Giao trinh FeatureCAM2010

Getting Started

FeatureCAM 2010


Copyright © 1995-2009 Delcam plc. All rights reserved
Delcam plc has no control over the use made of the software described in
this manual and cannot accept responsibility for any loss or damage
howsoever caused as a result of using the software. Users are advised that
all the results from the software should be checked by a competent
person, in accordance with good quality control procedures.
The functionality and user interface in this manual is subject to change
without notice in future revisions of software.
The software described in this manual is furnished under licence
agreement and may be used or copied in accordance with the terms of
such licence.
Delcam plc grants permission for licensed users to print copies of this
manual or portions of this manual for personal use only. Schools that are
licensed to use the software may make copies of this manual or portions
of this manual for students currently registered for classes where the
software is used.
Acknowledgements
This documentation references a number of registered trademarks and
these are the property of their respective owners. For example, Microsoft
and Windows are either registered trademarks or trademarks of Microsoft
Corporation in the United States.

FeatureCAM Version: 2010 Date: 10/08/2009 11:43


Contents

Introduction

1

How this guide is organized...........................................................................1
Special features in this guide .........................................................................2
Tell us what you think ...................................................................................2

FeatureCAM overview

3

Why creating toolpaths is so fast ...................................................................4
What's new in this release..............................................................................5
Installing FeatureCAM ..................................................................................5
To install FeatureCAM ..........................................................................5
PAF Installation Instructions .................................................................7
Using a dongle .....................................................................................11
FeatureCAM maintenance releases .....................................................12
Evaluating FeatureCAM modules .......................................................13
Setting up Flex licensing .....................................................................14
Website ................................................................................................35

Using FeatureCAM

36

Starting FeatureCAM for the first time .......................................................36
Opening a part..............................................................................................39
Closing the Stock wizard .............................................................................41

Creating a simple part ..................................................................................42
Saving your work.........................................................................................44
Interface tour................................................................................................45
Title bar................................................................................................46
Menu bar ..............................................................................................46
Toolbars ...............................................................................................47
Graphics window .................................................................................56
Steps panel ...........................................................................................61
Part View panel....................................................................................75
Browser ................................................................................................77
Results window....................................................................................79
Assistance bar ......................................................................................80
Feature/Geometry Edit bar ..................................................................80

Getting Started FeatureCAM 2010

Contents • i


Status bar..............................................................................................80
Printing.........................................................................................................81
Keyboard shortcuts ......................................................................................82
Getting help..................................................................................................84

Customizing FeatureCAM

86

Managing your settings................................................................................86
Controlling wizards......................................................................................87

Setting up dynamic viewing options............................................................88
Adjusting colors ...........................................................................................89
Setting up snap and grid options..................................................................91
Customizing toolbars ...................................................................................92

Introduction to 2.5D milling

94

Creating a part file .......................................................................................94
Viewing........................................................................................................98
Toolpaths......................................................................................................99
Order of manufacturing operations........................................................... 100
Part documentation ................................................................................... 103
Controlling the automation ....................................................................... 105
NC code .................................................................................................... 106
Tool mapping ............................................................................................ 106
Changing post processors ......................................................................... 107
Saving NC code ........................................................................................ 108

Features from curves

109

Getting started........................................................................................... 110
Setting the snaps ....................................................................................... 111
Building circles ......................................................................................... 111
Drawing lines ............................................................................................ 112
Chaining a curve ....................................................................................... 114
Creating a feature from a curve ................................................................ 115

Simulating the part.................................................................................... 116
Modifying the boss feature to contour around the part ............................ 116
Changing the plunge point........................................................................ 117

Introduction to turning

120

Getting started........................................................................................... 120
Create a part file........................................................................................ 120
Making features ........................................................................................ 124
Viewing..................................................................................................... 128

ii • Contents

Getting Started FeatureCAM 2010


Toolpaths................................................................................................... 129
Ordering of operations .............................................................................. 130
Part documentation ................................................................................... 132
NC code .................................................................................................... 132
Changing post processors ......................................................................... 133
Saving NC code ........................................................................................ 133

Advanced turning and machine simulation 135
Getting started........................................................................................... 136
Setting up machine simulation.................................................................. 136
Adding a subspindle feature ..................................................................... 139
Adding a bar feed feature.......................................................................... 141

Running a subspindle simulation.............................................................. 141
Setting up the second turret ...................................................................... 142
Synchronizing operations ......................................................................... 143
Running synchronized multi-turret simulation......................................... 144

Introduction to turn/mill

145

Getting started........................................................................................... 145
Creating a turn feature .............................................................................. 146
Viewing..................................................................................................... 149
Creating a radial hole pattern on the face ................................................. 150
Engraving on the face ............................................................................... 152
Creating a pattern of wrapped slots .......................................................... 154
Simulating a turn/mill part........................................................................ 154

Creating features from 3D CAD models

156

Getting started........................................................................................... 156
Importing the CAD model ........................................................................ 157
Aligning the model ................................................................................... 159
Shading the part ........................................................................................ 161
Automatic feature recognition .................................................................. 162
Recognizing holes..................................................................................... 163
Recognizing pockets ................................................................................. 165
Creating a slot feature ............................................................................... 167
Creating a side feature .............................................................................. 168

Simulating the entire part.......................................................................... 170

Introduction to 3D milling

172

Getting started........................................................................................... 172
Creating the bottle surface ........................................................................ 175

Getting Started FeatureCAM 2010

Contents • iii


Viewing..................................................................................................... 176
Creating a surface milling feature............................................................. 178
Simulating the entire part.......................................................................... 180

Advanced 3D milling

181

Importing the part ..................................................................................... 181
Selecting toolpath strategies ..................................................................... 183
Simulating the toolpaths ........................................................................... 185
Cleaning up the fillets ............................................................................... 187
3D toolpath strategies ............................................................................... 189

Introduction to 5-axis simultaneous

194

Getting started........................................................................................... 194
Creating a surface milling feature............................................................. 195
Importing geometry .................................................................................. 198
Adding flowline operation ........................................................................ 199
Recognizing holes..................................................................................... 203
Recognizing side features ......................................................................... 204

Solid modeling basics

207

Getting started........................................................................................... 208
Creating the initial solid............................................................................ 208
Hidden line graphics ................................................................................. 212
Creating the curved lower surface ............................................................ 214
Creating constant and variable radius fillets............................................. 219
Adding thickness....................................................................................... 221
Creating a mold cavity .............................................................................. 223

Introduction to FeatureWIRE

225

Getting started........................................................................................... 225
Creating the profile ................................................................................... 226
Creating a wire EDM feature.................................................................... 228
Simulating a wire EDM toolpath .............................................................. 229
Generating NC code.................................................................................. 231

Adding a taper angle ................................................................................. 231
Creating the second profile ....................................................................... 234
Creating a 4-axis wire EDM feature ......................................................... 236
Modifying the start point .......................................................................... 238
Matching the curves.................................................................................. 239
Simulating the part.................................................................................... 241

iv • Contents

Getting Started FeatureCAM 2010


Index

243

Getting Started FeatureCAM 2010

Contents • v



Introduction
This guide is designed to quickly get you up to speed with FeatureCAM.
By the time you finish this book, you'll know enough about FeatureCAM
to use it straight away. You may also find this guide useful, if you have
upgraded FeatureCAM, and want to learn the new modules.
FeatureCAM is very easy to use, and does not require any specialist
computing knowledge. However, you need to know how to use the
mouse, the keyboard, and the Windows environment.

If you want to know more
You can find answers to using specific features, in the online help system
included with FeatureCAM.

How this guide is organized
This guide contains two distinct parts:
ƒ General overview of the FeatureCAM range, and common
functions;
ƒ Detailed step-by-step tutorials showing you how to program parts.
If you are familiar with the basic FeatureCAM features, you can skim
through the introductory pages and go straight to the relevant tutorials.
If you are new to FeatureCAM, it's best to read this guide sequentially.

Getting Started FeatureCAM 2010

Introduction • 1


Special features in this guide
Names of dialogs, menus, toolbars, and the menu options appear in
boldface.
The menu names are separated from the specific command on that menu
with a '>'. For example, a phrase 'select View > Simulation' instructs
you to open the View menu and select the Simulation option.
Any text that you have to type in a dialog or a text box appears in blue
boldface type.
Icons
This icon draws your attention to something that may not work the
way you think it should, and helps you to avoid common errors or hidden
pitfalls.

This icon is here to save your time, and shows you a more efficient
way of doing things in FeatureCAM.
This icon tells you how to avoid serious problems.

Tell us what you think
Tell us what you think of this guide. We need your opinion, and want to
know what we are doing right, and what we could do better.
Email your thoughts to
Thank you for choosing FeatureCAM!

2 • Introduction

Getting Started FeatureCAM 2010


FeatureCAM overview
FeatureCAM is a CAD/CAM software suite that automates machining
and minimizes programming times for parts on mills, lathes and wire
EDM. Unlike operations-based CAM systems, FeatureCAM generates
toolpaths based on the features of the part, and then automatically selects
appropriate tools, determines roughing and finishing passes, and
calculates feeds and speeds. The selections made can be based on the
built-in machining knowledge that Delcam supplies 'out-of-the-box' with
FeatureCAM, or from experience captured from your company, project or
individual users' preferences.
FeatureCAM includes five stand-alone modules:
ƒ FeatureMILL - 2.5D design and toolpath generation for 2- and
3-axis mills.
ƒ FeatureMILL3D - 3D surface modeling and 3-axis toolpath
generation.

ƒ FeatureTURN - 2-axis design and toolpath generation for 2axis lathes.
ƒ FeatureTURN/MILL - Supports lathes with C and Y-axis
milling capabilities.
ƒ FeatureWIRE - 2- and 4-axis wire EDM toolpath creation.
The following add-on modules are also available:
ƒ FeatureRECOGNITION - 3D surface and solid import and the
recognition of 2.5D features from solid models. Accelerates
making 2.5D and turned parts from solid models.
ƒ Solid Modeling - Solid modeling and tools for creating molds
from solid models.

Getting Started FeatureCAM 2010

FeatureCAM overview • 3


ƒ 5-Axis Positioning - Manufacture 2.5D features from 5-axis
orientations.
ƒ 5-Axis Simultaneous - Manufacture 3D features while
changing the tool axis.
ƒ Tombstone - Multiple part manufacturing for horizontal or
vertical milling machines with indexers.
ƒ Native Import Modules - Native data can be read directly
from SolidWorks, SolidWorks Assemblies, Autodesk Inventor,
SolidEdge, CATIA, Unigraphics, Pro-Engineer, and STEP files.
ƒ Machine Simulation - Modeling and simulation of a CNC
machine.
ƒ Advanced Turn/Mill - Includes support for
FeatureTURN/MILL in addition to support for B-axis (5-axis
positioning) and turret synchronization.

ƒ Network Database and Licensing - Flexible product
licensing allows sharing FeatureCAM licenses across a network.

Why creating toolpaths is so fast
FeatureCAM has the unique ability to generate toolpaths and create NC
code to run the machines with a minimum amount of user input.
Traditional CAM systems are operations-based and require you to
program every operation, one at a time, to create your part. FeatureCAM
is feature-based; this means the part is created using features that describe
that part, from simple holes to complex pockets to turned grooves.
Machinable features contain information and rules describing how and
where material removal should occur, cutting depths, whether to use
climb cutting, whether to spot drill or center drill, and preferred
machining strategies for roughing and finishing. This means that after you
import or draw the part and identify its features, FeatureCAM
automatically:
ƒ Selects the most appropriate tools and operations;
ƒ Recommends machining strategies;
ƒ Calculates speeds and feeds;
ƒ Generates toolpaths and creates the NC code.
You can customize this built-in 'intelligence' to your own style of
cutting.

4 • FeatureCAM overview

Getting Started FeatureCAM 2010


What's new in this release
If you are an existing FeatureCAM user and want to find out about new

functionality and other changes to FeatureCAM, see the What’s New
section of the FeatureCAM help file.

Installing FeatureCAM
You can install FeatureCAM from CD, or from hard disk if you have
downloaded the software from the Internet.

To install FeatureCAM
1. If you have a dongle (see page 11), attach it to your computer's
USB port or parallel printer port.
2. Insert your installation CD into your CD-ROM drive. In this
example, drive D is used. You must substitute the drive letter
where appropriate.
3. If you are installing FeatureCAM from a CD which runs
automatically, go to Step 4.
If you are installing FeatureCAM from a CD, and it does not
automatically run, select Run from the Start menu, and type:
D:\FeatureCAM.exe
If you are installing FeatureCAM from a hard disk, double-click
the file FeatureCAM.exe.
4. Click Continue to start the installation.
5. Read the information in the Welcome dialog, and click Next.
6. Read the terms of the License Agreement before installing
FeatureCAM. To accept the terms, click Yes.

Getting Started FeatureCAM 2010

FeatureCAM overview • 5

7. Choose the folder in which FeatureCAM is installed. The default
location is displayed in the Destination Folder field. You can
change the location by clicking the Browse button, and selecting a
new location in the Choose Folder dialog.

If you are upgrading an older copy of FeatureCAM, you can safely
overwrite old versions of FeatureCAM. When you are prompted
for the installation directory, use the same directory you did last
time. Your part files and customizations are preserved and can be
used with this version of FeatureCAM.
If you want to continue to run your older copy of FeatureCAM,
then install the new version in a different directory. Be aware that
your old version may not be able to read files from your new
version, but the new version is always backwards-compatible with
older versions of files.
8. Click the Next button to continue.
9. Select a program folder. This is the folder in which the
FeatureCAM program icons are created. You can:
ƒ Use a default folder shown in the Program Folders field.
ƒ Select a different folder from the Existing Folders list.
ƒ Type a new name in the Program Folders field.
10.Click the Next button to continue.
11.Review the installation settings, and click the Next button to install
FeatureCAM on your PC.

6 • FeatureCAM overview

Getting Started FeatureCAM 2010

12.In the Setup Complete dialog, click the Finish button.

PAF Installation Instructions
In order to simplify the process of upgrading your software or
installing it for the first time, these instructions were updated for
FeatureCAM 2010 (V16). If you are using an older version of the
software and have questions about fully licensing FeatureCAM,
please contact your support representative for further help or see
the section on Troubleshooting (see page 9).
1. Install the new version of FeatureCAM that either you received in
the mail or downloaded from the customer downloads area. If you
are installing Solid Plug-ins, please install them now.
2. Make sure your dongle is plugged into one of the PC's USB ports.
3. If the PC that you have installed FeatureCAM on can connect to
the Internet, please go to the Instructions for PCs with Internet
access (see page 7). If it can't, please go to the Instructions for PCs
with no Internet access (see page 8).
Instructions for PCs with Internet access
1. Open FeatureCAM. (If the New Part Document Wizard opens,
click Cancel.)
2. Select File > Evaluation Options from the menu. The
Evaluation Options dialog opens.

Getting Started FeatureCAM 2010

FeatureCAM overview • 7


3. In the Evaluation Options dialog, click the Diagnostics
button. The Dongle Diagnostics dialog opens:

4. In the Dongle Diagnostics dialog, click the Run PAFWizard
button. The PAFWizard opens.
5. In the PAFWizard, select Tools > Check for PAF updates
from the menu.
6. After your PC downloads the PAF file from our servers, you
should see the following message:

This process usually takes 10-20 seconds using a high-speed
connection.
7. Close the PAFWizard and restart FeatureCAM.
You should be in full access mode.
If the software is still in Evaluation Mode, please see the
section on troubleshooting (see page 9).

Instructions for PCs with no Internet access
Your company should have received an email from Delcam containing
your Product Authorization File (PAF).
We ship the software before sending the PAF file to you. It is very
possible that you will receive the upgrade package before you
receive the email containing the PAF file.

8 • FeatureCAM overview

Getting Started FeatureCAM 2010


If you don't have that email, please wait 72 hours before installing
the software or contacting support.
The email containing the PAF file could be sent to your supervisor,

IT department, or purchasing department depending on the email
address we have on file for your company.
If you need us to resend the PAF, or if you need us to send it to a
different email address, please contact your support representative
with your name, email address, company name, and the dongle
number that you need the PAF for.
1. Save the PAF file included in your email to the desktop on your
PC.
2. Go to Start > All Programs > FeatureCAM PAF Directory.
3. If you have any existing *.paf, *.flx, or *.lic files in this directory,
please delete them or rename them to dcam.old.
4. Drag the PAF file from the desktop into this directory.
5. Open FeatureCAM. You should be in full access mode. If the
software is still in Evaluation Mode, see the section on
troubleshooting (see page 9).
Troubleshooting PAF
Are you evaluating items that you do not have a license for?
1. Inside FeatureCAM, select File > Evaluation Options from the
menu.
You must close all files and windows in FeatureCAM before
you can access Evaluation Options.
2. Deselect any items that you don't have a license for and click
Apply.
Did you edit the PAF file in any way?
If you open the PAF file in any program other than Notepad, the file can
become corrupt. If this happens, delete the file and re-save the original
file that you received by email.
Is the PAF file being recognized?

Getting Started FeatureCAM 2010

FeatureCAM overview • 9


The file extension must be *.paf, although the name of the file may be
different. It is possible that an email program or something else has
created or hidden an extension of *.txt. You can check this by looking at
the Type of file. To do this, right-click on the PAF file and select
Properties. The file Properties dialog displays. The Type of file
should be Delcam PAF licence file or PAF file.
Is the dongle attached to the computer?
In order for FeatureCAM to function, the dongle must be attached to the
computer.
Do you have the latest Sentinel drivers installed?
1. In FeatureCAM, select File > Evaluation Options from the
menu.
The Evaluation Options dialog opens.
2. Click Diagnostics.
The Dongle Diagnostics dialog opens.
3. Check the value for Dongle. If it reads None, you must update
the Sentinel drivers.
4. Click Open Sentinel Driver directory.
The directory opens and contains the program file Sentinel
Protection Installer 7.4.0.exe.
5. Run this program.
6. Restart your computer.
Do you have more than one PAF file on your computer?
Most Delcam software reads any file with a *.paf extension, so if you
want to keep an old *.paf file, rename the extension to something other
than *.paf (such as dcam.old).

If you have followed the above instructions, and you still receive an error
stating "FeatureCAM: ", make a note of the error along with the message
and contact your FeatureCAM support representative.

10 • FeatureCAM overview

Getting Started FeatureCAM 2010


Using a dongle
A dongle is supplied with FeatureCAM for copy protection. The dongle is
a physical device that attaches to one of your computer's USB ports or the
parallel printer port. FeatureCAM checks to see if a dongle is present
before it generates NC code for your parts or before saving a file. The
dongle must remain connected for the entire time you are running
FeatureCAM.

If you have a USB dongle, install it on your computer by inserting it into
the USB port (or if you don't have USB, insert the parallel dongle into the
parallel printer port and screw in the thumbscrews).
If you are using a parallel dongle, you may have multiple devices
attached to your parallel port. Many computers have a printer attached to
that port. If you have any devices attached to the port, you need to chain
the devices in sequence and the FeatureCAM dongle should be the first in
the stack.
You must not connect multiple FeatureCAM dongles to a single
parallel port.
The dongle is a pass-through device. You can attach your dongle to the
computer and the other devices can hook up to the dongle. You may have
to experiment with the order of devices to find which sequence works

best with your devices. Printers should probably be at the end of the
device chain.
In general, try to put the FeatureCAM dongle in as the first or
second device in the sequence.

Getting Started FeatureCAM 2010

FeatureCAM overview • 11


Troubleshooting the dongle
If, when you start FeatureCAM, you see the Registration dialog with
the dongle picture, that means that either the dongle is not plugged into
the back of the computer, or that the computer is not recognizing the
dongle. Or that you do not have a PAF file installed or it is in the wrong
location.

When you close this dialog, FeatureCAM starts in evaluation mode.
To fix this problem:
1. Disconnect the dongle from the PC.
2. Download the latest release of the dongle driver from
(under Support > Downloads).
3. When the download is complete, install the software.
4. Connect the dongle to the PC.
5. Restart FeatureCAM.
If you come across any errors after following these steps, please
email or call your local FeatureCAM dealer.

FeatureCAM maintenance releases
If you have purchased and registered a FeatureCAM version, you are

allowed to install maintenance releases free of charge. A maintenance
release is any product version with the same first number as the product
you are licensed to run. For example, if you have version 2009.0.1.36, the
first number is 2009.
To check for a FeatureCAM maintenance release:
1. Make sure you are connected to the Internet, and select Help >
Check For New Version.

12 • FeatureCAM overview

Getting Started FeatureCAM 2010


2. If a newer version is available, you are given the option of updating
your version of FeatureCAM.

Evaluating FeatureCAM modules
When you are running FeatureCAM, you can evaluate other FeatureCAM
modules.
To enter evaluation mode:
1. Run FeatureCAM.
2. If the New Part Document wizard opens, click Cancel.
3. Select File > Evaluation Options from the menu.
4. In the Evaluation Options dialog, select the check boxes for the
modules you want to try.

5. Click OK.
FeatureCAM is now running in evaluation mode. You cannot save parts
or post, but you can create part models and generate toolpaths. When
FeatureCAM is in evaluation mode, the word evaluation is shown in the

Title bar.

Getting Started FeatureCAM 2010

FeatureCAM overview • 13


To exit evaluation mode:
1. Open FeatureCAM.
2. Click cancel to any dialogs that display.
3. If the New Part Document wizard opens, click Cancel.
4. Select File > Evaluation Options from the menu.
5. Deselect all Evaluate check boxes.
6. Click OK.

Setting up Flex licensing
Setting up the server
You need two files to install the flex license:
ƒ The license file (*.lic)
ƒ The server install Delcam Flex3001.msi (sent as a *.zip file)
These files are sent to you by email to the address we have on
record.
To set up the server:
1. Copy the *.lic file to the C:\dcam\config\pass directory.
If the path C:\dcam\config\pass does not exist, create the
folder structure and copy the file to there.
2. Change the license file name and extension from *.lic to dcam.flx.
3. Open dcam.flx in Notepad so that you can make changes to it.
Do not open the file in Microsoft Word or any other program
because it will become corrupt.

14 • FeatureCAM overview

Getting Started FeatureCAM 2010


The file looks similar to this one:

4. At the top of the file, you see the text SERVER flexserver. You
must change the text flexserver to be the name or IP address of
the server (the computer where the dongle will be installed).
You can find the server name by going to Control Panel >
System > Computer Name tab.
The name has been changed to FCServer in the example below:

If your computer name contains a hyphen (-), use the IP
address instead of the name.
5. Save the file.
Installing Delcam Flex3001:
1. Unzip ABC10_flex_server.zip and run Delcam
Flex3001.msi.
The Delcam Flex3001 - InstallShield Wizard opens.
Make sure the dongle is not attached.

Getting Started FeatureCAM 2010

FeatureCAM overview • 15


2. Click Next.

3. Select I accept the terms in the license agreement and click
Next.

4. Enter your Customer Information and click Next.

16 • FeatureCAM overview

Getting Started FeatureCAM 2010


5. Make sure the destination folder is correct and click Next.

6. On the Setup Type page, select Custom and click Next.

7. On the Custom Setup page, click Next.

Getting Started FeatureCAM 2010

FeatureCAM overview • 17