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SURFCAM DEMO TUTORIAL
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1 INTRODUCTION www.Truongalex.com

SURFCAM is a powerful and efficient CAD/CAM product that is very easy to learn. This booklet
provides some basic information on its hardware and memory requirements and its installation. It
also contains a detailed description of the SURFCAM user interface to enable you to more quickly
become familiar with operating SURFCAM.
The greater part of this booklet is devoted to the following activities that give you an overview of
some of SURFCAM’s powerful features.
1. Using SURFCAM Help on page 17
2. Create a 2D Part Design on page 23
3. Machine the Design on page 27
4. Create Dimensions on page 34
5. Create a Cross Section Surface on page 37
6. Create a Drive Curve Surface on page 39
7. Create a Fillet Surface on page 41
8. Single Surface Machining on page 45
9. Multiple Surface Machining on page 47
10. Z Rough Machining on page 51
11. Multi-Surface Planar Scallop Cutting on page 55
12. NC Operations Manager Tools on page 58
13. Challenge: Create Double Clamp Design on page 63
14. Challenge: Create Fork Bracket Design on page 70

1.1 DEMO DIFFERS FROM STANDARD VERSION OF SURFCAM

This Demo Tutorial booklet is normally accompanied by a copy of the demo version of SURFCAM,
which is used for evaluation and educational purposes. It creates, loads, and saves part files that
are neither compatible with, nor transferable to, the standard version of SURFCAM. Certain
functions have been de-activated. These include:
• Creation of files used for post processing to your machine tool.
• Output of the following types of files: DSN, CADL, IGES, VDA, FST, CSF, and DES.
Other differences between the demo version and the standard version of SURFCAM will be noted
in this tutorial as the occasion arises.

SURFCAM Demo Tutorial
Copyright © 2000 by Surfware, Inc. All Rights Reserved.

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2 SURFCAM Demo Tutorial

1.2 MANUALS AND VIDEO CLIPS www.Truongalex.com

• Online Manuals
All of the SURFCAM manuals, including this Demo Tutorial, are available on the SURFCAM CD-
ROM in portable document format (PDF). They can be viewed on your screen or printed using the
Adobe® Acrobat® Reader™. If you do not currently have this program installed, it will be installed
automatically when you install SURFCAM.
We refer to the manuals in this format as “online documents” or “online manuals.”
• Manual Cross References
Blue text in an online document signals a cross reference. Click on the blue reference to jump
immediately to the location mentioned. If you want to read this Demo Tutorial online, refer to Online
Manuals on page 20.
• Video Clips
Video clips are available on the SURFCAM CD-ROM to illustrate various features of SURFCAM.
Refer to Video Clips on page 19 for information on accessing them.
At installation of SURFCAM, you have the option to install manuals and video clips to your hard
drive.

1.3 HARDWARE/MEMORY REQUIREMENTS AND RECOMMENDATIONS

SURFCAM requires an Intel computer system with a 80486 DX microprocessor (for the 2 Axis
product) or a Pentium/Pentium Pro microprocessor (recommended for 3 Axis and above) and
Windows 95, Windows NT® 4.0, or later versions. The following are additional hardware
requirements/recommendations:
1. A fixed hard disk with at least 250 MB of storage.
2. A Windows® compatible graphics card (OpenGL recommended) and software driver.
3. A Windows® compatible pointing device (mouse) and software driver.
4. Recommended: Sound card and speakers for the video clips in the Help file.
5. RAM: Refer to Figure 1: Memory Requirement and Recommendations. www.Truongalex.com
RAM

APPLICATION MINIMUM RECOMMENDED

Design and 2 Axis machining 32MB 64MB
3-5 Axis single and multiple surface
64MB 128MB
machining on up to 750 surfaces
3-5 Axis multiple surface
128MB 256MB
machining on more than 750 surfaces
Swap file size should be a minimum of three times memory (RAM) size
Figure 1: Memory Requirement and Recommendations

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 3

1.4 SURFCAM INSTALLATION www.Truongalex.com
To install SURFCAM, insert the CD-ROM into your drive. Click Start, then Run. The Run dialog
box will be displayed. Type D:\SETUP.EXE or click Browse to search for the file. (If D is not your
CD-ROM drive, type the appropriate letter.) Click OK.
The installation program will begin. The Installation Wizard will guide you through the process.

At the bottom right corner of the screen is the Exit button. Click it to exit from the
installation program at any time.
The following is a partial list of the information you will need to supply during installation:
1. When you are asked which installation type you prefer, choose Full Installation.
2. The drive and the directory for your installation of SURFCAM.
3. Since this is the Demo version of SURFCAM, when you are given the choice to install a
licensed copy or a demonstration version of SURFCAM, you should choose the
demonstration version.
However, even if you choose to install the licensed copy, you will only be able to use the
features from the demonstration version. Refer to Section 1.1: Demo Differs from Standard Version
of SURFCAM on page 1.
4. By default, the Online Help Videos and the Online Manuals will be stored on your hard drive
in locations you indicate. The amount of space needed will be displayed on the screen. You
can choose to access them from the CD-ROM, instead of installing them on your hard drive.
5. The folder for your program files.
When the setup is complete, you may need to restart your system.

1.5 OPERATING INTERFACE www.Truongalex.com

Interact with SURFCAM through the computer’s display screen using the keyboard, the mouse, or
another input device. By entering information into dialog boxes, you guide SURFCAM in its
operations.
This section will help you become familiar with some of the tools that you will use throughout a
SURFCAM session. Some portions may not be too clear at first glance, but come back to this
section and use it as a reference as you become more familiar with SURFCAM.
• Run SURFCAM
Click Start, then navigate to Programs, then to SURFCAM 2000.1 Demo, then to
SURFCAM 2000.1 GL OFF (or ON if you have an OpenGl card installed). Then click
the left mouse button.

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4 SURFCAM Demo Tutorial

1.5.1 Display Screen www.Truongalex.com

1. Windows Control Menu 2. Windows Title Bar 3. Windows Minimize/
Maximize/Close Buttons

4. Main Menu bar 5. Toolbar 6. Status bar

7. Secondary Menu bar

8. Customize Toolbars — Right Click on any toolbar.

9. Workspace 10. SURFCAM pointer

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11. CView Indicator 14. Pointer 15. OpenGL
12. View Indicator Coordinates Status
13. Prompt Line

Figure 2: SURFCAM Screen

1. Windows Control Menu
Click the SURFCAM icon at the upper left corner of the screen for the standard
Windows® operations: Restore, Move, Size, Minimize, Maximize, or Close.

2. Windows Title Bar www.Truongalex.com
This displays the SURFCAM icon (which acts as the Windows® Control Menu), the name
SURFCAM 2000.1, and the name and path of the current file if one has been loaded.
3. Windows Minimize / Maximize / Close Buttons
When the minimize button is clicked, the SURFCAM window—not the
application—will be closed. The maximize button is used to open the window
to a full screen display. Click the button on the right to exit.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 5

4. Main Menu Bar
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Figure 3: Main Menu bar

MENU FUNCTION
FILE Manage files.
CREATE Create new 2D and 3D objects.
EDIT Edit existing objects.
DISPLAY Adjust the way objects are displayed on the screen.
NC Create the toolpaths that NC machines will use to cut the parts drawn.
ANALYZE Determine the size, location, and type of the objects on the screen.
OPTIONS Set various SURFCAM feature parameters.
HELP View help, status, version.
5. Toolbar
The SURFCAM Toolbar contains buttons used for file management, screen display, and the
Operations Manager. Refer to Section 1.5.2: SURFCAM Toolbar on page 6.
6. Status Bar
The Status bar, directly below the Toolbar, displays the status of the parameters SURFCAM
is currently using for construction of geometric objects. Click a Status command to quickly
change its setting. Refer to Section 1.5.3: Status Bar on page 11.
7. Secondary Menu Bar
Many commands on drop-down menus lead to the display of submenus or a Secondary
menu bar. Generally, the commands will be displayed at the beginning of the Secondary
menu bar, separated by the “>” symbol.

Figure 4: Sample Secondary Menu bar

Use the Next and Previous buttons to view all of the commands.

8. Customize Display www.Truongalex.com
Customize the display of the commands on the Toolbar, Status Bar,
and the Secondary Menu Bar by right-clicking on any of these bars
to display a dialog box.
You can change the size of the icons on all three bars. You can
display Secondary Menu Bar and Status bar commands without
text. You can re-arrange any one of these three bars. Figure 5: Customize
Commands
9. Workspace
The workspace occupies the largest portion of the screen. Use this window to create, edit,
and analyze geometry and toolpaths. The background color can be changed.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
6 SURFCAM Demo Tutorial

10. SURFCAM Pointer www.Truongalex.com
The SURFCAM mouse pointer will be one of the following six types: crosshair, arrow, hour
glass, I-beam, hand, or pencil.
11. CView Indicator
The CView Indicator (Construction View) displays the X, Y, and Z axes relative to the current
CView. You have the option of displaying or not displaying this set of axes. Refer to CView
Indicator / Background Color on page 25.
12. View Indicator
The View Indicator, located in the lower left corner of the workspace, is the XYZ world
coordinate indicator. As the image in the workspace is rotated, the axes display changes its
orientation to indicate the directions of the X, Y, and Z axes relative to the image. The axes
will change color as they switch from pointing toward you to pointing away from you.
13. Prompt Line
The prompt line, at the bottom of the screen, displays instructions or additional information
about commands, entering data, selecting elements, or locating positions. This is where
SURFCAM will prompt you for actions and will display critical information.
14. Pointer Coordinates
The XYZ coordinates of the current location of the crosshair pointer are displayed and
continuously updated.
15. OpenGL Status
This will say ON or OFF depending on your choice for using an OpenGL card.

1.5.2 SURFCAM Toolbar www.Truongalex.com
• File Buttons
The first three buttons are the New, Open, and Save file
Figure 6: File commands. These are standard Windows® operations.
Use the shortcut, Ctrl + S, to save the file.
• Display Buttons
These eight buttons control the display of objects on the
Figure 7: Display screen. For examples, refer to Practice with Display Buttons
(p. 7).

• Delete Button
Click this button to display the Delete menu.
Figure 8: Delete
This accomplishes the same thing as clicking Edit >
Shortcut: Ctrl + D Delete.

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Copyright © 2000 by Surfware, Inc. All Rights Reserved.
www.Truongalex.com SURFCAM Demo Tutorial 7

• Transform Button
Click this button to display the Transform menu.
Figure 9: Transform
This accomplishes the same thing as clicking Edit >
Transform.

• Operations Manager Button
Click the last button to display the dialog box for the NC
Figure 10: Operations Manager Operations Manager. This is a utility that helps you
manage a numerical control machining project.
For some aspects of the Operations Manager, refer to
www.Truongalex.com Section 2.10.3: Step 3 – Use the NC Operations Manager on page
54 and to Section 2.12: NC Operations Manager Tools on page
58.
• Practice with Display Buttons
In order to practice with the eight display buttons, you must have a part on the screen.

1. Open an existing file.
(Click the Open button on the Toolbar, or click File on the Main
menu bar and click Open.)
2. The Open dialog box will be displayed. Double-click the
Samples folder if it is not already open.
Figure 11: Valve.dsn
3. Type the name Valve.dsn in the File name box, or scroll through in Top View
the list and click the name.
4. Click Open to load the file.
5. Change to Isometric View.
If you are looking at the image from the Top View, it is difficult to
see the design shape. Use the shortcut keys—Ctrl + 7—to
change to Isometric View. Figure 12: Valve.dsn
in Isometric View

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Copyright © 2000 by Surfware, Inc. All Rights Reserved.
8 SURFCAM Demo Tutorial www.Truongalex.com

For the purpose of practicing with this example, the order of the toolbar buttons shown below
is not the same as the order on the toolbar.

Shrink the graphic image by half the current screen scale.
1. 1. Click the Zoom Out button.
Figure 13: www.Truongalex.com
Zoom Out
Ctrl + U

Before Zoom Out (Unzoom) After Zoom Out (Unzoom)

Use a “rubber-band” box to expand the graphic image to a defined region.
2. 1. Click the Zoom In button.
Figure 14: 2. Move the pointer to a point above and to the left of the element(s) you
Zoom In want to enlarge, and press the left mouse button. SURFCAM will anchor
Ctrl + Z one corner of a “rubber-band” box at the point you select.
3. Drag the mouse to a point diagonally opposite the first point until all
elements to zoom are entirely within the “rubber-band” box. The “rubber-
band” box stretches in the direction the mouse is moved.

4. Press the left mouse button. SURFCAM enlarges the image so that the
area that was inside the “rubber-band” box now occupies the entire
display window.
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Before Zoom In (Zoom) After Zoom In (Zoom)

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SURFCAM Demo Tutorial 9

Fit the graphic image to the screen viewing area.
3.
Figure 15:
Fit
Ctrl + F

Before Fit After Fit

Slide the graphic image using either mouse button. This command uses the
current screen scale.
4.
Figure 16: 1. Click the Zoom Out button to shrink the image.
Pan 2. Click the Pan button. www.Truongalex.com
Ctrl + P 3. Press and hold a mouse button while moving the mouse. SURFCAM
pans the workspace to center a different portion of the image in the
window.

Before Pan After Pan

Dynamic Rotation: Change the viewing angle of the graphic display by
5. pressing either mouse button and moving the mouse around the screen.
Figure 17: 1. First click the Fit button. Then click the Rotate button.
Rotate 2. Hold down the mouse button and move the mouse. SURFCAM will rotate
Ctrl + R the image in the workspace and simultaneously rotate the axes display to
show you the new axes orientation.
3. Press Ctrl + 7 to return to the full Isometric View.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
10 SURFCAM Demo Tutorial www.Truongalex.com

Before Rotate After Rotate

Display up to the 20 most recent screen displays. This includes view changes,
6. as well as any display command.
Figure 18: 1. Click the Last View button. The Next View command can be used to
Last View reverse this if you click Last View too many times. SURFCAM will display
the most recent previous view.
2. Repeat step 1 to show up to 20 previous views.

Before Last View After Last View

Display the previous 20 screen displays in the reverse order of Last view.
7. 1. Click the Next View button. The Last View command can be used to
Figure 19: reverse this if you click Next View too many times. SURFCAM will display
Next View the most recent previous view.
2. Repeat step 1 to show up to 20 next views.

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Before Next View After Next View

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www.Truongalex.com SURFCAM Demo Tutorial 11

Refresh the graphic viewing area. This is useful after deleting elements. The
8. Repaint command will display all active elements for the visible layers.
Figure 20:
Repaint
Ctrl + Q

Before Repaint (Redraw) After Repaint (Redraw)

1.5.3 Status Bar
The Status bar, directly below the Toolbar, displays the status of the parameters SURFCAM
is currently using for construction of geometric objects. Click a Status bar button to quickly
change its setting.
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The box shows the color currently used to draw elements. The identifying
number of the color is also indicated.
Color
Ctrl + O To change the color for new entities, click the Color button. A dialog box
containing 16 colored squares will be displayed. Click a color. The box will
disappear and the new color and its number will be displayed. The colors
are numbered from zero (black) to 15 (white).

This is the number of the view or “display view” from which you are
currently observing a drawing. View represents your line of vision when
View you observe the drawing.
Ctrl + V
There are eight predefined views. Use the shortcut keys to set the current
view to be one of these eight standard views: Ctrl + 1 through Ctrl + 8.
Another option is to click the View button to display the Views dialog box.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
12 SURFCAM Demo Tutorial

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Figure 21: Views dialog box
Press the <F1> key for context-sensitive help.

This is the number of the “construction view” or CView currently used to
create elements. There are eight predefined views.
CView
Ctrl + C Click the CView button to display the Views dialog box.

This is the number of the layer currently being used to store elements as
they are created.
Layer
Ctrl + L When you click the Layer button, the Layers dialog box will be displayed
showing the names, numbers, visibility status and selectability status of
the current layers. Various tasks related to layers can be accomplished
with this dialog box, including creating new layers.

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Figure 22: Layers dialog box
Press the <F1> key for context-sensitive help.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 13

Click the Shade button to toggle the shading of surfaces between ON and
OFF.
Shade
Ctrl + A www.Truongalex.com

The Coord parameter indicates whether coordinate locations are World
or View coordinates. Its setting determines whether the World or the
Coord Construction View dialog box will be displayed when you need to enter
the coordinates of a point.
World coordinates are the X, Y, and Z axes as defined in 3D space. World
coordinates are similar to absolute coordinates on an NC machine. They
are always measured from the origin (X0 Y0 Z0) point.
View coordinates use the construction view. Using View coordinates
gives you the option to measure from the origin as it is seen from a
particular view.
Click the Coord button to toggle between the two settings.

If ON is displayed, the masking command is operating. That is, some
elements are masked from being selected. If OFF is displayed, elements
Mask are NOT being masked. All elements are selectable.
Ctrl + Alt + M * Click the mask button to toggle between the two settings.
toggles Click the arrow to display the Mask Selection Settings dialog box.
Masking
ON and OFF. *Note: If no element or color has been selected for masking, when you
press the hot key combination, Ctrl + Alt + M, the Mask Selection Settings
dialog box will be displayed.

Ctrl + M
displays the
Mask Selection
Settings
dialog box.

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Figure 23: Mask Selection Settings
Press the <F1> key for context-sensitive help.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
14 SURFCAM Demo Tutorial

The Depth parameter tells SURFCAM the Z coordinate of entities created
using the Sketch command on the Select Point menu.
Depth
To change the depth value, click the Depth button. The Depth dialog box
will be displayed.

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Figure 24: Depth dialog box
Press the <F1> key for context-sensitive help.

The Scale parameter indicates the scale factor of the image—the larger
the number, the greater the magnification.
Scale
To change the setting, click the Scale button. The Display Scale dialog
box will be displayed for you to enter a value. After you click OK, the
screen will be redrawn accordingly.

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Figure 25: Display Scale dialog box

1.5.4 Hot Keys
When two keys are indicated in the following tables, they should be pressed simultaneously
(or press the first key, hold it down, and press the second key).

KEY HOT KEY FUNCTION

F1 Display Context-Sensitive Online Help.
ALT + F4 Exit SURFCAM.
ALT + TAB Switch between applications.
Figure 26: Hot Keys (Shortcuts)

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SURFCAM Demo Tutorial 15

KEY HOT KEY FUNCTION

ARROWS If you click Rotate on the Display menu or the Display menu bar—not the
toolbar—then continue to press an arrow key, SURFCAM will rotate the
image in 5º increments around the vertical axis or the horizontal axis.
If you click Pan on the Display menu or the Display menu bar—not the
toolbar—then continue to press an arrow key, SURFCAM will continue to
slide the image in the direction of the arrow.
In a dialog box, use the arrows to move the cursor one character in the
indicated direction.
BACKSPACE Display the previous menu.
In a dialog box, press the backspace key to delete the character to the left
of the cursor.
CTRL + 1 . . . Set the current view to be one of the eight standard views. Refer to Figure
CTRL + 8 21: Views dialog box on page 12.

CTRL + ESC Display the Start dialog box.
CTRL + A Shade the visible surfaces. To toggle ON/OFF, press Ctrl + A once again.
CTRL + B Display the User Application menu.
CTRL + C Display the CView dialog box.
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CTRL + D Display the Delete menu.
CTRL + F Fit the geometry to the screen.
CTRL + L Display the Layers dialog box.
CTRL + M Display the Mask Selection Settings dialog box.
CTRL + ALT + M Toggle Masking ON and OFF.
Note: If no element or color has been selected for masking, the Mask
Selection Settings dialog box will be displayed.
CTRL + N Display the NC Operations Manager dialog box.
CTRL + O Display the Color Selection bar. www.Truongalex.com
CTRL + P Enable the Pan function (same as clicking toolbar button).
CTRL + Q Automatically Repaint the current image.
CTRL + R Enable the Rotate function (same as clicking toolbar button).
CTRL + U Automatically scale the view by 1/2.
CTRL + V Display the Views dialog box.
Figure 26: Hot Keys (Shortcuts) (Continued)

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16 SURFCAM Demo Tutorial

KEY HOT KEY FUNCTION

CTRL + Z Enable the Zoom In function. www.Truongalex.com
ENTER Accept information entered in a dialog box.
ESC Cancel the current dialog box and display any previous one, or escape the
current menu and display the Main menu bar.
KEYPAD + OR - If you click Rotate on the Display menu or the Display menu bar—not the
toolbar— then continue to press the + or - keys, SURFCAM will rotate in 5º
increments around Z axis.
SHIFT + TAB Move the pointer one field backward in a dialog box.
TAB Move the pointer one field forward in a dialog box.
Figure 26: Hot Keys (Shortcuts) (Continued)
The following table lists Hot Keys that are applicable when SURFCAM is drawing a toolpath
and the tool is being displayed. Refer to this in activities which draw toolpaths.

KEY FUNCTION

TAB 1st press of tab key:
Display the tool holder holding the tool.
2nd press of tab key:
Turn off the display of the tool and the holder. (The toolpath will be
drawn most quickly when neither the tool nor the holder is visible.)
3rd press of tab key:
Turn on the display of the tool only. www.Truongalex.com

NUMBER KEYS Zero through 9:
Change speed of the moving tool—0 is fastest, 9 slowest.
ENTER KEY Toggle between starting and stopping the tool motion if tool is visible.
SPACE BAR Move tool one step at a time after the tool motion has been stopped.
Figure 27: Shortcut Keys used when SURFCAM is drawing a toolpath

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 17

2 ACTIVITIES

2.1 USING SURFCAM HELP www.Truongalex.com

SURFCAM Help contains topic descriptions displayed in special Help windows. By clicking “hot
spots” you can jump to other windows or display pop-up windows.
Use the Table of Contents to access video clips and the online manuals. Use the Index to search
for specific information.
Whether you use help as a quick reference or for context-sensitive help, press <Esc> to exit.

2.1.1 Help as a Reference

To use Help as a quick reference, browse through the Table of
Contents or the Index looking for topics of interest to study.
1. To access the Help file, click Help on the Main menu bar.
2. Click Contents on the drop-down menu that appears. Figure 28: Help Menu
3. The following SURFCAM Help File window will be displayed.
Buttons: Help Topics, Back, Print, Browse, and Main Contents and Index

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Contents and
Index Tabs

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Figure 29: SURFCAM Help Window

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18 SURFCAM Demo Tutorial www.Truongalex.com

The right side of the screen gives some information about efficient use of the Help file.

Click the Help Topics button to toggle between viewing the help
window by itself and viewing a two-paned screen showing the help
window with either the Index or the Table of Contents.

If the Back button is available, click it to view the previous screen.

Click the Contents tab to show the Help File Table of Contents.

Click the Index tab to see the Help File Index.

Several files make up the SURFCAM help file. Click the Main
Contents and Index button if you are not able to find an item in the
current help file.

Throughout the Help File, move the mouse around the screen. If a
hand or an arrow appears over a graphic or over words, click the
mouse for more information.

More than 40 Video Clips are currently available as supplements
to various SURFCAM Help Topics. In a Help Topic, click a Video
Clip button to play the clip.
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The Help window’s topic area can contain hot spots that point to additional Help
windows. When the pointer passes over a hot spot, a picture of a hand or an arrow will
appear on the screen.
Some hot spots will be graphics. Other hot spots will be green colored words that are
underlined.
When you click on a hot spot, SURFCAM will jump to another Help window or will
display a pop-up window containing information.

2.1.1.1 Table of Contents www.Truongalex.com

On the left side of the screen in Figure 29: SURFCAM Help Window there is a list of
topics, many preceded by a book icon. These are the major content areas into
which the Help file is currently organized. Double-click a book icon to “open” it to
its pages.
Pages of books have page icons. Click a page icon to jump to the page
containing information on the topic indicated.
• Example
1. Double-click the book Tour of SURFCAM Menus to “open” it.
2. Then click the page SURFCAM 2000.1 Menus. SURFCAM’s Main menu bar will
be displayed.
3. Move the pointer to the green, underlined words to see a hand appear.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
www.Truongalex.com SURFCAM Demo Tutorial 19

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Figure 30: Tour of SURFCAM Menus
From the Help File display of SURFCAM’s Main menu bar, you can navigate through
various other menus and dialog boxes.
• Video Clips
A video clip is a screen capture of someone performing a series of steps in SURFCAM.
If your computer has a sound card and speakers, you can listen to these descriptions
as well as observe the steps being performed.
During installation of SURFCAM you had the opportunity to install the videos onto your
hard drive. If you chose not do so, you will need to use your CD-ROM to access them.
There are two common methods to
access a video clip:
1. Choose a video clip from the Table
of Contents.
www.Truongalex.com Double-click Video Clips. The book
will open. You can choose:
A. A list of all video clips.
B. A video showing the Smart
Cursor.
C. A list containing more books. Figure 31: Portion of the Table of Contents

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
20 SURFCAM Demo Tutorial
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Continue to open books and look through pages until you see the page with the
video clip you want to view. Then click on the page.
2. Click a video-clip button in a Help window.
Following is an example showing how to select a video clip from a Help window.
A. In the Help Contents, double-click the book Tour of SURFCAM Menus.
B. Click the page SURFCAM 2000.1 Menus. SURFCAM’s Main menu bar will be
displayed.
C. Click the Edit hot spot. The Edit Menu will be displayed.
D. Scroll down to the Transform hot spot. Click it to display the Transform Menu.

E. Move the pointer to the Rotate button. In this case, when the pointer changes
to an arrow, the pointer will be on the video clip hot spot. In some cases in the
Help file, the arrow pointer will indicate a jump to the online manual. The
context of the Help file will make it clear which type of hot spot is available.
F. Click the Rotate button to run the video clip showing how to perform a rotation.
When the video clip is finished, you will be returned to the Help window.

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Figure 32: Click the Rotate button on the Transform Help Window
• Online Manuals
All of the SURFCAM manuals are available on the SURFCAM CD-ROM in portable
document format (PDF). They can be viewed on your screen or printed using the
Adobe® Acrobat® Reader™. If you did not have this program installed, it was
automatically installed when you installed SURFCAM.
We refer to the manuals in this format as “online documents” or “online manuals.”

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
www.Truongalex.com
SURFCAM Demo Tutorial 21

The Help file offers one way to access these
online manuals. During installation of SURFCAM
you had the opportunity to install the manuals
onto your hard drive. If you chose not do so, you
will need to use your CD-ROM to access them.
Look again at the Table of Contents for the Help
file. That portion of the Help Window is shown in
Figure 33: Help File Table of Contents.
If you double-click Online Manuals on the Table
of Contents, the “book” will open and you will see
a list containing more books. Either open the
Master Table of Contents or continue to open
books and look through pages until you see the
page with the information you want to view. Then
click on that page. Choose the Demo if you want
to continue reading this tutorial as an online Figure 33: Help File Table of Contents
document.

2.1.1.2 Index
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To use the Help file index, click the Index tab on the upper left of the
SURFCAM Help window to display the index. Refer to Figure 29: SURFCAM
Help Window on page 17.
Type a word in the box above the index and click on the word in the index list, or just
click on any item in the index to display the screen with corresponding information. In
Figure 34: SURFCAM Help Window showing the Index on the left panel on page 22, Hot Keys was
clicked.
You can continue to choose index items and see the appropriate window displayed.
Note: Several files make up the SURFCAM help file. Click the
“Main Contents and Index” button if you are not able to
find an item in the current help file.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
22 SURFCAM Demo Tutorial www.Truongalex.com

www.Truongalex.com

Figure 34: SURFCAM Help Window showing the Index on the left panel

2.1.2 Context-Sensitive Help www.Truongalex.com
When you use Help as a context-sensitive reference, you will usually be in the middle of a
SURFCAM project and want to know about a feature that is currently displayed on the
screen.
To access Help in a context-sensitive mode, press the <F1> key on your keyboard
when the SURFCAM feature is visible on the screen.

Once the Help file is open, you can use all of the features discussed in Section 2.1.1: Help as a
Reference on page 17.
Press <Esc> to exit Help.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 23

2.2 CREATE A 2D PART DESIGN

Create the 2D part design shown in Figure 35: 2D Part.
• Clear the Screen
1. If you have an existing geometry on the screen,
clear the work space by clicking the New button.
2. If you have not saved your data, SURFCAM will alert you and give you Figure 35: 2D Part
the opportunity to save it. In the Demo version of SURFCAM, any file
you save will be saved with a DEM extension, rather than a DSN
extension.

2.2.1 Step 1 – Select a Construction View www.Truongalex.com

SURFCAM is a true three dimensional design environment and it is necessary to select the
correct construction view (CView) before you begin to create geometry.
A Top View, much like a plan view in a drawing, must be defined for this activity.

Figure 36: Status Bar
1. Click CView:0 on the Status bar.
2. The Views dialog box will be displayed.
The eight predefined views (plus any special views that were created for the current
drawing) will be listed.

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Figure 37: Views dialog box
Double-click Top View, or type 1 in the box next to CView and click OK.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
24 SURFCAM Demo Tutorial

3. You can also select a working color from the Status bar. Click color, then click a color
on the chart that will be displayed. Every item drawn from this point on will be in the
color you chose.

2.2.2 Step 2 – Create the Geometry
• Create a Rectangle
1. Click Create on the Main menu bar.

2. Click Line on the Create menu.

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3. Click Rectangle on the Create > Line menu (on the Secondary menu bar).

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Figure 38: Create > Line > Rectangle
Note The shortcut format that is used throughout the tutorial for steps 1, 2, and 3 is
“Click Create > Line > Rectangle.”
4. The Create Line Rectangle dialog box will be
displayed. Click OK to accept the default:
Select Two Corner Points.
5. The Select Point menu will be displayed. Click
Keyboard.

Figure 39: Create Line Rectangle dialog box

Figure 40: Select Point > Keyboard

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 25

6. SURFCAM will display the World dialog box.
In this activity, define the lower left corner
first: X = 0, Y = 0, Z = 0. Then click OK.
7. The Select Point menu will still be displayed
on the screen. Click Keyboard again.
8. The World dialog box will again be displayed. www.Truongalex.com
This time define the upper right corner:
X = 7, Y = 5, Z = 0. Then click OK. Figure 41: World dialog box

9. Click the Fit button on the toolbar to fit the geometry
into the workspace.
Your screen should look like the image in Figure 42: Rectangle.

CView Indicator / Background Color Figure 42: Rectangle
You can toggle the display of the CView Indicator—the smaller of the two displayed
coordinate systems, and you can change the background color of the workspace.
Click Options > Display. Modify the Show CView Indicator and the Color Scheme fields
of the Display Options dialog box. Refer to Figure 132: Display Options dialog box on page 59.
• Create a Circle www.Truongalex.com
Next, create a circle with its center on the lower left corner of the rectangle.
1. Click Create on the Main menu bar.

2. Click Circle on the Create menu.

3. Click Center/Diameter on the Create > Circle menu.

Figure 43: Create > Circle > Center/Diameter

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
26 SURFCAM Demo Tutorial

4. A Create Circle dialog box will be
displayed.
Type 7 for the diameter and click OK.
5. In the prompt line at the bottom of the
workspace, SURFCAM will display: www.Truongalex.com
“Creating an arc, select the center
point.” Figure 44: Create Circle dialog box

The Select Point menu will be displayed. Click Keyboard to
display the World dialog box.
6. Define the coordinates of the center:
X = 0, Y = 0, Z = 0.
www.Truongalex.com
Then click OK.
Your screen should look like Figure 45: Arc on Rectangle.

Figure 45: Arc on Rectangle

2.2.3 Step 3 – Edit the Geometry
The design requires fillets at every corner.
1. Click Create > Fillet.
2. The prompt line will display the current radius: “Radius: 0.5000.” If it is not .5, click
Change Radius; enter a radius value of .5; and click OK.
3. You need to select two intersecting entities for SURFCAM to create a fillet. In this
activity the entities are either two lines or one line and either a circle or an arc.
Click on each pair of intersecting entities—on the side that
you want to retain in your design. (You will have five pairs.)
If you make a mistake, you can select Undo or Other. Other
will provide multiple solutions and you can continue without
starting from scratch.
Figure 46: Click on pairs of intersecting entities gives an example
indicating one pair of entities to select to create a fillet.
Figure 46: Click on pairs
of intersecting entities
After you have selected the five pairs of entities, your screen
should look like Figure 47: The 2D Part.

Figure 47: The 2D Part

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 27

2.2.4 Step 4 – Save the File
www.Truongalex.com
1. Click the Save button
on the toolbar.
(Or click File > Save.)
2. The Save As dialog box will
be displayed since you
have not yet saved this file.
If the Samples folder is not
open, double-click on it to
open it.
In the File name box, enter
PART1 and click Save.

Figure 48: Save As dialog box
Then click Yes in the NCPOST dialog box that will be displayed.
In the Demo version of SURFCAM, any file you save will be saved with a DEM
extension, rather than a DSN extension. (Even if you type a DSN extension, when you
open the file again, you will see that the extension is DEM.)
Note that if you attempt to overwrite a DSN file, the Demo version of SURFCAM will
save your file with a DEM extension instead of overwriting the DSN file.

2.3 MACHINE THE DESIGN www.Truongalex.com

Follow the steps below to machine the 2D part you designed in the previous activity. In this activity
you will create a toolpath that will remove the interior of the part.

2.3.1 Step 1 – Load an Existing Design

If the design in Figure 47: The 2D Part is still on your screen, skip to Section 2.3.2: Step 2 – Select
the Appropriate Machining Mode on page 28. If not, follow this procedure:

1. Click the Open button on the toolbar.
(Or click File > Open.)
2. An Open dialog box will be displayed. If the Samples folder is not open, double-click on
it to display its contents.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
28 SURFCAM Demo Tutorial

www.Truongalex.com

Figure 49: Open dialog box
3. Type the name of the file you saved from Section 2.2.4: Step 4 – Save the File on page 27 and
click Open, or scroll through the list and double-click on the file name.

2.3.2 Step 2 – Select the Appropriate Machining Mode

Once the part is displayed, you can begin developing a toolpath by
selecting the appropriate machining operation. In this activity you will be
using the 2 Axis Pocket operation. To select that operation:
1. Click NC > 2 Axis.
2. SURFCAM will display the NC > 2 Axis menu bar.
3. Click Pocket.
4. SURFCAM will display the
www.Truongalex.com

NC > 2 Axis > Pocket > Select Chain menu Figure 52: NC menu
and “Select beginning element” on the prompt line.

Figure 50: NC > 2 Axis menu

Figure 51: Select Chain menu

2.3.3 Step 3 – Identify the Material to Cut
You need to specify the area on the part from which to remove material: the boundary that
defines the “pocket.” You do this with a process called chaining. There are a number of
different methods of chaining or identifying the geometry to pocket. The fastest is the
automatic chaining method.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 29

To identify the pocket from which material will be removed:
1. Click Auto on the Select Chain menu. www.Truongalex.com

Figure 53: Select Chain > Auto
2. The Select menu will then be displayed. Click Visible.

Figure 54: Select > Visible
3. After the geometry is highlighted, click Done on the Select menu.

Figure 55: Select > Done
4. SURFCAM will re-display the Select Chain menu. Click Done.

Figure 56: Select Chain > Done
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SURFCAM will next display the 2 Axis Pocket dialog box that contains the machining
parameters used to cut a pocket.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
30 SURFCAM Demo Tutorial

2.3.4 Step 4 – Enter Machining Parameters
The 2 Axis Pocket dialog box contains machining parameters that are displayed on four tabs.
The Tool Information tab contains parameters related to the cutting tool.

www.Truongalex.com

Figure 57: 2 Axis Pocket Tool Information dialog box
1. On the Tool Information tab, click the button after the description of the current Tool.
SURFCAM will display a Select Mill Tool dialog box. Refer to Figure 58: Select Mill Tool
dialog box on page 31.
www.Truongalex.com
Scroll through the visible tool library or click a tool button on the toolbar to display
another list of tools.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 31

Tool buttons

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Figure 58: Select Mill Tool dialog box

2. For this activity:
Click the second tool button on the toolbar to choose an end mill tool.
www.Truongalex.com
3. Select tool #34 which is a 1/2 Inch HSS End mill tool.
4. Click OK on the Select Mill Tool dialog box.
Since you are creating a pocketing toolpath, you will need to define a depth in order for
SURFCAM to create the necessary passes. Click the Cut Control tab.
Near the middle of the tab there are two columns: On Sides and In Z. The first refers to
values applied to movements in the X and Y directions; the second to movements in the
Z direction.
In this activity we will use a pocket depth of 1.5 with equal passes of .75.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
32 SURFCAM Demo Tutorial

www.Truongalex.com

Pocket Depth: 1.5
Increment: .75

Figure 59: 2 Axis Pocket Cut Control tab
5. Enter the pocket depth and increment values from Figure 59: 2 Axis Pocket Cut Control tab.
6. Now click the Tool Information tab again.
7. Click the button after the description of the current Material.
8. SURFCAM will display the Select Material dialog box.

www.Truongalex.com

Figure 60: Select Material dialog box

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
www.Truongalex.com SURFCAM Demo Tutorial 33

Scroll through the material library to see what is available, but select material #8 which
is a Tool Steel.
9. Click OK on the Select Material dialog box.

10. Click OK on the 2 Axis Pocket dialog box.
11. SURFCAM will generate the toolpath. Depending on certain settings, it may then
display the Keep Operation dialog box. Regardless of your response, remember that in
the Demo version of SURFCAM, toolpaths cannot be saved.

Figure 61: Keep Operation dialog box

2.3.5 Step 5 – Change to Isometric View www.Truongalex.com

Figure 62: Toolpath in Top View shows what your screen should look like if you are in Top View.
In this case it is difficult to see the multiple passes in Z. To look at the image in a 3D view,
press Ctrl + 7. (Or click the View button on the Status bar and double-click Isometric View in
the dialog box that will be displayed).
It may be necessary to click the Fit button on the toolbar to fit the geometry into the
workspace.

www.Truongalex.com

Figure 62: Toolpath in Top View Figure 63: Toolpath in Isometric View
This completes the machining for this activity. The next step of the procedure—which we will not
cover in this tutorial—would be post processing to produce NC code for the machine that will cut
the pocket.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
34 SURFCAM Demo Tutorial

2.4 CREATE DIMENSIONS www.Truongalex.com

2.4.1 Step 1 – Load an Existing Design and Change to Top View
In this activity you will display various dimensions on the screen along with the part.

1. Open an existing file named 2dribs.dsn.
2. If you are not looking at the model from the Top View, change the view by pressing Ctrl
+ 1. (Or click the View button on the Status bar and double-click Top View.)
3. In order to provide enough room on your screen to place the dimensions, click
the Zoom Out button on the toolbar to reduce the image by half.

Figure 64: 2dribs.dsn in Top View Figure 65: 2dribs.dsn — half size

2.4.2 Step 2 – Create Linear Dimensions

Use the Linear command on the Dimension menu to create linear
dimensions that are either horizontal or vertical. The system changes
the direction based on the location of the text as it is moved to
different locations.
To create a linear dimension: www.Truongalex.com
1. Click Create > Text/Dimension.
2. The Create > Text/Dimension menu will be displayed.

Figure 67: Create > Text/Dimension menu
Figure 66: Create > 3. For this activity, if StyleText is visible (on the far right), click it to
Text/Dimension toggle it to MouseText.

Figure 68: Create > Text/Dimension > MouseText

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 35

4. Click Linear on the Text/Dimension menu.

Figure 69: Create > Text/Dimension > Linear
5. The Select Point menu will be displayed. Click Center.

www.Truongalex.com

Figure 70: Select Point > Center
With the Center command you can select the center of an arc, the center of a circle or
the midpoint of a line.
6. Refer to Figure 71: Points to select for dimensions. Position the pointer near one of the circles
representing drilled holes and click the left mouse button.
7. Click another circle representing a drilled hole. The dimension will appear on the
screen.
8. Don’t press the mouse button yet. First move the mouse to move the dimension to the
desired location, and anchor it there by pressing the left mouse button.
9. Continue to create additional dimensions by selecting more circles.

Figure 71: Points to select for dimensions Figure 72: Various Linear Dimensions

2.4.3 Step 3 – Create a Radial Dimension www.Truongalex.com

You will next use the Radius command on the Dimension menu to create a dimension for a
radius of an arc or a circle.
1. Click Back on the Select Point menu.
2. The Text/Dimension menu will re-appear. Click Radius.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
36 SURFCAM Demo Tutorial

3. SURFCAM will prompt you to “Select an arc to dimension.”
Select the lower left drill hole.
4. Again, the dimension will appear. Don't press the mouse button yet. First move the
mouse to move the dimension to the desired location, and anchor it there by pressing
the left mouse button.
Notice that if you select the outside arc, rather than the hole, you will get a radius of
0.2000 instead of 0.1000.

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Figure 73: Various Radial Dimensions

2.4.4 Step 4 – Create Additional Dimensions
www.Truongalex.com
Refer to Figure 74: Various Dimensions on page 37 and create other dimensions (or text) by
clicking the Align, Diameter, Angular, Leader, or Text commands on the Dimension menu.
Follow the directions on the prompt line to select element(s).
Note: If you choose to create a Radius, Diameter, or Angular dimension, when you finish,
the Text/Dimension menu will still be displayed. Otherwise, click Back to return to
the Dimension menu when you want a different type of dimension.
Note: When the Text/Dimension menu is displayed, press the F1 key to get Help.
Note: With the Align command, as well as with the Linear command, you need to indicate
on the Select Point menu whether you want to measure from the center or use
another method to select points.
Change Colors
To change the colors of the images and dimensions on your screen:
1. Click Edit > Color.
2. Click on a color.
3. The Select menu will be displayed. Click Visible. The colors will change. (Note: to
change the color of new entities created, use the Color button on the Status bar.)

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 37

Click Cancel or press <Esc> when you are finished.

www.Truongalex.com

Figure 74: Various Dimensions

Save the file if you wish.

2.5 CREATE A CROSS SECTION SURFACE www.Truongalex.com

In this activity you will use the Cross Section command on the Surface menu to create a surface
through multiple cross sections.

2.5.1 Step 1 – Load an Existing Design and Change to Isometric View

1. Open an existing file named Blade.dsn.
2. If you are not looking at the model in Isometric
View, it is difficult to see the design shape.
Use the shortcut keys to change to Isometric Figure 75: Blade.dsn in Top View
View: Ctrl + 7.
3. If necessary, click the Fit button on the toolbar to
fit the geometry into the workspace.
www.Truongalex.com

Figure 76: Blade.dsn in Isometric View

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
38 SURFCAM Demo Tutorial

2.5.2 Step 2 – Create the Surface

To create the surface through the cross sections:
1. Click Create > Surface.
2. Click Cross Section on the Create > Surface menu.

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Figure 78: Create > Surface > Cross Section

3. Click Sections on the Create > Surface > Cross Section menu.

Figure 77:
Create > Surface

Figure 79: Create > Surface > Cross Section > Sections

4. The Select menu will be displayed. If Single is not highlighted, click Single.

Figure 80: Select > Single
5. SURFCAM will prompt you to select the contour(s) to be chained. Select each cross
section as shown in Figure 81: Select each cross section.
6. When you are finished, click Done. SURFCAM will generate a smooth surface through
the sections as shown in Figure 82: The Cross Section Surface.

First Cross Section

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Figure 81: Select each cross section. Figure 82: The Cross Section Surface
Optional
Shade
Click the Shade button on the Status bar (or press the Hot Key shortcut: Ctrl
+ A) to toggle shading on and off.
Change Colors
Refer to Change Colors on page 36.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 39

The colors of the image will change, but if surface shading is on, the current
shade color will remain the same. (This can be changed using Display >
Shade > Options, but we will not do that in this tutorial.)
Note that to change the color of new entities that you will create, click Color
on the Status menu and choose a color.
Practice with Toolbar
Refer to Section 1.5.2: SURFCAM Toolbar on page 6.

7. Save the file if you wish.

2.6 CREATE A DRIVE CURVE SURFACE www.Truongalex.com

In this activity you will use the Drive Curve command to create a surface by “driving” a section
along a “curve.” This type of surface is often referred to as a “swept” surface.

2.6.1 Step 1 – Load an Existing Design and Change to Isometric View

1. Open an existing file named Swept.dsn.
If you are NOT looking at the model in Isometric View, it is difficult to see the design
shape. Use the shortcut keys to change to Isometric View: Ctrl + 7.
2. It may be necessary to click the Fit button on the toolbar to fit the geometry into the
workspace.

Figure 83: Swept.dsn in Top View Figure 84: Swept.dsn in Isometric View

2.6.2 Step 2 – Create the Surface
1. Click Create > Surface.
2. Click Drive Curve.

Figure 85: Create > Surface > Drive Curve

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
40 SURFCAM Demo Tutorial

3. A Select Chain menu will be displayed. If Chain is not highlighted, click Chain.

Figure 86: Select Chain > Chain

4. SURFCAM will prompt you to select the
beginning element of the drive curve.
For the beginning point, select a point
along the curve to the left or to the right
of the intersection of the curve with the www.Truongalex.com
cross section.
5. SURFCAM will prompt you to select the
ending element.
Figure 87: Click one of these for a beginning point.
Click the Close button, which now appears on the menu, to let SURFCAM make the
selection automatically.
6. SURFCAM will then prompt you to “Select beginning element of cross-section 1.”
The Select Chain menu will be displayed. Click Single.

Figure 88: Select Chain > Single

7. Click any point on the cross section.
SURFCAM will display the Select Point
menu and prompt you to “Select
attachment point on drive curve.” Click End
Point.

www.Truongalex.com Figure 89: Beginning element of cross section

Figure 90: Select Point > End Point

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 41

8. Now click near the intersection of the curve and the
cross section.
9. Click the Done button which now appears on the
Select Chain menu. Your screen should look like www.Truongalex.com
Figure 91: Drive Curve Surface.

10. Save the file if you wish.

Figure 91: Drive Curve Surface

2.7 CREATE A FILLET SURFACE www.Truongalex.com

In this activity you will use the Fillet command on the Surface menu to create a constant radius
fillet surface and then a variable radius fillet surface between two surfaces.

2.7.1 Step 1 – Load an Existing Design and Change to Isometric View

1. Open an existing file named Fillet.dsn.

If you are NOT looking at the model
in Isometric View, it is difficult to see
the design shape. Use the shortcut
keys to change to Isometric View:
Ctrl + 7.
2. It may be necessary to click the Fit
button on the toolbar to fit the
geometry into the workspace.
Figure 92: Fillet.dsn Figure 93: Fillet.dsn
Top View Isometric View

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
42 SURFCAM Demo Tutorial

2.7.2 Step 2 – Create a Constant Radius Fillet

1. Click Create > Surface.
2. Click Fillet.

Figure 95: Create > Surface > Fillet
3. The Fillet Options dialog box will be displayed.
Set Variable Radius to No to produce a constant radius fillet.

Figure 94:
Create > Surface

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Figure 96: Fillet Options dialog box
4. Enter .5 for the fillet radius.
5. Click OK.
6. SURFCAM will display the prompt “Select first surface.”
Click the arrow attached to the flat plane to select
that surface.
7. You will be prompted to “Select second surface.”
Click the arrow attached to the cylinder to select it
as the second surface.
8. SURFCAM will create a fillet surface.
9. Save the file if you wish.

www.Truongalex.com Figure 97: Constant Radius Fillet

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 43

2.7.3 Step 3 – Create a Variable Radius Fillet
SURFCAM is also capable of easily creating variable radius fillets.

1. Open the original fillet.dsn file again. www.Truongalex.com

2. If you are NOT looking at the model in Isometric View, it is difficult to see the design
shape. Use the shortcut keys to change to Isometric View: Ctrl + 7.
3. Click Create > Surface > Fillet. (Note: Fillet on the Surface menu, not the Create menu.)
4. SURFCAM will again display the Fillet dialog box.
Set Variable Radius to Yes.
5. Click OK.
6. SURFCAM will display the prompt, “Select first surface.” Select the plane.
7. You will then be prompted to “Select second surface.” Select the cylinder.
8. SURFCAM will prompt you to “Select the reference curve.” Select the light blue curve.

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Figure 98: Select reference curve.
9. The following Select Point menu will be displayed so you can define the locations of the
changes in radii. Click Point.

Figure 99: Select Point > Point

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
44 SURFCAM Demo Tutorial

10. There are four points along this curve. Click one. A dialog box will be displayed. Enter
the corresponding radius value indicated on the following drawing and click OK. Repeat
the procedure with the other three points.

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.125
.375

.375

.500

Figure 100: Enter a value for each of the four points.
11. When you are finished, click Done on the Select Point menu.
12. SURFCAM will display the Variable Fillet Information dialog box.

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Figure 101: Variable Fillet Information dialog box
For this activity, click OK to accept Blended for both Start and End, and Constant
Between Same Radius.
13. The resulting image is shown in Figure 102: Variable
Radius Fillet.
Optional
Shade the surface using either the Shade button
on the Status menu or the shortcut keys: Ctrl + A.
Optional
Use the toolbar to make various changes. Refer to
Section 1.5.2: SURFCAM Toolbar on page 6.

14. Save the file if you wish. Figure 102: Variable Radius Fillet

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 45

2.8 SINGLE SURFACE MACHINING

SURFCAM has seven machining modes which can be seen by clicking NC on the Main menu bar.
The 3 Axis mode is often used to machine surfaces. There are two basic types of surface
machining. One machines a single surface at a time. The other machines a virtually unlimited
number in one step. The following activity shows how to machine a single surface.

2.8.1 Step 1 – Load an Existing Design and Change to Isometric View

1. Open an existing file named Valve.dsn. www.Truongalex.com
2. If you are NOT looking at the model in Isometric View, it is difficult to see the design
shape. Change to Isometric View.
3. It may be necessary to click the Fit button on the toolbar to fit the geometry into the
workspace.

Top View Isometric View

Figure 103: Valve.dsn

2.8.2 Step 2 – Select the Appropriate Machining Command
In this activity you will cut a single surface with the 3 Axis Cut command.
Click NC > 3 Axis. The NC > 3 Axis menu will be displayed.

Figure 104: NC > 3 Axis menu
Click Cut.

2.8.3 Step 3 – Create a Toolpath www.Truongalex.com
1. On the prompt line, SURFCAM will prompt you to “Select a surface.”
To select the valve surface, click anywhere on the surface or click on the surface arrow
attached to the corner of the valve drawing.
2. The 3 Axis Cut dialog box will be displayed with the Tool Information tab on top.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
46 SURFCAM Demo Tutorial

www.Truongalex.com

Figure 105: 3 Axis Cut Tool Information tab
Click the button after the description of the current Tool.
3. SURFCAM will display a Select Mill Tool dialog box. Refer to Figure 58: Select Mill Tool
dialog box on page 31.
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Scroll through the visible tool library or click a tool button on the toolbar to display
another list of tools.
4. For this activity:
If the mill ballnose tool library is not on your screen, click the first tool button on
the toolbar.
5. Select tool #6 which is a 1/2 Inch HSS Ballnose tool.
6. Click OK on the Select Mill Tool dialog box.
7. The Tool Information tab will again be visible on your screen.
Click the button after the description of the current Material.

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www.Truongalex.com SURFCAM Demo Tutorial 47

8. SURFCAM will display a Select Material dialog box. Refer to Figure 60: Select Material
dialog box on page 32.

Scroll through the material library and select any material.
9. Click OK on the Select Material dialog box.
10. Optional: In the next step, you might want to try the hot keys used when a tool is
displayed and SURFCAM is drawing a toolpath. Refer to Figure 27: Shortcut Keys used
when SURFCAM is drawing a toolpath on page 16.
11. Click OK on the 3 Axis Cut dialog box to start the toolpath creation.

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Figure 106: 3 Axis Cut Toolpath

12. SURFCAM will generate the toolpath. If SURFCAM displays the Keep Operation dialog
box, click Accept to keep the operation. Regardless of your response, remember that in
the Demo version of SURFCAM, toolpaths cannot be saved.

Figure 107: Keep Operation dialog box

2.9 MULTIPLE SURFACE MACHINING

This activity shows how to machine multiple surfaces in one step.

2.9.1 Step 1 – Load Design and Change to Isometric View

1. Open an existing file named Phone1.dsn.
2. If you are NOT looking at the model in Isometric View, it is difficult to see the design
shape. Change to Isometric View.

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48 SURFCAM Demo Tutorial
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It may be necessary to click the toolbar Fit button to fit the geometry into the workspace.

Figure 108: Phone1.dsn in Top View Figure 109: Phone1.dsn in Isometric View

2.9.2 Step 2 – Create a Toolpath www.Truongalex.com
1. Click NC > 3 Axis.

Figure 110: NC > 3 Axis
2. Click > Planar.
3. The Select menu will be displayed and you will be prompted to “Select surfaces to cut
across.”
Click Visible.

Figure 111: Select > Visible

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SURFCAM Demo Tutorial 49

4. The 3 Axis Planar dialog box will be displayed with the Tool Information tab on top.
Click the button after the description of the current Tool.

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Figure 112: 3 Axis Planar Tool Information tab

5. SURFCAM will display a Select Mill Tool dialog box. Refer to Figure 58: Select Mill Tool
dialog box on page 31.
Scroll through the visible tool library or click a tool button on the toolbar to display
another list of tools.
6. For this activity: www.Truongalex.com
If the mill ballnose tool library is not on your screen, click the first tool button on
the toolbar to choose the mill ballnose tool.
7. Select tool #6 which is a 1/2 Inch HSS Ballnose tool.
8. Click OK on the Select Mill Tool dialog box.
9. The Tool Information tab will again be visible on your screen.
Click the button after the description of the current Material.

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50 SURFCAM Demo Tutorial

10. SURFCAM will display a Select Material dialog box. Refer to Figure 60: Select Material
dialog box on page 32.
Scroll through the material library and select any material.
11. Click OK on the Select Material dialog box.
12. Click OK on the 3 Axis Planar dialog box.
13. SURFCAM will then display the Select Point menu. Click End Point.

Figure 113: Select Point > End Point

14. SURFCAM will prompt you to “Select point to begin.”
Refer to Figure 114: Selection Points. Select the point that will define the starting point of
the toolpath.
You will then be prompted to “Select point in direction of cut.”

Offset Side
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Then click here.
Click here first.

Figure 114: Selection Points

15. SURFCAM will then prompt you to “Select offset side.” You need to define which side
you wish to machine. Don’t select the offset side until you read the following Optional
step.
Optional www.Truongalex.com
After you select the offset side, you might want to try the hot keys used when the
tool is displayed and SURFCAM is drawing a toolpath. Refer to Figure 27: Shortcut
Keys used when SURFCAM is drawing a toolpath on page 16.
To select the offset side, place your pointer to the left of the part and click anywhere.
Refer to Figure 114: Selection Points and click on the side of the part that says Offset Side.
SURFCAM will highlight each surface and then begin to generate a toolpath to machine
all of them.

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www.Truongalex.com SURFCAM Demo Tutorial 51

When this process is completed, your screen should look like Figure 115: Planar Toolpath.

Figure 115: Planar Toolpath
16. Depending on certain settings, SURFCAM may then display the Keep Operation dialog
box. Regardless of your response, remember that in the Demo version of SURFCAM,
toolpaths cannot be saved.

2.10 Z ROUGH MACHINING
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SURFCAM has an operation called Z Rough with which you can remove large amounts of material
from around multiple surfaces in preparation for finish cutting of those surfaces. In this activity you
will create a Z Rough toolpath and observe a tool traverse the path on the screen.

2.10.1 Step 1 – Load Design and Change to Isometric View

1. Open an existing file named Phone1.dsn.
2. Press Ctrl + 7 to change to Isometric View.

Figure 116: Phone1.dsn
in Isometric View

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52 SURFCAM Demo Tutorial

2.10.2 Step 2 – Create the Z Rough Toolpath
1. Click NC > 3 Axis > Z Rough.

Figure 117: NC > 3 Axis > Z Rough
2. The Select menu will be displayed and you will be prompted to “Select surfaces to
rough.” Click Visible.

Figure 118: Select > Visible

3. The Material Information dialog box will be displayed. www.Truongalex.com

Figure 119: Material Information dialog box
Click the down arrow next to Material Type. There are six ways to describe the material
surrounding the part: Extents Box, Box, Bottom Profile, Top Profile, Surfaces, and No
Material. Select Bottom Profile.
4. You must now enter the height of the material above the bottom profile. Move the
pointer to the Material Height box and enter 3.5 and click OK.
5. A Select Chain menu will be displayed and you will be prompted to “Select beginning
element.” Click Chain.

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Figure 120: Select Chain > Chain
6. You must identify the bottom profile by chaining
it. Click on a side of the bottom profile near a
corner.
7. Click on an adjacent side of the bottom profile
near the same corner.
8. The bottom profile will be chained and the 3
Axis Z Rough dialog box will be displayed with
the Tool Information tab on top.
Figure 121: Identify the bottom profile

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SURFCAM Demo Tutorial 53

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Figure 122: 3 Axis Z Rough Tool Information tab
Click the button after the description of the current Tool.
9. SURFCAM will display a Select Mill Tool dialog box. Refer to Figure 58: Select Mill Tool
dialog box on page 31.
Scroll through the visible tool library or click a tool button on the toolbar to display
another list of tools.
10. For this activity:
If the end mill tool library is not on your screen, click the second tool button on the
toolbar to choose an end mill tool.
11. Select tool #34 which is a 1/2 Inch HSS End tool.
12. Click OK on the Select Mill Tool dialog box.
13. The Tool Information tab will again be visible on your screen.
Click the button after the description of the current Material.

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54 SURFCAM Demo Tutorial

14. SURFCAM will display a Select Material dialog box. Refer to Figure 60: Select Material
dialog box on page 32.
Click #2, Steel 18-26Rc.
15. Click OK on the Select Material dialog box.
16. Optional: In the next step, you might want to try the hot keys used when the tool is
displayed and SURFCAM is drawing a toolpath. Refer to Figure 27: Shortcut Keys used
when SURFCAM is drawing a toolpath on page 16.
17. Click OK on the 3 Axis Z Rough dialog box to start the toolpath creation.
When the toolpath has been drawn, depending on certain settings, SURFCAM may
display the Keep Operation dialog box giving you the opportunity to Accept or Reject
the toolpath.
For this Activity, click Accept so that the steps in the next section can be completed.
Remember that in the Demo version of SURFCAM, toolpaths cannot be saved.

2.10.3 Step 3 – Use the NC Operations Manager

1. Click the NC Operations Manager button on the SURFCAM toolbar to display
the NC Operations Manager dialog box.

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Figure 123: NC Operations Manager dialog box
The last icon in the operations tree—3axis Z Rough—is the icon for the Z Rough
operation you just performed.
With the NC Operations Manager dialog box open, you can perform many tasks that are
useful in managing an NC project.
2. Click the 3axis Z Rough icon you just created. Keep the left mouse button depressed.
Move the pointer so that the icon above is highlighted. Release the mouse button. You
should observe that the two icons have changed places.

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SURFCAM Demo Tutorial 55
www.Truongalex.com
With this method you can arrange NC operations in the order you want them performed
in the last stage of an NC project called post processing to NC code.
3. Not all of the buttons on the NC Operations Manager toolbar are available in the
demonstration mode. We will look at two that are: first, Hide Toolpath, then Delete.
Click the Hide Toolpath button.
The toolpath that was just drawn will be hidden.

4. You can use the Delete button to delete unwanted operations.
Highlight the 3axis Z Rough operation icon you just created.
5. Click the Delete button. The NC POST
dialog box will be displayed with a warning.
6. Click Yes to delete the toolpath data. (You
can do this activity over again to re-create
the operation you just deleted. Reminder:
You cannot save a toolpath in the Demo
version of SURFCAM.) Figure 124: NCPost dialog box
7. Click Done to exit the Operations Manager.
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2.11 MULTI-SURFACE PLANAR SCALLOP CUTTING

SURFCAM has a powerful feature by which you can cut multiple surfaces with dramatically
different slopes and maintain a constant scallop size. SURFCAM automatically adjusts the
distances between successive passes of the tool to maintain the constant scallop size.
In this activity you will create a 3 Axis Planar toolpath with a Scallop Step Type and observe the
tool traverse the path on the screen.

2.11.1 Step 1 – Load Design and Change to Isometric View

1. Open an existing file named Phone1.dsn.
2. Press Ctrl + 7 to change to Isometric View.

Figure 125: Phone1.dsn
in Isometric View

2.11.2 Step 2 – Create the Planar Toolpath
1. Follow steps 1 through 5 in Section 2.9.2: Step 2 – Create a Toolpath on page 48.
2. For this activity, select tool #5 which is a 3/8 Inch HSS Ballnose tool.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
56 SURFCAM Demo Tutorial

3. Click OK on the Select Mill Tool dialog box.
4. The Tool Information tab will again be visible on your screen. Click the Cut Control tab.

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Figure 126: 3 Axis Planar Cut Control tab
5. For the Step Type, choose Scallop.
6. Enter .001 as the Step Size.
7. Click OK on the 3 Axis Planar Cut Control tab.
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8. The Select Point menu will be displayed and you will be prompted to select a point to
begin.
SURFCAM must have a starting point and a point to determine the cutting direction.
Click End Point.

Figure 127: Select Point > End Point

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 57

9. Refer to Figure 128: Starting Point, Direction, Offset Side to select the point that will define
the starting point of the toolpath. You will then be prompted to “Select point in direction
of cut.”

Offset Side

Then click here to
define the direction.

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Click here first

Figure 128: Starting Point, Direction, Offset Side
10. Optional: In the next step, you might want to try the hot keys used when the tool is
displayed and SURFCAM is drawing a toolpath. Refer to Figure 27: Shortcut Keys used
when SURFCAM is drawing a toolpath on page 16.
11. SURFCAM will then prompt you to “Select offset side.”
Refer to Figure 128: Starting Point, Direction, Offset Side and select a point to indicate the
offset side. SURFCAM will create the toolpath and may display the tool traversing the
path on the screen.

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Figure 129: Multi-surface Planar Scallop Cut Toolpath
When the toolpath has been completed, you should be able to tell that in areas with
steep slopes, the tool passes are closer together than in areas where the surfaces are
flatter.
12. Depending on certain settings, SURFCAM may then display the Keep Operation dialog
box. Regardless of your response, remember that in the Demo version of SURFCAM,
toolpaths cannot be saved.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
58 SURFCAM Demo Tutorial

2.12 NC OPERATIONS MANAGER TOOLS www.Truongalex.com

In this activity you will use the Backplot Toolpath and Hide Toolpath buttons on the NC Operations
Manager toolbar to display and study the parameters associated with several kinds of lathe
toolpaths that have already been created in SURFCAM.

2.12.1 Step 1 – Load Design, Change to Top View

1. Open an existing file named Lathe1.dsn.
2. If you are NOT looking at the drawing in Top
View, press Ctrl + 1 (or Ctrl + V and double-click
Top View.)

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Figure 130: Lathe1.dsn in Top View

2.12.2 Step 2 – Change View Indicator

The View Indicator—the XYZ coordinate system in the
lower left corner of the drawing screen—is used for
milling operations. When performing lathe operations, it
is helpful to have the View Indicator display the DZ or
the XZ coordinate system.
1. Click Options > Axis > Lathe Radius.
2. Notice that the coordinates on the View Indicator
change to read X and Z.

Figure 131: Options > 3. Click Options > Axis > Lathe Diameter. The
Axis > Lathe Radius. coordinates of the View Indicator will become D
and Z.

2.12.3 Step 3 – Change the Tool Motion Speed
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It is helpful to have the tool move slowly when observing a toolpath being drawn.
1. Click Display on the Options menu to see the Display Options dialog box. Refer to Figure
132: Display Options dialog box on page 59.
2. Change the 0 in the Tool animation wait box to a 9 to make the tool move at its slowest
speed.
3. If you want, you can also remove the display of the CView Indicator if it appears on your
drawing.
If the box after Show CView Indicator is checked, the CView Indicator will be visible.
Otherwise, it won’t.

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SURFCAM Demo Tutorial 59

4. Click OK.

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Figure 132: Display Options dialog box

2.12.4 Step 4 – Open the NC Operations Manager dialog box
1. Click the NC Operations Manager button on the SURFCAM toolbar to open the
NC Operations Manager dialog box.

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60 SURFCAM Demo Tutorial www.Truongalex.com

2. Drag the dialog box to the bottom of the screen.

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Figure 133: NC Operations Manager dialog box at bottom of SURFCAM screen
.

2.12.5 Step 5 – Backplot the Lathe Turn Operation
1. In the NC Operations Manager dialog box, click on the Lathe Turn - Rough icon in the
operations tree.
2. Click the Backplot Toolpath button on the toolbar to draw the toolpath for this
operation.

Backplot is the name given to the process of showing the tool as it draws the toolpath.
If you click the similar looking Show Toolpath button, the toolpath will be drawn
without showing the tool.
The toolpath in this activity is for an outside diameter turning operation. It is a roughing
operation in that a large amount of material is removed from around the part. There is
one finishing pass made at the end of the operation.

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SURFCAM Demo Tutorial 61

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Figure 134: Backplot

2.12.6 Step 6 – Study the Turning Toolpath Information
When this toolpath was created, certain parameter settings were made in the tabs on the
Lathe Turn dialog box. These settings can be reviewed by opening the NC Operation
Information dialog box.
1. Click the NC Operations Manager button on the SURFCAM toolbar.
2. Right-click the Lathe Turn - Rough icon to open the NC Operation Information dialog
box.

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Figure 135: NC Operation Information dialog box
3. Click the Regenerate Toolpath... button.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
62 SURFCAM Demo Tutorial

4. The Lathe Turn dialog box will be displayed.

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Figure 136: Lathe Turn Tool Information tab
5. You can view the parameter settings on each tab. In the standard version of SURFCAM,
these settings can be changed and the toolpath regenerated and saved.
6. Click Cancel to close the Lathe Turn dialog box.
7. Click Cancel to close the NC Operation Information dialog box.

2.12.7 Step 7 – Erase the Turning Toolpath www.Truongalex.com

From the NC Operations Manager dialog box you can also erase or hide the toolpath that you
just had SURFCAM draw for you.
1. Open the NC Operations Manager dialog box by clicking its button on the toolbar, if it is
not already open.
2. Click the Lathe Turn - Rough icon.

3. Click the Hide Toolpath button to hide the toolpath for the highlighted operation.
Hiding the toolpath that was just drawn will clear the drawing so you can
experiment with observing other toolpaths.

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SURFCAM Demo Tutorial 63

2.12.8 Step 8 – Draw the Toolpaths for the Other Lathe Operations
Open the NC Operations Manager dialog box, if it is not still open, and use the other
operations in the operations tree for more practice backplotting and hiding toolpaths.
The Rough operations remove large amounts of material. The Finish operations make
several finishing passes over the final surface of the part.

2.12.9 Step 9 – Reset the Tool Speed

When you have finished looking at the other toolpaths, you should set the tool speed back to
its fastest.
Repeat Step 3 but change the 9 in the Tool animation wait box back to 0. Refer to Section
2.12.3: Step 3 – Change the Tool Motion Speed on page 58.
Note:
It would be good at this time to change back from lathe to milling operations. Refer to
Section 2.12.2: Step 2 – Change View Indicator on page 58 to change the menu command on
the Options menu back to Mill Axis.

2.13 CHALLENGE: CREATE DOUBLE CLAMP DESIGN www.Truongalex.com

In this activity you will create the design shown in Figure 137: Double Clamp.

Click the New button.

This activity does not include detailed step-by-step instructions. It is
intended as a challenge to new users of SURFCAM. However, some guides
will be supplied.
As you are going through the Activity, be sure to pay attention to the prompt Figure 137:
line at the bottom of the screen. Double Clamp

2.13.1 Step 1 – Create 2 Circles with 1 Inch Diameters

1. Click Create > Circle > Center/Diameter.
2. Enter 1 for the Diameter in the Create Circle dialog box and click
OK.
3. The Select Point menu will be displayed. Click Keyboard.
4. Enter the center of the first circle in the World dialog box:
Figure 138: Circles
X = 0, Y = 1.5, Z = 0 and click OK.
5. The Select Point menu will still be displayed on the screen. Click Keyboard again.
6. Enter the center of the second circle in the World dialog box: X = 0, Y = -1.5, Z = 0.

7. At various times throughout this activity, you may have to click the Fit button.

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64 SURFCAM Demo Tutorial

2.13.2 Step 2 – Create Lines and Offset Them
1. Click Create > Line > End Points > Keyboard.
2. Enter one end point of the first line:
X = 6.875, Y = 5.5, Z = 0 and click OK.
3. Click Keyboard and enter the other end point of the first line:
X = 7.875, Y = 5.5, Z = 0 and click OK.

4.
5. Click Keyboard and enter one end point of the second line:
X = 7.875, Y = -5.5, Z = 0 and click OK. Figure 139:
6. Click Keyboard and enter the other end point of the second Offset Lines
line:
X = 8.875, Y = -5.5, Z = 0 and click OK.

7. www.Truongalex.com
8. Click Back on the Select Point menu. The Create > Line menu will be displayed. Click
Offset.
9. If the Offset shown on the prompt line is not .5, click Change Offset and enter .5 in the
Offset dialog box.
10. Select one of the lines and click above it to indicate the offset side.
11. Select the same line and click below to indicate the offset side.
12. Repeat the previous two steps with the other line.
13. Click Edit > Delete. Then click Single—unless it is already highlighted.
14. Delete the two middle lines you created (in #2 through #5) for offset purposes.

15.

2.13.3 Step 3 – Create Arcs at Ends of Offset Lines

1. Click Create > Arc > 2 Points/Diameter > End Point.
2. Create an arc by selecting end points of a pair of offset lines in
counterclockwise direction.
3. Repeat the previous step until you have the four arcs.

Figure 140:
Create Arcs

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SURFCAM Demo Tutorial 65

2.13.4 Step 4 – Create More Offset Lines and Arcs

1. Click Create > Line > Offset > Change Offset.
2. Enter .25 in the Offset dialog box.

3. At various times you may have to click the Fit button.
4. Select each of the four offset lines and offset each outwardly.
5. Click Create > Arc > 2 Points/Diameter > End Point.
6. Create an arc by selecting the right end points of one pair of
offset lines in counterclockwise direction.
Figure 141:
7. Repeat the previous step to create the other arc. Offset Lines and Arcs

2.13.5 Step 5 – Trim Lower Lines to Extend Them www.Truongalex.com

You’ll notice that upper and lower sets of arcs and offsets do not line up vertically.
1. Click Edit > Trim/Break. Top line
For an in-depth discussion of Trim/Break refer to the online
SURFCAM Reference Manual, Chapter 1: Menus and Dialog Boxes,
Section 1.4.3: Edit > Trim/Break on page 96.
2. If Trim 2 is displayed, click it to display Trim 1.
3. Select the line on the bottom right as the first element to trim
(extend). Extend
these
4. Then click Location which will now appear on the Trim/Break
menu. Figure 142:
5. Click End Point on the Select Point menu. Trim Lines to Extend

6. Select the left end point of the top line as the element to trim to. The lower line will be
extended.
7. With Trim 1 still highlighted, select the other line on the lower right. Click Location > End
Point and again select the left end point of the top line as the element to trim to. The
other lower line will be extended.

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66 SURFCAM Demo Tutorial

2.13.6 Step 6 – Create Arc, Line, and Offset Circle
The next elements will be created with the intent of mirror-imaging them in a later step.
1. Click Create > Arc > Center/Radius.
2. The Create Arc dialog box will be displayed. Enter the following
values:
Radius: 4.75
Start Angle: 90
End Angle: 180 www.Truongalex.com
Direction: CCW
Click OK.
3. Click Keyboard on the Select Point menu that will be displayed. Figure 143: Arc, Line
and Offset Circle
4. Enter the center of the arc in the World dialog box:
X = 6.875, Y = 0, Z = 0 and click OK.
5. To create a vertical line, click Create > Line > Vertical > Keyboard.
6. The World dialog box will be displayed. Enter the coordinates of the point through which
the vertical line will be created: X = -0.875, Y = 0, Z = 0 and click OK.
7. Click Create > Circle > Offset > Change Offset.
8. Enter 0.5 in the Offset dialog box.
9. Select the upper circle only, as the element to offset.
10. Click on the left side of the line to indicate the offset side.

2.13.7 Step 7 – Trim the Vertical Line www.Truongalex.com

1. Click Edit > Trim/Break.
2. If Trim 2 is displayed, click it to display Trim 1.
3. Select the vertical line—near the top—as the element to trim.
(Select it near the top because that is the part we want to keep.)
4. Click Location which will now appear on the Trim/Break menu.
5. Click Keyboard on the Select Point menu.
6. Enter X = 0, Y = 0, Z = 0 in the World dialog box because we
want to keep the line from the top down to the horizontal line
that would be through (0,0,0). Then click OK. Figure 144:
Trim Vertical Line
7. With Trim 1 still highlighted, again select the vertical line as the element to trim—but this
time, select it near the bottom because we want to keep the bottom portion of the line.
8. Click Location on the Trim/Break menu.
9. Click Relative on the Select Point menu because we want a point that is a distance of
4.125 from the bottom of the line.

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SURFCAM Demo Tutorial 67

10. Enter X = 0, Y = 4.125, Z = 0 in the World dialog box as the relative values, and click OK.
11. Click End Point on the Relative menu.
12. Select a point near the bottom of the vertical line as the relative point so that end point
will be selected.

2.13.8 Step 8 – Trim with Auto Trim www.Truongalex.com

1. We will now trim unwanted parts from the
drawing using Auto Trim.
2. On the Edit > Trim/Break menu, click Auto
Trim.
3. If the button to the left of Auto Trim reads
Keep Segment, click it so that it reads Delete
Segment.
4. Now click the portions of the drawing
indicated in Figure 145: Circles and vertical line to
break. Figure 145: Circles and Figure 146:
vertical line to break After Auto Trim
Notice the pointer is now an arrow and a pair
of scissors. www.Truongalex.com
5. Your drawing should now look like the
drawing in Figure 146: After Auto Trim.

2.13.9 Step 9 – Create Arc and Fillet www.Truongalex.com

1. To create the top arc on the design, click Create > Arc
> Tangent 2.
2. Click Change Radius and set the radius to 20.
3. Click Location > End Point and select a point toward
the left end of the top line.
4. Click Location > End Point again and select a point Figure 147: Create Arc
toward the top of the vertical line. You may need to
click other.
5. To create the fillet, click Create > Fillet.
6. Click Change Radius and set the radius to 0.5.
7. Click the vertical line and the arc that intersects it.
\

Figure 148: Create Fillet

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68 SURFCAM Demo Tutorial

2.13.10 Step 10 – Create Horizontal Line, Vertical Line, and Arc Offsets

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Figure 149: Triangle-like Portion
1. Horizontal Line:
To begin to create the triangle-like portion on the
top left of the part, we draw a horizontal line.
Click Create > Line > Horizontal > Keyboard.

The World dialog box will be displayed. Enter the
coordinates of the point through which the
horizontal line will be created:
Figure 150: Horizontal
X = 0, Y = 3.125, Z = 0 and click OK.
and Vertical Lines
2. Vertical Line:
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Click Back > Offset > Change Offset and enter 1 for the offset value.
Select the top vertical line as the line to offset and click to the right to indicate the offset
side. Refer to Figure 150: Horizontal and Vertical Lines.
3. Arc Offsets:
Click Create > Arc > Offset.
Refer to Figure 151: Arcs to Offset and select one arc
to offset. For the offset side, select the inside.
Repeat with the other arc.

Figure 151: Arcs to Offset

2.13.11 Step 11 – Create Fillets

1. Click Create > Fillet > Change Radius and set
the radius to 0.125.
2. Create fillets in the three places indicated in
Figure 152: Fillet Locations.

Figure 152: Fillet Locations

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SURFCAM Demo Tutorial 69

2.13.12 Step 12 – Trim Remaining Elements

1. To trim the remaining elements of the triangle-like
portion of the design, click Edit > Trim/Break.
2. With Trim 2 highlighted, click on the portions of the
two elements that you want to keep. (Click Other if
necessary.)

Figure 153: Trim Locations

2.13.13 Step 13 – Mirror Elements www.Truongalex.com
1. Your design should now look like Figure 154: Elements
to Mirror. We need to copy elements to the bottom
portion of the design to complete the design.
2. Click Edit > Transform > Copy > Mirror.
3. If MultSelOff is displayed on the menu, click it to
toggle to MultSelOn so you can select multiple
elements.
4. Click Single on the Select menu.
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5. Select the elements in the top portion of the design
that you want to copy. Then click Done.
6. Mirror Line:
Click End Point on the Select Point menu to select the Figure 154: Elements to Mirror
beginning point of the mirror line.
7. Then select near the end points as shown in the
figure.

8. The Transform Copy dialog box will be displayed. Copy to Original Color and Original
Layer and click OK.
This completes the design. Your screen should look like Figure 137: Double Clamp on page
63.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
70 SURFCAM Demo Tutorial

2.14 CHALLENGE: CREATE FORK BRACKET DESIGN

In this activity you will create the design shown in Figure 155: Fork Bracket.

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Figure 155: Fork Bracket
This activity does not include detailed step-by-step instructions. It is intended as a challenge to
new users of SURFCAM. However, some guides will be supplied.

2.14.1 Step 1 – Create Circles

1. Use Create > Circle > Center/Diameter to create a 1”
diameter circle.
Click Keyboard to define the center at (0, 0, 0).
2. Click Back. Create two 2” diameter circles.
Figure 156: Circles
Click Keyboard to define the centers at
(-3, -0.75, 0) and (3, -0.75, 0).

3.
4. Click Back. Create two 0.5” diameter circles at positions relative to the 1” diameter
circle. Click Relative and enter X = -1.5, Y = -0.25, Z = 0 for the relative value for the
first circle. Click Center and select the 1” circle.
Click Relative again and enter X = 1.5, Y = -0.25, Z = 0 for the relative value for the
second circle. Click Center and again select the 1” circle.
5. Click Create > Circle > Offset and change the offset to 0.25” to create offset circles 0.25”
larger than the 1” and the two 2” circles.

2.14.2 Step 2 – Create Lines www.Truongalex.com

1. Use Create > Line > Tangent and select the circle that is
offset from the 1” circle. Then select the circle that is offset
from one of the 2” circles.
2. Now select the circle offset from the 1” circle again. Then
select the circle offset from the other 2” circle. Figure 157: Lines
3. Click Horizontal > Keyboard to create a horizontal line through (0, -2.375, 0).
4. Click Back. Click Vertical > Keyboard to create a vertical line through (-3.5, 0, 0). Click
Keyboard again and create a vertical line through (3.5, 0, 0).

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
SURFCAM Demo Tutorial 71

2.14.3 Step 3 – Trim

1. Click Edit > Trim/Break. With Trim 1 highlighted, select a
vertical line—near the bottom because we want to remove
the top portion of the line 0.375 units up from its
intersection with the horizontal line.
Click Location > Relative
and enter X = 0, Y = 0.375, Z = 0. Figure 158: Trim
Click Intersect and select the vertical line then the
horizontal line.
2. Repeat the process for the other vertical line.

2.14.4 Step 4 – Create Tangent Lines www.Truongalex.com

1. Click Create > Line > Tangent. Select a circle offset from
one of the 2” circles.
Click Location > End Point.
Select the vertical line near that circle.
2. Repeat the process for the offset of the other 2” circle and Figure 159: Tangent Lines
the vertical line near it.

2.14.5 Step 5 – Create Offset Lines

1. Click Offset.
Change the offset to 1.5 and select each vertical line and
offset inside.
2. Change the offset to .75 and select each new vertical line
and again offset inside.
Figure 160: Offset Lines
3. Change the offset to 0.625 and select the horizontal line and offset up.
4. Change the offset to 0.25 and select the new horizontal line and offset up again.

2.14.6 Step 6 – Trim and Break www.Truongalex.com

We now trim and break wherever necessary to clean up the
profile so it looks like Figure 161: After Trims and Breaks.
Suggestion: Save your design and try to do the necessary trims
and breaks on your own. The best way to learn trimming and
breaking is to practice with it. Figure 161:
After Trims and Breaks
If you have difficulty, open the saved file and use the following
guides.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
72 SURFCAM Demo Tutorial

1. We need to extend the four inside vertical lines upward to
meet the appropriate horizontal lines. The Trim operation
can extend lines.
Click Edit > Trim/Break > Trim 1.
Refer to Figure 162: Trim to Extend. Select the vertical line 1
as the line to trim (extend). Then select the horizontal line
2 as the line to trim to.
Repeat with lines 3 and 4.
Repeat the process for the lines on the opposite side.
Figure 162: Trim to Extend

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Figure 163: After Extending Vertical Lines

2. After you have extended the four vertical lines you will need to trim away the unneeded
segments in the drawing.
Click Auto Trim.
Make sure the Delete Segment button (to the left of the Auto Trim button) is showing. If
the Keep Segment button is showing, click it to change it back to the Delete Segment
button.
3. Notice the pointer is now an arrow and a pair of scissors. With Auto Trim you can now
modify your design to look like Figure 161: After Trims and Breaks.
With one click at a time, delete each of the unneeded segments.
4. If you delete the wrong thing click the Undo button to bring it back.

2.14.7 Step 7 – Delete Circle and Create Fillets www.Truongalex.com
1. Use the shortcut, Ctrl + D, to display the Delete menu. Click Single and select the circle
that was offset from the 1” circle. (A fillet will be created here later.)
2. Click Create > Fillet. Change the radius to 0.25 and make two fillets as indicated in
Figure 164: Create Fillets.

Figure 164: Create Fillets

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
www.Truongalex.com
SURFCAM Demo Tutorial 73

3. Change the radius to 0.09 and create fillets where necessary. You’ll need eleven of this
size. Don’t forget the one at the top where the circle was deleted.

2.14.8 Step 8 – Create Vertical Lines and Offsets
1. Click Create > Line > Vertical > Center. Select each of the
two horizontal lines at the bottom.
2. Click Back. Click Offset. Change the offset to 0.10 and
select one vertical line and offset it on one side. Then select
it again and offset it on the other side.
3. Repeat the process with the other vertical line.
4. Use the shortcut, Ctrl + D, to display the Delete menu. With Figure 165: Vertical lines
Single highlighted, delete the two center lines.
5.

2.14.9 Step 9 – Finish Slots
The only thing left is to finish the slots so your design will look like Figure 166: Fork Bracket.

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Figure 166: Fork Bracket
Save your file and try to do this on your own. If you have difficulty, open your saved file and
use the following guides. There are several ways the design can be finished.
1. With Trim 1 highlighted, select the offset of the left 2” circle at about the 9 o’clock
position. As the element to trim to, select the tangent line at the top.
2. Again with Trim 1 highlighted, select the offset of the same 2” circle at about the 9
o’clock position. As the element to trim to, select the tangent line at the bottom.
3. We have to treat the circle on the right in a slightly different manner since the 3 o’clock
position is a break point.
4. With Trim 1 highlighted, select the offset of the right 2” circle at about the 2 o’clock
position. As the element to trim to, select the tangent line at the top.
A portion of the circle was deleted. We’ll trim to extend it.
5. With Trim 1 highlighted, select the offset circle at about the 2 o’clock position. As the
element to trim to, select the tangent line at the bottom. The arc will be extended.
6. Now use the Auto Trim operation on the Trim/Break menu to create the two slots in the
Fork Bracket.
With Auto Trim in the Delete Segment mode, trim away the unneeded parts of the four
vertical lines. Then trim the unneeded horizontal line segments and the unneeded arcs.
This completes the design. Your screen should look like Figure 166: Fork Bracket.

Copyright © 2000 by Surfware, Inc. All Rights Reserved.
74 SURFCAM Demo Tutorial

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LIMITED WARRANTY AND LIMITATION OF LIABILITY 
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