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Panelization and manufacturing of “the Predator” by Greg Lynn and Fabian Marcaccio
In this lab students will be utilizing a number of modeling softwares prior to using SURFCAM.
Alias, Maya, FormZ, Rhino, 3D Studio, none can be directly read by SURFCAM. The data must be
translated into a standard format that can be understood by SURFCAM. The “Initial Graphics Exchange
Specification” (IGES) can transfer CAD data from one system to another.
SurfCAM is therefore the software program that we use to take a geometry file (in our case the IGES
file from Maya), interpret the surfaces within the context of the milling machine, develop a set of tool
paths that will carve out the intended geometry, and then it post processes the toolpaths into G-code
that is specific to the Precix 3axis Mill.
The clean and precise manufacturing of a piece depends on many factors, chief among them being, the
quality of the CAD file or model, the parameters and translations used in creating the toolpaths, and a
successful understanding of the resulting G-code sent to the Machine.
The more information the data of transfer, the more likely the information will be distorted in the
second party software.
In order to minimize interface distortion one should limit the transfer of information to NURBS or
curves. When possible, avoid trimming, stitching, blending operations. If these are unavoidable be
prepared to leave time for adjustments as a result of transferring.
File Preparation for SurfCAM in Maya:
One of the major constrains of the 3 axis CNC mill is that it can’t perform undercuts. CNC mills can
basically cut an infinite number of variations of a bowl. It means that the machine can mill a ‘U’, but
not a ‘C’-like profile.
Ensure that all surfaces are free of undercuts.
Ensure that the file you have generated in MAYA has been done with the Z axis set to up. (the default
is for Y to up – from the animation industry!)
Ensure that the model is in the positive x, y and the negative z area.
- The (0,0,0) coordinate will be your origin on the milling machine, with z=0 as the top of your
material.
Create a reference line, because SurfCAM will import your model in a wrong scale.
Your bounding box can also act as your scale reference marker.
Launch SurfCAM, click once on the image in the center of the screen = ready!
- >File>Open your igs file in the file command
- Save the file as DEM Format
- NOTE, in SurfCAM there is NO UNDO!!!!! Please SAVE as often as possible!!!
- There are two different views : V View is the Visual View (what you see on the display), C
View is the Construction View (what your model sees): You must be careful to always match
the views (usually to TOP = #1) when processing new tool paths.
- This is easily accomplished by double clicking on either view, selecting the view and clicking
both buttons at the bottom of the selection window: VIEW + CVIEW
Checking the scale of the object:
Measure the known distance of the line that was created in MAYA and calculate the scaling factor.
NOTE: ALL MEASUREMENTS IN SURFCAM ARE IN MILIMETERS!!!
- >Analyze> Distance> Sketch( or Endpoints)
- The line that you created in MAYA should be the same measured value in SurfCAM.
- If required apply a scaling factor to the entire drawing, be careful to maintain the position and
orientation of the piece – scale about the origin!
- >Edit> Transform> Move> Scale> visible> Keyboard (...,...,...)>Keyboard (0,0,0,) (+SAVE)
Create bounding box (if not already done in the maya file)
For any object that will have 2 or more sides milled (top and bottom), a bounding box with bridges
will be required to stabilize the milling.
For other (flat) jobs, a bounding box is often a good idea, so as to demarcate the piece from the
material, or to set up even & square cutting or post-finishing lines.
- >Create> line> string> polyline> sketch (don’t forget the bridges, if you are milling two sided)
the minimal distance between the line and the model should be at least the diameter of the
milling bit.
- >Create> rectangle> draw a rectangle around the part where the bridges hit the model (only
for hard materials such as MDF and Acryl).
Information may appear in control windows which is not included of discussed in this manual. All
information which has been bypassed is not relevant to the following procedures and therefore should
not be manipulated. If a student would like to investigate more complex procedures which would
require the manipulation of omitted parameters, he/she should be familiar with the procedure outlined
in this manual.
2d contour cutting: Cutting along a line at a prescribed depth. This will result in etching or cutting
of material in 2d. A sacrificial layer under the material should be used if the cut is to be completely
through the material.
Z-Rough: Used to mill off the bulk of the material to a set height above a surface. This is a rough
operation and is often used in conjunction with a finishing operation. It produces a topographical
modell.
Z-Fine or cut: Used as the fine tuning after a Z-Rough cut. It will fine cut the surface (or surfaces
with steep angle’s) and should be set to use a different endmill to increase precision. It produces a mill
path along the geometry of the surface.
Planar: a linear fine milling of the project surface, all toolpaths are parallel and the mill moves with
the surface in the Z axis.
Planar – Flow: A fine milling of the surface, however the toolpaths are calculated based on the
inherent geometry and orientation of the U&V geometry within the NURBS surfaces.
Creating a NC job (ROUGH CUT)
Operations Manager: Highlight the Fine Cut folder
Simulation
- >Operation manager> highlight the toolpath> click Simulation button (Errors will be shown red
in the simulation)
- >NC mode> 3axis> cut> select the surface (Surfcam will only allow individual sequences for
finish cuts. These can be grouped later on in the operation manager)
- Tool Information: > select the endmill size and type (6mm/ 3mm Endmill, rounded milling
bit)
- stock to leave: >0 (as one is not excavating a surface from the material, but finishing it)
- step type: >2 (this is the finish of the surface, its ‘grooviness’. Typically, 2 will give adequate
results. For extremely smooth surfaces this should be set higher, but will increase the run time.
Strong pattern can be produced with a thicker bit and half the diameter of the bit.)
- step type:> increment
- retrace: >bi-directional (how often the bit is cutting. Typical, means it is cutting one stroke,
then retracing, returning near the beginning of the prior stroke and cutting again. Bidirectional
means the bit is always cutting. Bidirectional is typical as it minimizes cutting time.)
- rapid plane: >3mm-5mm (this is the height of retraction above the top surface of the model
the bit will maneuver while executing routines. This option has to be double-checked when
editing or redoing NC sequences as it will change back to variable defaults)
- For more complex procedures the gouge check might be useful. For instance, if there are
adjacent surfaces which may get gouged. >Multi surfaces will check the adjacent surfaces and
determine which surfaces should be avoided. Click first on the surface, which has to be cut and
then click on the adjacent surfaces.
- >OK
Flipping the material for a double-sided model:
If you are creating a piece that has 2 sides then it is imperative that you have very good control over
the placement of the XYZ origin in both SurfCAM and on the Milling table!
- Set both the VIEW and your current view (CVIEW), which is the view in which you work, to
right side view.
- >Click views> right view> click cview+ click view >ok
- >Edit> transform> copy (just in case, remember there is no ‘undo’ command)
- >Rotate> keyboard (0,0,0) (the model has been flipped around the origin. You’ll have to do the
exact action at the milling table, just flipping your working piece around the origin.)
It is often helpful to mark the material BEFORE milling to ensure that the origins will line up with
the zero-points for the file.
Repeat the set up for both rough and fine cut for the other side of the piece – don’t forget to name
your folders in the operations manager with the side number as well.
Post processing:
Simulate your job before post process, to make sure that you didn’t do any errors!
Once all the toolpaths have been calculated the job can be post processed. Post processing is the act of
translating the SurfCAM toolpaths format into the native Precix .gc (G-Code format).
- Open up the Operation manager. Simulate your NC jobs and check for any errors. Highlight
the Rough folder (Fine folder), containing the jobs for one side, with the same milling bit. They
can be grouped for one job on the milling machine.
- Ensure that the Precix mill is set in the machine selection box.
- >Post
- A window will be opened with your job written in g-code.
- Select >file> save as> save file as “filename.gc’ (make sure you type the .gc end)
G-Code is a standard used in the CNC machining industry. It is a small set of relatively simple
commands for moving from one coordinate point to another. With a very brief introduction it is possible
to read and edit G-Code manually.
It is also possible to program directly in G-Code using script generators. There are several graphical
verification tools available for native G-Code.