click to see: how to use online documents surfcam online ... · click to see: how to use online...

Click To See: How to Use Online Documents SURFCAM Online Documents

685)&$0�5HIHUHQFH�0DQXDO

��

For a general discussion of toolpath creation and management, refer to the SURFCAM Getting Started Manual, Chapter 2: NC Project Basics, Section 2.3: Toolpath Creation and Management on page 54.

In both the 4 Axis and the 5 Axis modes, SURFCAM provides six machining operations. Since these operations are similar and since they involve almost the same set of machining parameters, both the 4 and the 5 Axis modes are described in this chapter.

CutUse the Cut operation to cut a single surface by following flow lines that define the surface. Refer to Section 4.2: Cut — 4 Axis and 5 Axis on page 264.

ProjectRefer to the SURFCAM Getting Started Manual, Chapter 4: Common NC Operations, Section 4.3: Project — For 3, 4 and 5 Axis Machining on page 110.

SwarfA Swarf cut uses the side of the tool to cut a surface. Refer to Section 4.4: Swarf on page 267.

ContourContour is a one pass operation that can be used as a swarf operation, a contour operation, or both. Refer to Section 4.5: Contour on page 274.

TrimThe Trim operation is used to trim excess material from the edge or periphery of a part. Refer to Section 4.6: Trim on page 280.

DrillRefer to the SURFCAM Getting Started Manual, Chapter 4: Common NC Operations, Section 4.2: Drill — For 2, 3, 4 and 5 Axis Machining on page 99.

Set AxisRefer to Section 4.8: Set Axis on page 283.

4

4.1 INTRODUCTION

Figure 1: NC 4 Axis and 5 Axis menu

SURFCAM Reference Manual, Chapter 4 • 4 Axis and 5 AxisCopyright © 2000 by Surfware, Inc. All Rights Reserved.

264 SURFCAM Reference Manual, Chapter 4 • 4 Axis and 5 Axis

OptionsRefer to Section 4.9: 4 And 5 Axis Options Tab on page 287.

.

The Cut operation is used to cut a single surface by following the flow lines that define the surface. Surfaces are defined by a grid of splines flowing in two directions. The splines form two sets of flow lines. The surface arrow, attached to each surface, points in the direction of one set of flow lines. It can be changed to point in the direction of the other set by using the Edit > Surfaces > Direction command.

In the Cut operation, the direction of the cut is always in the direction of the surface arrow.

If needed, the Cut operation provides the capability of cutting a small portion of the surface with a process called Tool Containment. Refer to the SURFCAM Getting Started Manual, Chapter 4: Common NC Operations, Section 4.4: Tool Containment — Cut and Swarf on page 115.

Lead TypeLead/Lag Surface

Clicking Lead/Lag makes the Lead Angle parameter available so you can enter the angle (measured between the normal to the surface and the shank of the tool) at which the tool passes over the part. It can range from -90 to 90º.

The tool is normal to the surface at 0º (the default value).

4.2 CUT — 4 AXIS AND 5 AXIS

When you click Cut, SURFCAM will prompt you to “Select a surface.”

Click a surface arrow or a point on the surface.

The 4-5 Axis Cut dialog box will then be displayed.

Figure 2: 4-5 Axis Cut dialog box

Figure 3: 4 Axis tool motion normal to the surface

Figure 4: 5 Axis tool motion normal to the surface

Copyright © 2000 by Surfware, Inc. All Rights Reserved.

SURFCAM Reference Manual, Chapter 4 • 4 Axis and 5 Axis 265

You can select an angle that allows the tool shank to lead the tip across the surface. This is considered a positive lead angle. This action effectively drags the tool tip over the surface.

Note: This is usually the more desired method in 4 axis machining.

Selection of a negative angle allows the tool shank to follow the tip across the surface. This produces a pushing affect on the cutter. A negative lead angle is commonly called a lag angle.

Note: It is recommended that you not use a lag angle with standard end mills. This would require the bottom of the end mill to perform the cut, and may not produce the desired results during the cutting process.

Note: For 4 axis machines with rotary axis limits, it is recommended that cuts be made with the Retrace Type parameter set to Bidirectional so the rotary axis unwinds on each pass.

PointSelect Point to force the center of the shank to pass through a defined point. This will control the tool vector. It is only available in the cut cycle and is commonly used when there is an undercutting application where the tool must cut between surfaces or underneath another surface.

Figure 5: 4 Axis tool motion with 10º lead angle

Figure 6: 5 Axis tool motion with 10º lead angle

Figure 7: 4 Axis tool motion with -10º lead angle

Figure 8: 5 Axis tool motion with -10º lead angle



CurveThe Curve option is similar to the Point option. This method provides greater control over where the tool vector passes. It is commonly used for more complex undercutting applications where the tool must cut between surfaces or underneath another surface.

Figure 9: View:74 Axis Point Vector Control

Figure 10: View:24 Axis Point Vector Control

Figure 11: 5 Axis Point Vector Control

Figure 12: 4 Axis Curve Type Vector Control Figure 13: 5 Axis Curve Type Vector Control

Point controllingtool vector

Point controllingtool vector

Curve controllingvector

Curve controllingvector



Lead Angle Lead Angle—active when Lead Type is Lead/Lag Surface—is the value of a lead or lag angle. A lead angle occurs when the tool shaft precedes the tool tip. A lag angle occurs when the tool shaft trails the tool tip. The angle is measured from the surface normal.

After you click OK in the 4-5 Axis Cut dialog box, one of three things will happen:

1. If you selected the Lead/Lag Surface type and entered a value for the Lead Angle, the 4 Axis Cut or the 5 Axis Cut dialog box will be displayed.

2. If you selected the Point type of cut, the Select Point Menu will be displayed and you will be prompted to “Select tool axis point.” After you select the point, the 4 Axis Cut or the 5 Axis Cut dialog box will be displayed.

3. If you selected the Curve type of cut, the Select Chain menu will be displayed and you will be prompted to “Select beginning element of the tool axis curve.” After selecting the beginning element, you will be prompted to “Select ending element of the tool axis curve.” After you select the ending element, the 4 Axis Cut or 5 Axis Cut dialog box will be displayed.

Refer to

1. the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.2: Tool Information Tab on page 64,

2. the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.3: Cut Control Tab — 3, 4 and 5 Axis on page 80, and

3. Section 4.9: 4 And 5 Axis Options Tab on page 287.

After you click OK, SURFCAM will create the toolpaths and display the tool motion on the screen. The Keep Operation dialog box will then be displayed. Click Accept to keep the operation.

Note: To permanently save the toolpaths in the ICD file of your NC project, you must re-save the DSN file using the Save command on the File menu.

Refer to the SURFCAM Getting Started Manual, Chapter 4: Common NC Operations, Section 4.3: Project — For 3, 4 and 5 Axis Machining on page 110.

The Swarf operation is used to cut a single surface with the side of the tool. The tool shank is oriented parallel to the surface during the cut with the side angle having a value of zero.

4.3 PROJECT

4.4 SWARF



If needed, the Swarf operation provides the capability of cutting a small portion of the surface with a process called Tool Containment. Refer to the SURFCAM Getting Started Manual, Chapter 4: Common NC Operations, Section 4.4: Tool Containment — Cut and Swarf on page 115.

Swarf TypeRuled

This causes the shank of the tool to be oriented parallel to the flow lines of the surface being cut with no regard to the true Z.

Minimum TiltThis option is used to maintain the tool tip in the most negative Z axis orientation. The tool shaft is not allowed to be oriented in a more negative Z axis orientation than the tip.

Note: This type of cutting may cause the tool to pivot unpredictably if the part of the surface being cut is parallel to the XY plane. This occurs when the shank orientation is parallel to the XY plane. The cut may gouge the part in an attempt to maintain the tool tip in the most negative Z axis orientation.

In 4 Axis machining, the tool shank orientation is maintained by rotary axis rotation.

The tool shaft should not be driven along a surface that is concave (as measured along the shank of the tool).

With swarf cuts there are two possible ways that the tool shank can be oriented along the surface. The tool can be oriented with the tool shank shifted off centerline to either the plus or the minus side of the part.

To insure proper tool orientation for the machining process, the Tool Display should be On during the cut. To accomplish this, click Options > Display. A Tool Display Options dialog box will be displayed. Set the Draw the Tool parameter to Yes. Figure 14: Swarf Cut

If the tool is required to tilt along the axis of rotation, a 5 axis swarf cut must be used.

After you click Swarf on the menu, the prompt line will direct you to select a surface. The 4-5 Axis Swarf dialog box will then be displayed. The parameters in the box direct the cutter shank orientation during the Swarf cut.

Figure 15: 4-5 Axis�Swarf dialog box



Minimum Tilt, while available for 4 Axis Swarf, is a less desirable technique than in 5 Axis Swarf since it requires the rotary axis to rotate 180º while moving along the linear axes. This may cause the tool to gouge the surface.

Start Z Angle > 90The Start Z Angle > 90 parameter is used to direct the shank orientation at the beginning of the surface cut. This parameter is not used if the Minimum Tilt mode is used.

In 4 axis, the tool is shifted off the axis of rotation centerline. The Start Z Angle > 90 parameter determines the direction off centerline to shift. You can choose either side of centerline for the shank orientations when the swarf cutting starts.

In 5 Axis, the Start Z Angle > 90 parameter is the true angle between the tool shank and the positive Z axis. You can choose either of the two possible shank orientations when the swarf cutting starts.

Once the cutting is started the orientation of the tool shank is controlled by the shape of the surface.

No4 Axis

Choosing No will leave the tip of the tool below the shank (in Z, as depicted on the screen).

The tool is oriented to the side of the part that requires the least amount of part rotation.

Figure 16: Tool orientation to the point that the tool is parallel to the XY plane

;

Figure 17: Tool orientation change to maintain the tip in the most negative Z axis orientation



5 AxisChoosing No will leave the tip of the tool below the shank (in Z). This does not guarantee that the tool tip will always be the lowest part of the tool.

When the surface goes “over a hill” in the direction across the cuts, the tool tip will become more positive in Z axis than the rest of the tool.

Yes4 Axis

Click Yes to begin cutting with the tool shank on the opposite side of the rotary axis centerline.

5 AxisSome machines are capable of pivoting the tool so that the tip is higher in Z than the rest of the shaft. Click Yes to begin cutting with the tool tip more positive in Z axis than the shank.

Side AngleSpecify an angle for shank clearance. The side angle can also be used for an undercut.

You can also adjust for tapered tools during Swarf cutting. The tool taper angle is input for Side Angle to maintain the tool shaft parallel to the surface. A larger angle can be used when shank clearance is desired for these tools as well.

Figure 18: The tool orientation for this type of cut— The drawings are oriented with the axis of rotation along the X axis.

Figure 19: The drawings indicate the tool orientation for this type of cut.



Note: A positive angle value orients the tool shaft away from the surface. A value of 90º is normal to the surface.

Note: Side Angle is used the same way as the Lead Angle in 5 Axis Cut.

Part used for 4 Axis Swarf Examples

View: 5Rotation occurs for this

side cut along the axis of rotation.

View: 2No tool rotation is possible.

The part rotates back to zero for the cut across the axis of rotation.

View: 2No tool rotation is possible.

The tool orientation is normal to the surface. A Side Angle of zero was used.



Part rotated additional 10 degrees for the side angle

The part is rotated back to zero for this cut.

View:2.No tool rotation is possible.

The tool orientation with a positive side angle of +10º was used.

Part is rotated 10 degrees less for the side angle.

Part is rotated back to zero for this cut.

View:2.No tool rotation is possible.

The tool orientation with a negative side angle of -10º was used.

Figure 20: 4 Axis Swarf Cut Examples



After the Swarf type has been selected and the Start Z Angle > 90 and Side Angle have been identified, click OK. The 4 Axis or 5 Axis Swarf Cut dialog box will be displayed.

Refer to

1. the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.2: Tool Information Tab on page 64,

2. the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.3: Cut Control Tab — 3, 4 and 5 Axis on page 80, and


View: 2 View: 5 View: 2 View: 5

The above drawings show a Side Angle of zero.


Tool orientation with a positive side angle of +10º


Tool orientation with a negative side angle of -10º

Figure 21: 5 Axis Swarf Cut Examples



After you click OK, SURFCAM will create the toolpaths and display the tool motion on the screen. The Keep Operation dialog box will then be displayed. Click Accept to keep the operation.


Contour is a one pass operation that can be used as a swarf operation, a contour operation, or both. It is a swarf type operation when it is performed using a single surface as the guide surface. A guide surface must be associated with the spline being cut.

A guide surface must be associated with one or more other surfaces, called bottom surfaces, that are used to control the swarf cut along the tool vector. If the guide surface is not cut, it can act as a guide for a contour cut performed on the bottom surface(s). Both kinds of cuts can be performed together on the same pass.

Both cuts are also guided by a cutter intersect spline, called the contour curve, that is projected onto the guide surface. The contour curve must have been previously created. The closer it is created to the guide surface, the more accurately it can be projected onto that surface.

SURFCAM provides gouge detection and avoidance on all bottom surfaces.

The amount of material to be removed by the swarf cut on the guide surface is controlled by the Stock To Leave on Guide Surface parameter on the Cut Control tab. The amount of material to be removed by the contour cut on the bottom surface is controlled by the Stock To Leave at Bottom Surfaces parameter.

The tool orientation is dependent on the guide surface arrow side, direction, and the value for the Side Angle parameter on the Cut Control tab.

Note: In performing a Contour cut, if the tool is required to tilt along the axis of rotation, a 5 Axis Contour cut must be used.

When you click Contour on the 4 Axis or the 5 Axis menu, you will be prompted to “Please select the guide surface.” After you select a surface, you will be prompted to “Please select the bottom surfaces.” After you select one or more surfaces and click Done, the Select Chain menu will be displayed and you will be prompted to “Select beginning element of contour curve.” Select a point near one end of the cutter intersect spline you previously created as the contour curve. SURFCAM will place a small square around that end of the curve. You will then be prompted to “Select ending element of contour curve.” Click a point near the other end of the curve.

SURFCAM will display the 4 Axis or the 5 Axis Contour dialog box. For a description of Tool Information tab parameters and Options tab parameters, refer to

1. the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.2: Tool Information Tab on page 64 and to


4.5 CONTOUR



For descriptions of Cut Control parameters not in the following list, refer to the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.3: Cut Control Tab — 3, 4 and 5 Axis on page 80.

Stock To Leave on Guide SurfaceSpecify the amount of stock to leave on the guide surface.

Stock To Leave at Bottom SurfacesSpecify the amount of stock to leave on the bottom surfaces.

Side AngleSpecify an angle for shank clearance. The side angle can also be used for an undercut. You can also adjust for tapered tools during swarf cutting. The tool taper angle is input for Side Angle to maintain the tool shaft parallel to the surface. A larger angle can be used when shank clearance is desired for these tools as well.

Curve ToleranceContour moves along a spline will be broken into linear moves along a chord—between two points on the spline. When driving the tool around a spline curve, SURFCAM will adjust the length of the chordal moves to make sure that the edge of the contour is never a greater distance from the chord than the value of the Curve Tolerance.

Figure 22: 5 Axis Contour Cut Control tab



Rapid PlaneSpecify an absolute location to move to for clearance above the part surface. This should include clearance above any clamps or obstructions.

Minimum ZThis sets the most negative Z axis move allowed. The toolpath will not move below this level. The toolpath maintains this Z level along the contour until the end of the contour or a higher Z level is intersected.

After you click OK on the 4 Axis or 5 Axis Contour dialog box, SURFCAM will create the toolpaths and display the tool motion on the screen. The Keep Operation dialog box will then be displayed. Click Accept to keep the operation.


4.5.1 Four Axis Contour Examples

The tool axis perpendicular to the axis of rotation performs a swarf of the selected surface. When a side angle is entered, the part is rotated to tilt the tool away from the surface wall. It is only applied to the walls that are being swarf cut. The following drawings show the tool position that is perpendicular to the axis of rotation.

Note: SURFCAM will display the cut with the tool tilted. During the machine cut, the tool remains vertical while the axis is rotated for the swarf cutting of the tool. This also applies to the side angle cuts.

Part used for 4 Axis Contour Examples

View:5Rotation occurs for this side

cut along the axis of rotation.

View:2No tool rotation is possible.

The tool orientation is normal to the surface. A side angle of zero was used.





The part is rotated an additional 10º for the side angle.



The tool orientation with a positive side angle. A side angle of +10º was used.

The tool orientation is normal to the surface. A side angle of zero was used.



The part is rotated 10º less for the side angle.



The tool orientation with a negative side angle. A side angle of -10º was used.

Figure 23: 4 Axis Contour Examples

4.5.2 5 Axis Contour Examples

The lead angle is applied to the cutter in the plane of the normal to surface orientation. The drawings that follow indicate the tool orientation for contour cutting. These examples have the surface arrow at the top of the cone, on the outside, and directed around the surface.

Part used for 5 Axis Contour Examples



View: 2 View: 5

View: 2 View: 5

This cut is normal to the surface (zero degree side angle).

View: 2 View: 5

View: 2 View: 5

The cut is a +10º side angle cut.



The Trim operation is used to trim excess material from the edge or periphery of a part.

One application is to trim the edges of a part that has been formed from a relatively thin sheet of material by some process such as vacuum forming or stamping.

The toolpath is directed by a trimming curve that coincides with the final edge of the part. During the Trim operation the outside edge of the tool is tangent to the trimming curve. The center of the tool is offset to one side or the other of the trimming curve. This makes it possible to trim material from the edges of a hole in the interior of a part, as well as material from the outer edges. Doing both on the same part requires two separate Trim operations.

The angle between the top surface of the part and the edge that is cut by the side of the tool is determined by direction lines that you attach to the trimming curve at appropriate locations. The angle at which the direction lines intersect the surface is the angle at which the tool will cut. If a direction line is normal to the surface at a given location, the angle between the surface and the edge will be 90º. The size of the cutting angle, as the tool moves from the location of one direction line to the next, will change in a smooth transition.

Direction lines must be attached to the trimming curve at end points of elements that make up that curve. If you must put a direction line between the end points of an element (such as a spline, an arc or a line), you must use the Break 1 command on the Edit > Trim Break menu to break that element where it intersects the direction line.

View: 2 View: 5

View: 2 View: 5The cut is a –10º side angle cut.

Figure 24: 5 Axis Contour Examples

4.6 TRIM



.

To access the Trim operation, click NC > 4 Axis > Trim or NC > 5 Axis > Trim. The Select Chain menu will be displayed and you will be prompted to “Select beginning element of trimming curve.”

Complete the chaining of the trimming curve. The Trim dialog box will be displayed. For a description of Tool Information tab parameters and Options tab parameters, refer to

1. the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.2: Tool Information Tab on page 64 and to


A trimming curve Trimming curve with direction lines

Tool tangent to trimming curve Tool offset to interior of trimming curve

Trim toolpath showing tool Tool tilted by the direction line

Figure 25: Trim Curve Examples



For descriptions of Cut Control parameters not in the following list, refer to the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.3: Cut Control Tab — 3, 4 and 5 Axis on page 80.

Cutting DepthThis is the depth your tool will cut into the material.

Curve ToleranceContour moves along a spline will be broken into linear moves along a chord—between two points on the spline. When driving the tool around a spline curve, SURFCAM will adjust the length of the chordal moves to make sure that the edge of the contour is never a greater distance from the chord than the value of the Curve Tolerance.

After you click OK at the bottom of the 4 or 5 Axis Trim dialog box, the Select menu will be displayed. You will be prompted to “Select tool direction lines or vectors.” Select the vectors and click Done.

You will then be prompted to “Select offset side.” Click the appropriate side of the trimming curve.

SURFCAM will then create the trim toolpath and display the tool motion on the screen. The Keep Operation dialog box will then be displayed. Click Accept to keep the operation.

Figure 26: 4 Axis Trim Cut Control tab




Refer to the SURFCAM Getting Started Manual, Chapter 4: Common NC Operations, Section 4.2: Drill — For 2, 3, 4 and 5 Axis Machining on page 99.

Since there are significant differences as well as similarities between the operations found on the 4 axis and 5 axis menus, this section is devoted to special considerations for the two NC modes.

SURFCAM 4 Axis creates tool path files along three linear axes and one rotary axis or two linear axes and one rotary axis. The rotary axis can be located at any orientation. Typical placement of the rotary axis is along the X axis or the Y axis.

The axis of rotation can be set at any angle and in any direction in 3D space. It must be set in relation to the physical placement of the machine tool’s rotating axis. A common configuration is to have a rotary table mounted on the X positive end of the machine tool table. This requires the axis of rotation to be defined along the X axis. The first selection point is at the X negative end of the rotational axis. (This could be the center of the rotary table face.) The second selection point is at the X positive end of the rotational axis. This produces a positive motion when the rotary axis turns counterclockwise. When the points are selected in reverse order, a positive motion is a clockwise rotation.

4.7 DRILL

4.8 SET AXIS

4.8.1 NC 4 Axis Special Considerations

Part orientation in 3D space and the axis of rotation are important to 4 axis cutting. These two factors affect the rotary axis zero. The part geometry and axis of rotation must be created in relation to the physical placement of the rotary table to insure that the proper NC code and machine tool motion are created.

When performing a 4 axis cut, SURFCAM will visually display the tool moving around the geometry. The tool motion depicted is opposite the actual rotary motion created. Clockwise tool motion creates positive rotary motion. Counterclockwise tool motion creates negative rotary motion. The sign of the rotary axis motion can be overridden by the post processor.

Figure 27: Typical Vertical Milling Machine

with Rotary Table along the X Axis

4.8.1.1 Set Axis for 4 Axis



The axis of rotation can be selected with any orientation. When this command is not used, SURFCAM defaults to the axis rotation defined in the SURFCAM.INI file. When this parameter is set for the machine configuration, it is not necessary to click the Set axis command.

Note: The default axis of rotation is set in the SURFCAM.INI file with the ROT4AXIS parameter. Refer to Chapter 7: Configuration Tools, Rotary 4 axis on page 376.

Viewing the box from the right side is View:5. The front side of the box is View:2. The tool is above and perpendicular to the horizontal lines of the View:2 and View:5 sides. This indicates the Rotary axis rotation zero position.

SURFCAM can be used to index the rotary axis for positioning. The rotary axis can be positioned for each cutting view. These views can be created from part sides, fixture sides, or work offset locations. The views define the index positioning for each SURFCAM operation.

In Figure 28: Axis of Rotation, the line in the center of the face is the axis of rotation. When the end with the circle is selected first and the opposite end is selected second, the arrow indicates the direction of positive tool motion.

The arrow indicates negative tool motion if the end points of the line are selected in the opposite order.

Note: A similar drawing can be created to indicate the machine tool’s rotary axis orientation and axis of rotation. Figure 28: Axis of Rotation

4.8.1.2 Rotary Axis Zero

Setting the axis of rotation does not set the Rotary Axis Zero position. SURFCAM designates this position as normal to CView:1 in the Z plus direction.

Viewing a horizontal line from View:2 or View:5, the Rotary Axis Zero position exists when the tool is above, and perpendicular to the line with the tip pointing toward the line as in the drawing.

The tool location on the X, Y, or Z axis does not affect the Rotary Axis Zero position. The axis of rotation is identified with the line entering the right side of the box and exiting the left side.

Figure 29: The Rotary Axis Zerois at the 12 o’clock position.This drawing is in View:7.

4.8.1.3 Indexing Operations



A view to define each index must be created. After selecting the X and Y axis locations for the view, the origin is defined. This location defines the local coordinate system for that view. The origin for the standard views is at World X0, Y0, Z0. It is not required that you create views parallel to the 8 standard views when the desired origin is World X0, Y0, Z0.

Note: It is recommended that the origin be placed at the center of rotation for each view. When different origins are used, care must be taken in selecting clearance plane locations.

The following SURFCAM operations can be indexed in the 2 axis mode: Pocket, Contour, Drill, and Contour 3D. In the 3 axis mode SURFCAM operations that can be indexed are: Cut, Planar, and Contour 3D.

The part geometry must be created in 3D space around the axis of rotation. The operation must be performed in View Coordinates. In the Status bar, Coord must be set to VIEW. The CView must be set to the appropriate view for the operation.

Note: Rotary axis indexing operations are not accomplished in the 4 axis mode. The Post Processor outputs the rotary axis positioning for the 2 axis or 3 axis mode operations.

The front pocket must be cut in CView:2. The output for the front is indexed 90º prior to machining the pocket.

The drawing shows the axis of rotation along the X axis from negative to positive. This is indicated by the line through the center of the box. The arrow indicates the positive direction of tool motion for the rotary axis.

The top of the box is machined in View:1. The front of the box is machined in View:2.

With SURFCAM set to VIEW Coordinates, pocket the top in CView:1. The output for the top pocket is positioned at a rotary axis of zero.

Figure 30: Axis of Rotationalong the X Axis from Negative to Positive

Figure 31: The Tool Orientation for Indexing during the Pocket Operation



You can choose either 3 axis or 4 axis simultaneous motion. This option is selected in the NC 4 Axis Menu under Options. The Limit rotary motion parameter can be set to 3 or 4 axis. The axis number selected determines the tool motion for the 4 axis operation performed.

Selection of 3 axis simultaneous motion uses one rotary axis and two linear axes for motion. The use of 4 axis simultaneous motion provides one rotary axis and three linear axes of motion.

The selection of 4 axis simultaneous motion allows movement of all four axes during the operation. When 3 is selected, axis motion is dependent upon the axis of rotation. When the axis of rotation is on the X axis, no Y axis motion occurs. When the axis of rotation is along the Y axis, no X axis motion occurs. When the axis of rotation is not along any standard axis, all 4 axis motion can occur.

3 AxisWhen 3 axis simultaneous motion is selected the operation is performed with the tool tip pointing through the axis of rotation. The Lead angle entry, in the Lead angle dialog box, has no effect on the tool angle. The tool is always pointing through the axis of rotation.

4 AxisDuring the 4 axis simultaneous motion, the tool orientation is often normal to the surface.

To perform 5 axis cutting, SURFCAM calculates I, J, and K vectors to direct the tool shank in relation to the tool tip contact point. These vectors identify the tool shank orientation during the cutting process. You can adjust the tool shank vectors used with lead angle and side angle inputs.

The cutting procedures described in this section are all performed in the Top View.

4.8.1.4 Simultaneous Axis Motion

3 Axis Simultaneous Motion 4 Axis Simultaneous Motion

Figure 32: Tool Orientation during a Cut

4.8.2 NC 5 Axis Special Considerations



With SURFCAM you can generate NC programs in a local coordinate system. Thus you can machine different sections of the work with independent machining orientations—a necessity with most parts. SURFCAM can be used to change the machining orientation of the part by using construction views. This is accomplished by setting the CView (construction view) parameter to the number of the view that matches the machining orientation of the piece currently being cut.

The Set Axis command is used when one (or more) of the axes on the machine is rotary. It changes the output of the toolpath rapid movements to be represented by cylindrical motion rather than linear.

Before the Set Axis command can be used, the Number of Rotary Axis parameter on the 5 Axis Options tab must be set to 1. Refer to Number Of Rotary Axis (5 Axis) on page 289. The initial default value for Number Of Rotary Axis is zero. To change the default value, run the SURFCAM Config Tools program and select the SURFCAM.INI file from the Select SURFCAM Initialization File dialog box. Click the Rotary 5 axis button on the NC Options tab of the Options dialog box. (Refer to Chapter 7: Configuration Tools, Rotary 5 axis on page 376.)

If Number of Rotary Axis is 1, when you click Set Axis, the Select Point Menu will be displayed and you will be prompted to “Select first point on rotation axis.” Then you will be prompted to “Select second point on rotation axis.” After selecting a second point, you will be returned to the NC 5 Axis menu.

If Number of Rotary Axis is 0, clicking Set Axis will display a message stating “Number of Rotary Axis is zero. Press any key to continue.”

The Options command displays the NC Option dialog box which contains all the NC mode Options tabs. It provides a convenient way to view and/or edit the 4 or 5 Axis Options tabs and the tabs of the other NC modes at the same time.

4.8.2.1 Set Axis for 5 Axis

4.9 4 AND 5 AXIS OPTIONS TAB



Following are the 4 Axis and 5 Axis Options dialog boxes.

Limit Rotary Motion (4 Axis)This parameter is used to set 3 or 4 axis motion.

When 4 Axis motion is selected, one rotary axis and three linear axes are used to cut the surface. When 3 Axis motion is selected, one rotary axis and two linear axes are used dependent upon the axis of rotation. When the axis of rotation is on the X axis, no Y axis motion occurs. When the axis of rotation is along the Y axis, no X axis motion occurs. When the axis of rotation is not along any standard axis, all 4 axis motion may occur.

When 3 Axis is selected, the operation is performed with the tool tip pointing through the axis of rotation. When Swarf cutting, the Side Angle entry in the 4-5 Axis Swarf dialog box (displayed after you select a surface) has no effect on the tool angle. The tool is always pointing through the axis of rotation.

During 4 axis simultaneous motion, the tool orientation is often normal to the surface.

Figure 33: 4 Axis and 5 Axis Options dialog boxes



Number Of Rotary Axis (5 Axis)Select the number of rotary axes used for 5 axis machining. Select 0 when the machining center has no rotary axis or 1 for the first rotary axis. This parameter affects only the display of the rapid motion between cuts. It does not have any affect on the final NC code.

Feed Between ClearanceThis is the relative distance to move straight up when finished with a cutting pass before feeding to the start of the next cutting pass. This value is used when the distance between the end of one pass and the start of the next is less than the Maximum Feed Between size.

Maximum Feed BetweenWhen the move is smaller than this value, the cutter moves to the Feed Between Clearance before moving to the start of the next pass. If the move is larger than this value, the cutter moves to the Rapid Plane.

ConstantThe value entered is used for the distance of the Feed Between move.

Cutter RadiusThe value entered is multiplied by the radius of the cutter selected to determine the Feed Between distance.

Feed Between RateThis sets the speed for the Feed Between moves. This feed rate can use the Plunge, Feed, or Rapid speeds.

Lead On Feed Between3 Axis

YesThe tool path will apply any leadin type to each Feed Between move.

NoThe leadin move will be created for the first cut.

4 and 5 AxisYes

The leadin move will be performed at each Feed Between move.

NoThe leadin and leadout moves will only be at the beginning and end of the surface cut.



Change Tool Axis Vector (4 and 5 Axis)This determines when the tool axis vector is applied. The tool axis vector is the orientation of the tool shaft after the type of cut and lead angle are applied.

During XYThe tool orientation is applied during the first XY move at the beginning of the program.

At TopThe first XY move is completed. Then the tool orientation is applied.

During ZThe tool orientation is applied during the first Z axis move to the part. This is not recommended when there is no leadin move.

Figure 34: The Lead On Feed Between option is selected as Yes for this 5 Axis cut�

Figure 35: The Lead On Feed Between option is selected as No for this 5 Axis cut�

Leadout move at end of cut

Leadin move at beginning of cut

Leadin and Leadout moves for each Feed Between move

Leadout move at end of cut

Leadin move at beginning of cut

No Leadin move on Feed Between



At BottomThe orientation is applied after the Z axis move is made. The orientation is completed before the leadin move is started.

Tool Vertical For Rapid (4 and 5 Axis)Yes

The tool is positioned to vertical before any rapid move is made.

NoThe tool orientation is maintained during the rapid moves.

Rapid FrequencyThis controls how a surface containing obstructions is cut.

Per PassThe cutting tool will retract to pass over an obstruction on every cutting pass.

Per RegionAll the cutting that can be done on one side of an obstruction is done first before the cutting tool is lifted and placed on the other side of the obstruction.

Side Step ModeThis controls how the tool will move between each cut. This command applies only to the Cut feature.

Follow EdgeThis keeps the tool in contact with the material as it moves to the next cut.

DirectThis moves the tool in X, Y then Z between moves if the next cut is lower in Z or reverses the order if the next move is higher.

Figure 36: Side step mode set to Follow Edge



Write NormalThis option has a Yes/No toggle. It is used to output the I, J, K vector normal to the surface at the contact point of the tool. This is used by some machines for 3D cutter compensation. If set to Yes, SURFCAM will output the vector. If set to No, it will not.

ToolLib Gauge LengthYes

SURFCAM will enter the value for Total Height from the Tool Library in the Z Gauge Length box on the Tool Information tab.

NoZ Gauge Length will remain zero or the value you for it.

Rapid Plane ClearanceThis is the default Z level for lateral rapid moves.

Plunge ClearanceThis is the default Z level to “rapid to” before beginning the plunge move. This a value that is relative to the next depth of cut.

Sort TypeRefer to the SURFCAM Getting Started Manual, Chapter 6: 2 Axis, Sort Type on page 187.

Restore DefaultsThe Restore Defaults button is on each Options tab. It is used to return all the parameters on an Options tab to the settings they had when the current session of SURFCAM was started.

SURFCAM will display the 4 axis tool motion with the tool axis constantly changing. The actual machine motion requires the part to rotate while the tool typically remains vertical and the direction

Figure 37: Side step mode set to Direct.

4.10 GRAPHIC TOOL DISPLAY



of the tool axis remains fixed. The drawings in this section compare the way a part is displayed in SURFCAM with the way it is actually machined.

TOOL ORIENTATION AS DISPLAYED IN SURFCAM

ACTUAL TOOL ORIENTATION

This was accomplished with 4 axis cut. Actual orientation for 4 axis cut at left

This was accomplished with 4 axis swarf with the start angle set to greater than 90°.

Actual tool orientation used by the machine tool for the swarf cut at the left

This was accomplished with 4 axis Swarf with the start angle set to less than 90°.

Actual tool orientation used by the machine tool for the swarf cut at the left

Figure 38: Graphic Tool Display
