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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.

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Using Surfcam to Produce a Numeric Control (NC) Program

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Using surfcam to produce a numeric control nc program

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

  • The CAD/CAM process consists of the following steps:

  • The production of a drawing using a CAD program.

  • The identification of the types of cuts to be made and the sequence of the cuts (NC).

  • The Post Processing that converts the tool path sequences into G-Codes for use by the machine.

  • Making the part on the machine.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

Surfcam Instructions

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:.


Using surfcam to produce a numeric control nc program

The following settings need to be made for

converting the 2d .DXF data to Surfcam data.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

The Hole Processing dialogue box will appear.

Change Coolant to Off.

Select Select Tool.


Using surfcam to produce a numeric control nc program

Select Drill from the drill bit icons.

Scroll through the list and select the HSS drill (#151).

Select OK.


Using surfcam to produce a numeric control nc program

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.

Select OK.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

The contouring tool paths are now complete.

The next steps will produce the G-Code for the machine to run.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

The Operations Manager should now appear as shown below.


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

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.

-.55


Using surfcam to produce a numeric control nc program

Save the program at this point.

Select Toolpath Verification to inspect the program that has been created.


Using surfcam to produce a numeric control nc program

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 .


Using surfcam to produce a numeric control nc program

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) .


Using surfcam to produce a numeric control nc program

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.


Using surfcam to produce a numeric control nc program

  • At the CNC milling machine:

  • Insert the flash drive into the computer

  • open the Velocity 4CNC software

  • select File, Open NC Code

  • Select your file (NCC file extension)

  • Open the code editor.

  • Insert a line of code at the start of the program before the M3 line that reads G00 Z.3

  • Insert a line of code at the end of the program directly prior to the M5 line that reads G00 X0 Y0 Z.3

  • Exit the code editor.

  • Run an emulation

  • Verify that the tool path is accurate

  • secure your material on the mill

  • Turn on the mill

  • Zero the cutter to the material

  • Zero the software

  • Cut the material.


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