NC code is highlighted (blue).
Select Post and the contour data will be processed into NC code (G-code) .
The editNC screen will appear. The code can be edited here, but we will make any necessary changes in the Velocity 4CNC software.
Exit the screen and select Done.
Save your file.
You can now exit Surfcam.
Your NC file should be saved on the flash drive with the name of your original DXF file , but with an NCC file extension .
You are now ready to proceed to the mill to cut the plastic.