CAMWorks 2011

Wire EDM Tutorial

Disclaimer
Geometric Technologies (A division of Geometric Americas, Inc.) makes no warranties, either express or implied with respect to this manual. Geometric Technologies reserves the right to revise and improve products as it sees fit, and to revise the specifications and information contained herein without prior notice. Due to continuing product development, specifications and capabilities described in this manual are subject to change without notice.

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The following and other product names and corporate references herein are registered or proprietary trademarks of their respective owners. CAMWorks® is a registered trademark of Geometric Ltd. SolidWorks® is a registered trademark of Dassault Systèmes SolidWorks Corp. FeatureManager™ is a trademark owned jointly by DS SolidWorks and Bentley Systems, Inc. All other brands and names are property of their respective owners.

Copyright ©2003-2011 Geometric Technologies (A division of Geometric Americas Inc.) All Rights Reserved.
Geometric Technologies (A division of Geometric Americas, Inc.)

CW60k 01182011

Table of Contents
CHAPTER 1 LEARNING WIRE EDM BASICS 1-1 Wire EDM 1 .................................................................................................... 1-2 What You'll Learn ...................................................................................... 1-2 Steps to Generate EDM Toolpaths and NC Code ................................ 1-2 Step 1: Model Part in SolidWorks/CW Solids or Import Part ............. 1-2 Step 2: Change to CAMWorks Feature Tree ...................................... 1-2 Step 3: Define the Machine ................................................................. 1-4 Step 4: Define the Stock ...................................................................... 1-6 Step 5: Define Machinable Features ................................................... 1-7 Step 6: Generate Operation Plan/Adjust Machining Parameters ........ 1-9 Step 7: Generate Toolpaths ............................................................... 1-10 Step 8: Post Process Toolpaths .......................................................... 1-13 CHAPTER 2 LEARNING 2 AXIS CONTOUR CUTTING 2-1 2-Axis Contour 1 ............................................................................................. 2-2 What You'll Learn ...................................................................................... 2-2 Extracting Machinable Features and Customizing AFR ...................... 2-2 Generating a 2 Axis Contour Operation and Toolpaths ....................... 2-4 Simulating and Post Processing Toolpaths........................................... 2-5 2-Axis Contour 2 ............................................................................................. 2-6 What You'll Learn ...................................................................................... 2-6 Inserting 2.5 Axis EDM Features ......................................................... 2-6 Generating Operations and Toolpaths .................................................. 2-8 Changing the Machining Order and Post Processing ........................... 2-9 2-Axis Contour 3 ........................................................................................... 2-10 What You'll Learn .................................................................................... 2-10 Inserting a Part Setup.......................................................................... 2-10 Inserting Vertical and Tapered Open Profile Features ....................... 2-11 2 Axis Contour 4............................................................................................ 2-14 What You'll Learn .................................................................................... 2-14 Changing the Processing Order .......................................................... 2-14 CHAPTER 3 LEARNING 4 AXIS CONTOUR CUTTING 3-1 4-Axis Contour 1 ............................................................................................. 3-2 What You'll Learn ...................................................................................... 3-2 Defining the Machine, Stock and Machining Direction....................... 3-2 Defining a 4 Axis Die Feature Interactively......................................... 3-3 Generating a 4 Axis Contour Operation and Toolpaths ....................... 3-3

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Table of Contents

4-Axis Contour 2 ............................................................................................. 3-5 What You'll Learn ...................................................................................... 3-5 Automatically Extracting Sync Curves to Define a 4 Axis Feature ..... 3-5 Generating the 4 Axis Contour Operation and Toolpaths .................... 3-7 4-Axis Contour 3 ............................................................................................. 3-8 What You'll Learn ...................................................................................... 3-8 Using Sketches to Define a 4 Axis EDM Feature ................................ 3-8 Changing the Leadin Point ................................................................. 3-10 4-Axis Contour 4 ........................................................................................... 3-11 What You'll Learn .................................................................................... 3-11 Picking Sync Curves to Define a 4 Axis EDM Feature ..................... 3-11 INDEX

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The exercise parts are installed when you install CAMWorks and are in the \Examples\EDM folder. This folder is inside the CAMWorks data folder (\CAMWorksData\CAMWorksxxxx\Examples\EDM).Chapter 1 Learning Wire EDM Basics This chapter provides an opportunity to learn CAMWorks Wire EDM through a step-by-step tour of the features and functions. The exercises in this chapter are intended to show you how to use CAMWorks and may not correspond to actual machining practices. Learning Wire EDM Basics 1-1 .

you will follow steps that are not explained in depth. 4. Model the part or open the part file in SolidWorks/CAMWorks Solids. Step 3 on page 1-4 explains how to change the machine to an EDM machine. Generate the operation plan and adjust operation parameters. planes and axes in the part. The CAMWorks Feature tree displays.Wire EDM 1 Wire EDM 1 What You'll Learn Steps to Generate EDM Toolpaths and NC Code The following steps are used to generate wire EDM toolpaths and NC code: 1. sketches. SAT file. When you define the operations and toolpaths. 5. 2. Define machinable features. This exercise uses an existing SolidWorks part. Sample parts are provided for the exercises in this manual. When you install CAMWorks. Parasolid. Set the machine type and machine parameters. Change to the CAMWorks Feature tree. you work with a part that was previously modeled in SolidWorks. In order to give you a general understanding of how to use CAMWorks. The tabs at the bottom or top are for moving between the SolidWorks/CAMWorks Solids trees and the CAMWorks trees. 1-2 Learning Wire EDM Basics . Step 1: Model Part in SolidWorks/CAMWorks Solids or Import Part A part is a solid that is created with SolidWorks/CAMWorks Solids or imported into SolidWorks/CAMWorks Solids from another CAD system via an IGES. This is done to show you the basics of generating toolpaths from start to finish without getting into the details at this time. Step 2: Change to CAMWorks Feature Tree 1. Generate toolpaths. 7. The next series of exercises show you how to generate toolpaths on a SolidWorks or CAMWorks Solids part model. Click the CAMWorks Feature Tree tab.SLDPRT in the \Examples\EDM folder. Define the stock shape and material. 1. these files are installed automatically. The FeatureManager design tree lists the features. Post process the toolpaths. Open the part file EDM2AX_1. 8. 3. The Machine item may indicate that a mill machine is currently selected. 6. etc.

The tabs are for moving between the SolidWorks/CAMWorks Solids trees and the CAMWorks trees.  Stock Manager The stock is the material from which the part will be machined.Wire EDM 1 CAMWorks toolbar Feature Tree tab CAMWorks menu Operation Tree tab CAMWorks Feature tree Graphics area Part model CAMWorks Machining Trees The CAMWorks trees provide an outline view of the machining information for the model.Multiple CAMWorks datasets are supported in part mode.   Learning Wire EDM Basics 1-3 . this tree expands to include Part Setups and machinable features.  Configurations . You can define the stock as a rectangular bounding box or as an extruded sketch. Initially. Each dataset is called a configuration. Recycle Bin The Recycle Bin in the CAMWorks Feature tree is used to store machinable features that you do not intend to machine. mill-turn or EDM). Stock Manager. turn. the tool definitions and the machine controller (post processor) are also specified. For mill and turn machines. As you follow the steps to generate an NC program. NC Manager. You can use configurations to support multiple machines and SolidWorks configurations. Machine The Machine item defines the machine type that will be performed on the part (i. the CAMWorks Feature tree shows the Configurations.. The machines are set up in the Technology Database. Machine and Recycle Bin items. mill. You can also specify the type of material.e.

If the machine type changes. The shortcut menu displays. 1-4 Learning Wire EDM Basics . Select Edit Definition on the shortcut menu. The icons that display in the tree identify the current machine: Mill Turn Mill-Turn Wire EDM An alternative machine can be selected at any time to output different G-code programs for alternative machine tools. A number of icons for all the major CAMWorks commands are displayed. Step 3: Define the Machine The Machine item in the tree identifies the type of machine: mill. Locate the CAMWorks toolbar. Click CAMWorks on the SolidWorks/CAMWorks Solids menu bar. click each tab to view the options and settings that you can change in CAMWorks Click the Help button at the bottom of the dialog box. The CAMWorks menu lists the CAMWorks commands.Wire EDM 1 CAMWorks Menu 1. 4. then all features and operations will be deleted. Right-click shortcut menus display commands that are appropriate for the item that is highlighted in the tree. The toolbar can be customized by selecting Tools on the menu bar and then selecting Customize. 5. turn or wire EDM. 2. The right-click shortcut menus provide access to a variety of commands. In case the Options icon is not displayed. Right click on the NC Manager in the tree. CAMWorks Toolbar The CAMWorks toolbar provides access to the main CAMWorks commands found on the CAMWorks menu. In the Options dialog box. Click on the Options button. 2. The commands are explained in the CAMWorks online Help. The machine type defines the machinable feature set that can be recognized automatically and defined interactively. Each tab is explained in the online Help. Right click the Machine item in the CAMWorks Feature tree. 2. Click Cancel to close the Options dialog box. 1. click on the forward arrow button to view the Options icon. Define the machine: 1. Click the Close button in the upper right corner of the Help window to close the window. 3. This is a shortcut menu.

highlight Wire EDM Mode–inch and click the Select button. Setup. make sure you define the machine tools available in your facility. Learning Wire EDM Basics 1-5 . The default machining type is specified in the Technology Database. In the Machine Selection dialog box. Milling is the default machining type that is set when CAMWorks is first installed. The Machine dialog box displays the Machine tab. Click OK. you can double click the following items: Stock Manager.. 4. Features and Operations. Contact your CAMWorks reseller for more information on obtaining and/or customizing machines for your facility. 7. The EDM Settings dialog box displays. In the Available machines list. 5. EDM machines are not currently defined in the Technology Database.. select TUTORIAL for the Make and TUTORIAL for the Model. Machine. Right click Wire EDM Mode–inch in the tree and click Select Machine on the shortcut menu. This Make and Model are supplied for tutorial purposes only. Before using CAMWorks for milling and turning to machine your parts. As an alternate to right clicking items in the tree and selecting the Edit Definition command. 3. then click OK. 6.Wire EDM 1 Did You Know . Right click Wire EDM Mode–inch and select Edit Settings on the shortcut menu.

This post processor has been set up for the TUTORIAL machine and does not need to be changed. use By Complete Feature.Wire EDM 1 8.008. On the Machine Setup tab. etc. For each Punch feature. Step 4: Define the Stock The stock is the material from which the part will be machined. cut rough pass. etc. the order is rough cut leaving glue stop. This tab identifies the post processor. 0 6 skim passes. glue stop cut off. 9. This database has been set up for the TUTORIAL machine. 10. The options on this page provide information used to generate the NC program. The cutting condition database sets machinespecific parameters for power settings. For the Punch and Die process order. glue stop cut off. the NC program will be generated in the following machining order: for each Die feature. This tab allows you to set the wire diameter. Click the EDM Setup tab. The default stock is the smallest bounding box that the part will fit into. You can change the stock definition by offsetting the bounding box from the part or by defining the stock from a sketch and a depth. With this option. then all skim passes. 1-6 Learning Wire EDM Basics . Click the down arrow next to the Wire diameter and select 0. maximum taper angle. the path to the CTC Database is identified. Click the Posting tab.

you need to define the feature using the Insert 2. The Manage Stock dialog box displays. For this exercise. The idea of AFR is to analyze the part for features that can be machined. and begin deciding how to define areas or features to machine and what machining processes you would need. CAMWorks is not machining the SolidWorks/CAMWorks Solids features directly. Step 5: Define Machinable Features In CAMWorks. Learning Wire EDM Basics 1-7 . This is because design features are typically not the same as manufacturing features. use the default bounding box. Punch (Boss) and Open Profile machinable features. Using the interactive method. Using Automatic Feature Recognition (AFR) Define machinable features automatically: 1. Double-click Stock Manager in the Feature tree. machining can be done only on machinable features.5 Axis EDM Feature and Insert 4 Axis EDM Feature commands. Click the Material button.Wire EDM 1 1. You would look it over. 3. you can define Die (Pocket). Click the CAMWorks Options button on the CAMWorks toolbar. You use the following two methods to define machinable features:  Automatic Feature Recognition (AFR) Automatic Feature Recognition analyzes the part shape and attempts to define Die (Pocket) and Open Profile machinable features for Wire EDM. select TOOLSTEEL and click OK. This process is much the same as what you would do if you were to pick up a part that you had to machine. take measurements. It creates a separate list of Machinable Features instead. 2.  Interactively created features If AFR does not recognize a feature you want to machine. Click OK to close the Manage Stock dialog box.

suppress. interactively inserted features that have no operations and features that could not produce operations because the feature conditions have not been defined in the Technology Database display in a different color. The Feature tree allows you to:  Rename. You can set the color on the Display tab in the Options dialog box. 1-8 Learning Wire EDM Basics . 3. CAMWorks generates the Part Setup and machinable features.Wire EDM 1 2. click the Message Window button on the CAMWorks toolbar. For each Part Setup. Y. The Extract machinable features section on this tab allows you to control whether or not AFR finds certain feature types and how it classifies them. and Z direction vectors. you can move the origin.5 Axis and 4 Axis EDM features  Search for a feature based on item name  Hide or show feature display in graphics area  Generate an Operation Plan and find the first operation for a feature Did You Know . If the CAMWorks Message Window is not displayed. There is only one Part Setup for this part because all features can be machined using a single setup orientation. This window reports the progress and status of the current process. The Part Setup is created automatically. Click the Extract Machinable Features button on the CAMWorks toolbar or right click NC Manager in the tree and select Extract Machinable Features on the shortcut menu. the machinable features are listed in the order in which they were recognized. then click OK. You can control whether this window displays temporarily or permanently by clicking the Pushpin button. It has an origin location. The items display in the CAMWorks Feature tree. The Part Setup is the 2 axis plane that the tool movement will be based on. and you can change the direction and angles of the X and Y axes. and X. Click the EDM Features tab. make sure the Perimeter punch feature option is not checked.. however. New features.. and delete machinable features  Change machinable feature parameters  Set the default order in which the features are machined  Insert additional 2. 4. A Part Setup is created for each different tool orientation.

Wire EDM 1 Step 6: Generate Operation Plan and Adjust Machining Parameters An Operation Plan contains information on how each machinable feature is to be machined and how the NC code will be output. and delete operations  Drag and drop copy operations and features  Change operation parameters  Change the machining order  Generate toolpaths  Simulate toolpaths  Post process the toolpaths  Hide or show toolpath display  Search based on item name To the left of each toolpath operation is a plus sign (+). These Machinable Feature items can be used to view geometric information.. When Generate Operation Plan is run. The CAMWorks Operation tree allows you to:  Insert. suppress. operations are listed under the Part Setup in the same order as the machinable features.. You can insert operations manually using the Insert Operation command. If an operation displays in a color instead of black. This command is explained in the CAMWorks online Help. Learning Wire EDM Basics 1-9 . The Stock Manager and Machine items function the same as in the CAMWorks Feature tree. rename. Clicking a plus sign displays the name of the Machinable Feature that this operation is going to machine. the operations defined for a feature may not be sufficient and additional operations may be required. The CAMWorks Operation tree provides an outline view of the operations for the machinable features. Did You Know . then toolpaths have not been generated. Note that clicking the toolbar button is the same as selecting the command from the NC Manager level. This occurs when you insert a new operation interactively. you insert a new feature interactively and generate operations for the new feature. which displays automatically. regardless of the active item in the tree. operations for each machinable feature are created automatically. or CAMWorks cannot generate the toolpath for an operation because of an error in the toolpath algorithm or a parameter is not correct. You can set the color on the Display tab in the Options dialog box. At the top of the tree is the NC Manager. In some situations. Initially. The operations are listed in the CAMWorks Operation tree. Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan. 1. CAMWorks generates the operation plan for all the machinable features in Part Setup1.

Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. Note that if you click the Save button before clicking OK. then click OK. On the EDM tab. 2. On the Leadin/Out tab. set the Leadin and Leadout to Parallel with a Length of 0. 5. Each operation contains machining parameters that affect how the toolpath is created and specific parameters that will be output to the NC program. On the Leadin/Out tab.10in. On the EDM tab. Double-click 2 Axis Contour2 in the tree. 1-10 Learning Wire EDM Basics . the current settings on the EDM and Leadin/Out tabs become the defaults for newly inserted or generated operations on this part or other parts. CAMWorks calculates the toolpaths for each operation in the Part Setup. then click OK. Step 7: Generate Toolpaths CAMWorks calculates toolpaths using the operation parameters and the feature's size and shape. The 2 Axis Contour dialog box displays.1in. Clicking the toolbar button is the same as selecting the command from the NC Manager level. Edit operation parameters: 1. regardless of the active item in the tree. set the following:  Number of skims = 2  Glue stop = Use Glue Stop  Stop distance = 0. 4. set the Leadin and Leadout to Perpendicular with a Length of 0. 1. This dialog box gives you access to all the parameters used to create the toolpath.Wire EDM 1 Generate Operation Plan generates one cutting operation per machinable feature. Double click 2 Axis Contour1 in the Operation tree.1in. These parameters can be edited before post processing the part. 6. set the following:  Number of skims = 2  Glue Stop = No Glue Stop 3. You can also generate toolpaths for each operation individually by right clicking on an operation and clicking Generate Toolpath on the shortcut menu.

Click the Select Chips to Remove button. The toolpaths for that operation display on the part. . etc. Compensation for each pass will be handled by the cutter compensation at the machine. or no display). the simulation can be for the current operation or for all previous operations up to the selected operation.  Run the simulation for all or selected operations. The Simulate Toolpath toolbar displays. CAMWorks provides the ability to simulate the toolpath showing the tool movement and the resulting shape of the part. Click each toolpath pass under the operation. If you want to simulate only the toolpaths for a given operation. 5. Learning Wire EDM Basics 1-11 8. The toolpath for that pass displays. shaded. Set the toolbar buttons as shown in the figure. Click the + sign next to 2Axis Contour1 and 2 Axis Contour2 in the tree. 3. rotate. you can right click that operation. tool and tool holder (wireframe. Notice a Tab cut is generated for the second operation since you set the Glue Stop to Use and set a Stop distance.  When simulating an operation. 4. The toolbar controls allow you to:  Customize the display of the stock. Under each machinable feature. pan. 7. 6. the toolpath passes that were generated for that feature are listed. then click the + sign next to Open Profile1 and Die1. Click the Run button. Click the Simulate Toolbar button of the CAMWorks toolbar or right click Part Setup1 in the tree and select Simulate Toolpath. Click the first operation in the tree. Note that the toolpaths for each cut are on center. The simulation runs. translucent. This button is enabled when the simulation is complete and provides two methods for removing loose chips. then select Simulate Toolpath.  Pause the simulation and dynamically change the orientation of the part using zoom.  Control the simulation speed by dragging the Simulation Speed Control slider left or right.Wire EDM 1 2.

picking the stock piece may be faster than picking each chip. 1. CAMWorks also provides the ability to step through the toolpath using the Step Thru Toolpath command. Click the Single Step button (single arrow) several times.Wire EDM 1 9. 13. 5. To activate this option.. select the Message Window option. On the General tab. Pick the two loose stock chips to remove. Click the Select Chips to Remove button. Did You Know . Click the X button in the upper right corner to exit. Click the X button in the upper right corner to close the simulation and return to the SolidWorks/CAMWorks Solids display. Click the Goto Start button and Run the simulation again. Forward multiple steps Number of toolpath segments to display 3. 14. 12. Multiple step increment Show toolpath points Single step 2. then press the D key on the keyboard.. select the Cutter coordinates in Message Window option. 10. The active toolpath node is highlighted. CAMWorks provides an option to display the XYZ position of the tool in the Message Window during Simulation and Step Thru Toolpath. 4. If there are many loose chips to remove. 1-12 Learning Wire EDM Basics . Set the Step Increment to 3 and click the Forward Multiple Steps button (double arrow) several times. Click the Goto End button. Save the part with the machinable feature data: 1. Click the Select Chips to Remove button to exit the function. On the Simulation tab. then press the D key on the keyboard. The loose chips are removed in the graphics area. The toolpaths are completed. 11. select the Options command on the CAMWorks menu or the NC Manager shortcut menu. Right click an operation in the tree and select Step Thru Toolpath. The Step Thru Toolpath toolbar displays. Hold down the Ctrl key and pick the stock piece you want to keep. Click the Options button the CAMWorks toolbar.

SAVE FREQUENTLY!  When you open a file. 4. If you click No. In the Save As dialog box. Note that you can also click CAMWorks on the menu bar or right click NC Manager in the tree and select the Options command.  CAMWorks provides an Auto save option on the General tab in the Options dialog box for automatically saving your CAMWorks data. the machining data is saved. the machining data is restored along with the part design information. when you save and close a part document. you will lose whatever you have been working on. If a power failure occurs. If you click Yes. when you save and close a part document that contains at least one CAMWorks Setup. This step translates generalized toolpath and operation information into NC code for a specific machine tool controller. When the part document is opened again. type cwedm1 and click the Save button. you are actually working on a copy of the file. a message indicates that Save/Restore is disabled. The original is still stored on disk. In this exercise. Click the Post Process button on the CAMWorks toolbar or right click NC Manager in the Operation tree and click Post Process on the shortcut menu. CAMWorks closes the part and discards any new CAMWorks data since the last save. 3. make sure the Save/Restore part option is checked. edit and print using a word processor or text editor. If this option is checked. CAMWorks creates NC code for each toolpath in the order the operation appears in the Operation tree and the Process order specified on the Posting tab in the EDM Settings dialog box. Learning Wire EDM Basics 1-13 . then click OK. CAMWorks saves all CAMWorks data before closing the file. CAMWorks creates the NC program file. Step 8: Post Process Toolpaths Post processing is the final step in generating the NC program file.Wire EDM 1 2. If this option is not checked. you post process all the operations and generate the NC program: 1. On the General tab. Periodically saving your file ensures that your latest work is retained. Click Save As on the File menu. This is a text file that you can read. When you post process a part.  Frequent saves prevent having to redo a time-consuming model or CAM operation.

make sure that you have generated the toolpaths. Click the Run button. 6. Click OK to close the Post Process Output dialog box.Wire EDM 1 2. For this exercise. 4. Click Save. The Post Process Output dialog box displays. Post processing continues until it is completed. Click the Step button on the control bar at the top. use the . 3. Click the Step button. 1-14 Learning Wire EDM Basics . You can change the folder if you want the file in another location. Click the down arrow to the right of the Save as type box. The post processing mode is set to post process one line of code at a time (Step mode). view the code using the vertical scroll bar. The Post Output File dialog box displays so you can name the NC program file. Both files can have the same name because they have different extensions. CAMWorks starts to generate the NC Run program and the first line of NC code Step displays in the NC code output view box. When the post processing is finished. Naming the post output file the same as the part file is the most common way of saving parts and NC programs. The next line of NC code displays. If the Post Process command is grayed out on the CAMWorks menu or on a shortcut menu. You do not have to type the extension. 7. 5.txt extension. 8. CAMWorks provides a list of commonly used extensions that you can select.

Learning 2 Axis Contour Cutting 2-1 . The exercises in this chapter are intended to show you how to use CAMWorks Wire EDM and may not correspond to actual machining practices.Chapter 2 Learning 2 Axis Contour Cutting This chapter provides an opportunity to learn CAMWorks Wire EDM through step-by-step exercises. We recommend that you go through the exercise in Chapter 1 first.

On the Posting tab. Feature-based machining provides numerous benefits because the definition of the feature enables a higher level of automation when creating machining operations and associated toolpaths. select TUTORIAL for the Make and TUTORIAL for the Model. Open the part file EDM2AX_2.SLDPRT in the \Examples\EDM folder. 11. Double click Stock Manager in the Feature tree. then click OK. In the Available machines list. Right click Wire EDM Mode-mm in the tree and click Select Machine on the shortcut menu.20mm. The Manage Stock dialog box displays. What You'll Learn Extracting Machinable Features and Customizing AFR 1. and an interactive method using the Insert 2. click the Select button. 7. cut rough pass. make sure the Process order for Die is set to By Complete Feature. 2-2 Learning 2 Axis Contour Cutting .2-Axis Contour 1 2-Axis Contour 1 CAMWorks is a feature-based machining system. 4. 2. Adding to this benefit. 6.5 Axis EDM Feature function. For this exercise. Double click the Machine item in the CAMWorks Feature tree. The Machine dialog box displays. Right click Wire EDM Mode-mm in the tree and select Edit Settings on the shortcut menu. highlight Wire EDM Mode-mm. Click the CAMWorks Feature Tree tab. 10. With this option. 5. then all skim passes. make sure the Wire diameter is set to 0. 9. A CAMWorks file can contain both types of features. On the EDM Setup tab. and then click OK. 3. In the Machine Selection dialog box. click OK to use the default bounding box and material. CAMWorks provides both an automatic method of extracting features called Automatic Feature Recognition (AFR). This exercise demonstrates some of the features that are identified automatically by the Extract Machinable Features command and explains how to control the types of features found by AFR. 8. the NC program will be generated in the following machining order: for each feature. glue stop cut off. then click OK.

2-Axis Contour 1 CAMWorks allows you to control the types of features that are created by AFR: 1. Generating Setups is always the last item. you may not want to use Wire EDM to machine all of these features. However. When you see it. Learning 2 Axis Contour Cutting 2-3 . click the Message Window button on the CAMWorks toolbar. On the EDM Features tab. AFR has generated all possible Open Profile and Die features. CAMWorks generates the Part Setup and machinable features. 2. Click each feature item in the tree to see the corresponding feature on the part. Click the Extract Machinable Features button on the CAMWorks toolbar or right click NC Manager in the tree and select Extract Machinable Features on the shortcut menu. you know the AFR process is almost complete. 5. You can delete these features individually by highlighting the features and pressing the Delete key or you can customize AFR to omit recognizing these features. This window reports the progress and status of the current process. 3. for example the countersink. If the CAMWorks Message Window is not displayed. make sure the Perimeter punch feature is checked and then click OK. counterbore and multi-step holes. Click the Options button on the CAMWorks toolbar. 4.

8. 9. If you want the System Defaults to apply. Turn and Wire EDM with the machine type stored. Optionally. Click the Options button on the CAMWorks toolbar. Templates allow you to maintain as many different documents for parts or assemblies as you need. remove the check marks from the Countersink holes. Generating a 2 Axis Contour Operation and Toolpaths Generate operations and toolpaths. 7. disable the Save/Restore part or Save/Restore assembly option on the General tab in the CAMWorks Options dialog box. On the EDM Features tab.. For new part/assembly documents.the current part as well as all new parts Did You Know . then post process: 1. Click the Extract Machinable Features button on the CAMWorks toolbar or right click NC Manager in the tree and select Rebuild. the CAMWorks settings in the selected template will be used. The Circular Die features for the countersunk. you can create separate part templates for Mill. change the Apply to: setting. CAMWorks data is saved in part and assembly template documents. Counterbore holes and Multi-step holes options and check the On Rebuild Delete option for these features types. For example. then save the template with a new name.2-Axis Contour 1 6.the part that you are currently working on  System Default .all new parts that are created (note that the values that displayed when you opened this dialog box will be retained for the current part)  All Possible .. 2-4 Learning 2 Axis Contour Cutting . Click OK. counterbore and multi-step holes are now in the Recycle Bin. 10. This option allows you to select how the settings on this tab will be applied:  Active Document . Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the shortcut menu. not the CAMWorks System Defaults.

11. Learning 2 Axis Contour Cutting 2-5 . Click the Post Process button on the CAMWorks toolbar or right click NC Manager in the Operation tree and click Post Process on the shortcut menu. Hold down the Ctrl key and pick the stock piece you want to keep. click Save. 2. 8. then press the D key on the keyboard. Click the Simulate Toolpath button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the tree and select Simulate Toolpath. When the post processing is finished. 5.2-Axis Contour 1 When you select Generate Operation Plan. use the vertical scroll bar to view the code and notice the machining order. 4. 2. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. 3. Click OK to close the dialog box. The loose chips are removed in the graphics area. In the Post Output File dialog box. 6. Set the display:  Stock. 10. Click the X button in the upper right corner to cancel the simulation and return to the SolidWorks/CAMWorks Solids display. Simulating and Post Processing Toolpaths 1. Operations are not generated for suppressed features and features in the Recycle Bin. Click the Select Chips to Remove button. Tool and Holder = Shaded Display  Target Part = No Display Click the Run button. Post process the part and view the code: 7. 9. Click the Run button in the Post Process Output dialog box. operations are created for every selected feature.

On the EDM Features tab. Click the Extract Machinable Features button on the CAMWorks toolbar. then all skim passes.SLDPRT in the \Examples\EDM folder. In this exercise. cut rough pass.5 Axis EDM Features 1. Click the Options button on the CAMWorks toolbar. For each Punch feature. glue stop cut off. then click OK. The Machine dialog box displays. AFR finds only the irregular die in the center of the part. click OK to use the default bounding box and material. 9. Open the part file EDM2AX_3. then click OK. 2-6 Learning 2 Axis Contour Cutting . 12. 10. glue stop cut off. You interactively insert 2. make sure TUTORIAL is selected for the Make and TUTORIAL for the Model.2-Axis Contour 2 2-Axis Contour 2 What You'll Learn Automatic Feature Recognition may not be able to find all features on a part or may not recognize all the features that you want to machine. make sure the Perimeter punch feature is not checked and click OK. With this option. make sure the Process order is By Complete Feature for both Punch and Die. 6. then click OK. In the Manage Stock dialog box. In the Available machines list. In the Machine Selection dialog box. On the Posting tab. highlight Wire EDM Mode–inch. 2. Inserting 2. Right click Wire EDM Mode–in in the tree and select Edit Settings.5 Axis EDM features to cut the two dies on the sides and the outside of the part. When this occurs. 7. Double click Stock Manager in the Feature tree. 0 . Click the CAMWorks Feature Tree tab. 4. click the Select button. the NC program will be generated in the following machining order: for each Die feature. Right click Wire EDM Mode–inch in the tree and click Select Machine on the shortcut menu. AFR finds only the Irregular Die in the center of the part.6 skim passes. 3. Double click the Machine item in the CAMWorks Feature tree. 5. the processing order is rough cut leaving glue stop. you can define these features interactively. 13. 11. 8.

Click the End Condition tab. Click the Close button to close the Feature definition dialog box.5 Axis EDM Feature on the shortcut menu. 10. However. Click the Punch button for the Feature type. Three Die features are shown in the ‘Selected entities for features’ box. Rotate the part and pick the bottom face. When necessary. The direction is correct for this part. The red arrow on the triad indicates the negative Z direction.5 Axis EDM features interactively: 1. make sure Die is the selected Feature type. . Learning 2 Axis Contour Cutting 2-7 5. it is used as a reference for certain CAMWorks functions (for example. In the Feature Definition dialog box. 9.5 Axis EDM Feature on the shortcut menu. Click Insert to use the default End Condition and insert the features. 6. This is the Irregular Die feature that has already been found by AFR so you can delete it. Highlight Die – 1 in the list and press the Delete key. Insert 2. Click Die – 2 and Die – 3 to view the features on the part. Define the feature to machine the outside of the part: Once again right click EDM Part Setup1 in the tree and select Insert 2. Rotate the part so that the bottom face is visible. Rectangular Die2 and Rectangular Die3 are listed in the Feature tree. Click Die – 1. 2. The End Condition page provides options to define the end condition for the features you are inserting. Click EDM Part Setup1 in the tree and notice the Z machining direction. 8. Right click EDM Part Setup1 in the tree and select Insert 2. This amount is calculated automatically based on the position of the stock. 4. you can reverse the direction by double clicking Part Setup1 in the tree and clicking the Reverse Setup Direction option in the EDM Setup PropertyManager.2-Axis Contour 2 14. 11. 3. offsetting the stock). The default Upto Stock defines the depth to the material face. Note that the SolidWorks/CAMWorks Solids axis does not control CAMWorks machining. 7.

Leave the Lead in location set to Mid-point and pick the segment shown in the figure. 3. mid. The Lead in Location dialog box displays. Rotate the part and notice that this location may gouge the part. Click the End Condition tab. then expand Punch1. Punch1 displays in the tree. Click Insert. You set the Process order for Punch to By Complete Feature on the Posting tab in the EDM Settings dialog box and the code for all Punch features will be output based on this order.2-Axis Contour 2 12. Click the Close button to close the Feature definition dialog. Click the + sign next to 2 Axis Contour 1 in the tree to expand the operation. The current location is indicated on the feature. 6. You can set the leadin/leadout location to be at the start-. 7. The processing order is rough cut. Generating Operations and Toolpaths Generate operations and toolpaths: 1. Click OK to close the dialog box. 15. Right click Irregular Die1 and select Edit Leadin Point on the shortcut menu. Punch – 1 is listed in the Selected entities for feature box. Expand 2 Axis Contour4 in the Operation tree (click the + sign). 2. Use the mouse to drag and drop the features in the order shown in the above diagram. 8. Pick the same face on the bottom of the part. Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the shortcut menu. 2-8 Learning 2 Axis Contour Cutting . You can use the default Upto Stock. 16. Rotate the part so that the top face is visible. 13. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. skim passes. then glue stop cut off. 14. 5.or end-point of a segment. Click Close button to close the Feature Definition dialog box. 4.

2. Click the Options button on the CAMWorks toolbar. 1. 4. Close the editor.2-Axis Contour 2 9. 3. click the Browse button. click OK. The processing order is rough cut. you use to modify NC program files. The operations for the Die features will now be post processed before the operation for the Punch feature. Changing the Machining Order and Post Processing CAMWorks processes the punches and dies according to the order of the items in the Operation tree. When the post processing is finished. then expand Rectangular Die2. glue stop cut off. 10. You set the Process order to By Complete Feature on the Posting tab in the EDM Settings dialog box and the code for all Die features will be output based on this order. Click the Post Process button on the CAMWorks toolbar or right click NC Manager in the Operation tree and click Post Process on the shortcut menu. then skim passes. You do not have to type the extension. 9. In the Post Output File dialog box. Learning 2 Axis Contour Cutting 2-9 . Click the + sign next to 2 Axis Contour 2 in the tree to expand the operation. Browse and select the editor: if you know the location of the editor. select Notepad.exe in the \Windows or \WINNT folder and click Open. 6. 11. Otherwise. so you can reorder the operations before post processing. 7. then click OK. 5. type a name for the file and click Save. open the folder and select the program. 8. Click the Run button in the Post Process Output dialog box. Notice that G-code has been generated for the Die features and then the Punch feature. The File Output tab contains an option to automatically open the G-code file when you close the Post Process Output dialog box. Click the File Output tab. Check the Open G-code file in editor option. Highlight 2 Axis Contour1 in the tree and drag it on bottom of 2 Axis Contour4. The program file opens automatically in the editor you selected. The operation for the Punch feature is listed first in the tree.

Inserting a Part Setup 1. Double click the Machine item in the CAMWorks Feature tree. Right click Wire EDM Mode-mm in the tree and select Edit Settings on the shortcut menu. The Machine dialog box displays. In the Machine Selection dialog box. With this option. 6. Open the part file EDM2AX_4. 2-10 Learning 2 Axis Contour Cutting . make sure TUTORIAL is selected for the Make and TUTORIAL for the Model. 11. the only features you want to machine are the vertical and tapered open profiles at the end of the part. then click OK. Click the Extract Machinable Features button on the CAMWorks toolbar or right click NC Manager in the tree and select Extract Machinable Features on the shortcut menu. On the Posting tab. In the Available machines list. set the Process order for Die to By Complete Feature. 8. Click the CAMWorks Feature Tree tab. so you need to insert a Part Setup. then click OK.6 full skim passes. In the Manage Stock dialog box. then click OK. 0 . 10. Right click Wire EDM Mode-mm in the tree and click Select Machine on the shortcut menu. 5. highlight Wire EDM Mode–mm. AFR does not find these features. then define the 2 features interactively using the Insert 2. 4. click OK to use the default bounding box and material. the NC program is generated in the following machining order: Rough cut. click the Select button. 3.5 Axis EDM command. 7. Double click Stock Manager in the Feature tree. You should run AFR even when you know AFR cannot find any features on a part. glue stop cut off.2-Axis Contour 3 2-Axis Contour 3 What You'll Learn In this exercise.SLDPRT in the \Examples\EDM folder. 2. Running AFR sets up information for associativity that is necessary for the Rebuild function. 9.

the chaining direction is based on the fewest number of edges between the first and last selected edges. 5. Pick the lower edge on the left. This feature is vertical and no changes need to be made on this tab. then click the Flip direction check box. Learning 2 Axis Contour Cutting 2-11 . The blue faces define a tapered wall. EDM Part Setup1 is listed in the tree. you can chain select between the first and last edges of the feature. the chaining direction is based on the greatest number of edges between the first and last selected edges. 1. The arrow direction is reversed.  If the Shift key is pressed. Right click Part Setup1 in the tree and select Insert 2.  If the Ctrl key is pressed. you want to cut on the other side. Click Open Profile – 1 in the Selected entities for features list. 4. Select Open Profile for the Feature type. Notice the arrow indicates which side of the feature to cut on. then click OK in the EDM Setup PropertyManager.2-Axis Contour 3 12. 3. Click the End Condition tab. 2.5 Axis EDM Feature on the shortcut menu. then hold down the Ctrl key and pick the lower edge on the right. Inserting Vertical and Tapered Open Profile Features The yellow faces define a vertical wall. 13. When you define an Open Profile Feature from multiple edges. First. In this case. you define the vertical open profile feature. Right click Stock Manager in the tree and select Insert Part Setup on the shortcut menu. then the tapered open profile feature. Pick the face on the top of the part.

Click the Reverse Taper button to reverse the taper so it is going outward. set the following:  Number of skims = 2  Glue Stop = No Glue Stop  Process as = Die On the Leadin/Out tab. then click the Flip direction check box. 11. 3. then click OK. Click the Insert button. The 2 Axis Contour dialog box displays. 9. Click the Close button to close the 2 AXIS EDM Feature dialog box. Generate operations and toolpaths: 15. Click the End Condition tab. Rotate the part and notice that the feature outline indicates the taper is going inward.5 Axis EDM Feature on the shortcut menu. Click the Taper On/Off button to turn it on.2-Axis Contour 3 6. On the EDM tab. 4. 2. Right click Part Setup1 in the tree and select Insert 2. Open Profile 1 is listed in the Feature tree. 14. 5. Pick the top edge on the left side. 16. Double-click 2 Axis Contour1 in the Operation tree. 7. Hold down the Ctrl key and pick the top edge on the right. set the Leadin and Leadout to Parallel. 13. 10. This is the order the features will be processed when the NC code is generated. This dialog box gives you access to all the parameters used to create the toolpath. and then click Close button. 12. Set the degrees to 10 and press the Tab key. 2-12 Learning 2 Axis Contour Cutting . Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the shortcut menu. 8. 1. Click Insert. Next. Click Open Profile – 1 in the Selected entities for features list. Inserted features are listed in the feature tree. This button functions as a toggle. There is a 10degree taper. you define the tapered open profile feature. Zoom in on the right side of this feature. Double click 2 Axis Contour2 in the tree.

Click the Run button in the Post Process Output dialog box. 10. View the code. 9. click OK. The program file may open automatically in an editor if you enabled this option in the previous exercise. In the Post Output File dialog box. 8. 11. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. Tool Holder and Target Part = Translucent Display  Tool = Shaded Display Click the Run button. 12. Click the Post Process button on the CAMWorks toolbar or right click NC Manager in the Operation tree and click Post Process on the shortcut menu. 14. click Save. Make the same changes as for 2 Axis Contour1. 7. Click the Simulate Toolbar button of the CAMWorks toolbar or right click Part Setup1 in the tree and select Simulate Toolpath. then click OK. and then close the editor. Click the X button in the upper right corner to cancel the simulation and return to the SolidWorks/CAMWorks Solids display. 13.2-Axis Contour 3 6. 16. Set the display:  Stock. When the post processing is finished. 15. Learning 2 Axis Contour Cutting 2-13 .

8. make sure the Process order for Die is By Complete Feature. 2-14 Learning 2 Axis Contour Cutting . glue stop cut off. 6. Open the part file EDM2AX_5. highlight Wire EDM Mode–mm. click the Select button. Right click Wire EDM Mode–mm in the tree and select Edit Settings on the shortcut menu. Changing the Processing Order 1. 7. In the Machine Selection dialog box. 4. For more information on the Process order options. then click OK. In this exercise.SLDPRT in the \Examples\EDM folder. then post process using each of the Process order options for dies and compare the code that is generated. Click the CAMWorks Feature Tree tab. then click OK. 3. Right click Wire EDM Mode–mm in the tree and click Select Machine on the shortcut menu. see the Posting Tab topic in the Wire EDM online Help.6 full skim passes. 0 . you generate operations and toolpaths for two die features. 2.2 Axis Contour 4 2 Axis Contour 4 What You'll Learn Post processing translates generalized toolpath and operation information into NC code for a specific machine tool controller. On the Posting tab. 5. In the Available machines list. Double click the Machine item in the CAMWorks Feature tree. then click OK. the NC program is generated in the following machining order: Rough cut leaving glue stop. The Machine dialog box displays. CAMWorks creates NC code for each toolpath in the order the operation appears in the Operation tree and the Process order specified on the Posting tab in the EDM Settings dialog box. make sure TUTORIAL is selected for the Make and TUTORIAL for the Model. With this option.

2. If you know the location of the editor you use to modify NC program files. Make the same changes on the EDM and Leadin/Out tabs. 18. click OK to use the default bounding box and material. Rectangular Die1 and Circular Die2 are listed in the tree. set the following:  Number of skims = 2  Glue Stop = Use Glue Stop  Stop distance = 2mm On the Leadin/Out tab. 5. 3. 17. 10. 16. click the Browse button. Post process the Die features and view the code: Click the Options button on the CAMWorks toolbar. 12. Check the ‘Open G-code file in editor’ option. 13. Click the ‘File Locations’ tab. 20. Double click 2 Axis Contour2 in the tree. Click the Options button on the CAMWorks toolbar. 15. then click OK. 14. Double click 2 Axis Contour1 in the Operation tree. Click the Post Process button on the CAMWorks toolbar or right click NC Manager in the Operation tree and click Post Process on the shortcut menu. then click OK. 4.exe in the \Windows or \WINNT folder and click Open. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. open the folder and select the program. Click the Extract Machinable Features button on the CAMWorks toolbar or right click NC Manager in the tree and select Extract Machinable Features on the shortcut menu. select Notepad. You can browse and select the editor that you want to open the G-code file when you close the Post Process Output dialog box. The File Locations tab contains an option to open the G-code file automatically. set the Leadin and Leadout to Perpendicular with a Length of 6mm. remove the check mark from Perimeter punch and click OK. Otherwise. 11. Learning 2 Axis Contour Cutting 2-15 .2 Axis Contour 4 9. 1. Double click Stock Manager in the Feature tree. 19. On the EDM Features tab. On the EDM tab. In the Manage Stock dialog box. Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the shortcut menu.

Name the file die rough-glue stop-all skims. set the Process order for Die to Rough / Glue Stop / All Skims. Click the Run button in the Post Process Output dialog box. then click OK. set the Process order for Die to Rough / Glue Stop / Skim Passes. Right click Wire EDM Mode–mm in the tree and click Edit Settings on the shortcut menu. type die complete for the File name and click Save. 12. View the code and notice the following processing order:  Cut all rough passes from first feature to last  Glue stop cut off on each feature from last to first  Perform all skim passes on each feature from first feature to last Close the editor. You do not have to type the extension. 17. 13. On the Posting tab. In the Post Output File dialog box. 11. View the code and notice the following processing order:  Rough cut leaving glue stop  Glue stop cut off  0 . 2-16 Learning 2 Axis Contour Cutting . 10. Right click Wire EDM Mode–mm in the tree and click Edit Settings on the shortcut menu. When the post processing is finished. Post process the part again.6 full skim passes Close the editor. 19. click OK. 9. 18. 14. Name the file die rough-glue stop-skim passes. View the code and notice the following processing order:  Cut all rough passes from first feature to last  Glue stop cut off on each feature from last to first  Skim pass one on each feature from first to last  Skim pass two on each feature from last to first  Etc.2 Axis Contour 4 6. The program file opens automatically in the editor you selected. 7. 8. 15. 16. Post process the part again. then click OK. On the Posting tab.

Learning 4 Axis Contour Cutting 3-1 . We recommend that you go through the exercise in Chapter 1 first.Chapter 3 Learning 4 Axis Contour Cutting This chapter provides an opportunity to learn 4 Axis Contour cutting through step-by-step exercises. The exercises in this chapter are intended to show you how to use CAMWorks Wire EDM and may not correspond to actual machining practices.

highlight Wire EDM Mode–inch. These include Pocket (Die). In the Available machines list. \CAMWorksData\CAMWorksxxxx\Examples\EDM). 5. The Manage Stock dialog box displays. you insert a 4 Axis Die feature.SLDPRT in the \Examples\EDM folder inside the CAMWorks data folder (e. You should run AFR even when you know AFR cannot find any features on a part. The Insert 4 Axis EDM Feature command allows you to define 4 axis features. click OK to use the default bounding box and material. then click OK.. click the Select button. Open the part file EDM4AX_1. you need to define features interactively using the Insert 4 Axis EDM Feature command. select TUTORIAL for the Make and TUTORIAL for the Model. the NC program will be generated in the following machining order: cut rough pass. 3-2 Learning 4 Axis Contour Cutting . then click OK. What You'll Learn Defining the Machine. On the Posting tab. but it cannot always recognize every feature on every part. 9. 7. then click OK. With this option.g. Click the Extract Machinable Features button on the CAMWorks toolbar. Click the CAMWorks Feature Tree tab. then all skim passes. Double click Stock Manager in the Feature tree. make sure the Process order for Die is set to By Complete Feature. In the Machine Selection dialog box. In this exercise. 8. glue stop cut off. To machine these areas.01in. 4. Stock and Machining Direction 1. On the EDM Setup tab. The Machine dialog box displays. For this exercise. Double click the Machine item in the CAMWorks Feature tree. 3. 11. Boss (Punch) and Open Profile features. 6. make sure the Wire diameter is set to 0. Running AFR sets up information for associativity that is necessary for the Rebuild function. Right click Wire EDM Mode–inch in the tree and select Edit Settings on the shortcut menu. Right click Wire EDM Mode–inch in the tree and click Select Machine on the shortcut menu. 12. nor does it currently support features where the side walls of the feature are not all vertical or not all constant taper. 10. 2.4-Axis Contour 1 4-Axis Contour 1 Automatic Feature Recognition (AFR) is a powerful tool.

pick the lower edge. Right click EDM Part Setup1 and select Insert 4 Axis EDM Feature on the shortcut menu.. Generating a 4 Axis Contour Operation and Toolpaths Generate operations and toolpaths. 3. The Insert 4 Axis EDM Feature dialog box displays. The start point on each curve is identified. Make sure Die is the selected Feature type. In this exercise. For Curve-2. 2. The Move Start Point buttons are used when Curve 1 and Curve 2 contain the same number of entities. 6. On the Leadin/out tab. 5. Pick the top face and click OK. Click Insert. 2. then click OK. then post process: 1. Rectangular 4-Axis Die1 is listed in the tree. Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the shortcut menu. Learning 4 Axis Contour Cutting 3-3 4. Right click Stock Manager in the Feature tree and select Insert Part Setup on the shortcut menu. AFR is not used since there are no 2 Axis EDM features on the part. click the Move Start Point button for one of the curves to change the position. If the start points are not as shown in Start points the figure. then click Close button to close the Insert 4 AXIS EDM Feature dialog. . pick the top edge of the rectangular pocket as shown in the figure. Double click 4 Axis Contour1 in the Operation tree. Defining a 4 Axis Die Feature Interactively Define a 4 Axis EDM feature interactively: 1. You need to insert a Part Setup interactively. 3.02in Length. The EDM Part Setup in the Feature tree is used to define the Z machining direction. Click the Close button to close the EDM setup dialog. 14. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. AFR creates the Part Setups necessary to machine the features that are recognized automatically. 4.4-Axis Contour 1 13. For Curve-1. set the Leadin and Leadout to Perpendicular with a .

This button is enabled when the simulation is complete and provides two methods for removing loose chips. use the vertical scroll bar to view the code. Click the operation in the tree to view the toolpath. Click the Post Process button on the CAMWorks toolbar or right click NC Manager in the Operation tree and click Post Process on the shortcut menu. The loose chips are removed in the graphics area. 11. 6. Post process the part and view the code: 15. Click the Select Chips to Remove button to exit the function.4-Axis Contour 1 5. Click OK to close the dialog box. Set the display:  Stock and Tool = Shaded Display  Holder = No Display  Target Part = No Display Click the Run button. 3. Click the Goto Start button and Run the simulation again. Click the Select Chips to Remove button. 3-4 Learning 4 Axis Contour Cutting . click Save. 12. 1. then press the D key. In the Post Output File dialog box. 2. When the post processing is finished. 5. Click the Select Chips to Remove button. Pick the loose stock chip to remove and press the D key. 4. picking the stock piece may be faster than picking each chip. Click the Simulate Toolpath button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the tree and select Simulate Toolpath. If there are many loose chips to remove. 9. 14. 7. 10. Click the Run button in the Post Process Output dialog box. Hold down the Ctrl key and pick the stock piece you want to keep. 13. 8. Click the X button in the upper right corner to cancel the simulation and return to the SolidWorks/CAMWorks Solids display.

click the Select button. then click OK. The sync curves are used to define sync points on the feature. 0 . Sync curves must be a single linear segment and can be selected from edges or 3D sketch objects. then the sync curves are ignored. The processing order is rough cut leaving glue stop. you insert the feature and automatically extract sync curves. Sync curves are similar to the guide curves used to create a loft feature in SolidWorks/CAMWorks Solids. 5. On the Posting tab. click OK to use the default bounding box and material. Automatically Extracting Sync Curves to Define a 4 Axis Feature 1. In the Machine Selection dialog box. then click OK. If the number of entities in Curve 1 and Curve 2 is equal.SLDPRT in the \Examples\EDM folder. Open the part file EDM4AX_2.4-Axis Contour 2 4-Axis Contour 2 What You'll Learn When defining 4 Axis Features. sync curves are required when the number of entities in Curve 1 is not equal to the number of entities in Curve 2. 10. 2. make sure TUTORIAL is selected for the Make and TUTORIAL for the Model. make sure the Process order for Punch is set to By Complete Feature. Learning 4 Axis Contour Cutting 3-5 . 9. then glue stop cut off. In the part below. In the Manage Stock dialog box. In the Available machines list. Double click the Machine item in the CAMWorks Feature tree. In this exercise. 3.6 skim passes. The Machine dialog box displays. the wire will arrive at the end points of each sync curve at the same time. Right click Wire EDM Mode–inch in the tree and click Select Machine on the shortcut menu. 8. Click the CAMWorks Feature Tree tab. Double click Stock Manager in the Feature tree. 6. 4. highlight Wire EDM Mode–inch. then click OK. Right click Wire EDM Mode–inch in the tree and select Edit Settings. As the wire cuts around the two curves defining the feature. 7. the number of entities in Curve 1 is not equal to the number of entities in Curve 2 of the 4 Axis feature.

4. For Curve-2. In such a case. 13.. then click Close. For Curve-1. 6. 3. you can pick an edge of the bottom face. You should run AFR even when you know AFR cannot find any features on a part. Right click Stock Manager in the Feature tree and select Insert Part Setup on the shortcut menu. Loop 2 will be selected in the Curve-2 area. Alternatively.. CAMWorks cannot extract sync curves automatically when a sketch is used for either Curve 1 or Curve 2 or both. Click Insert.4-Axis Contour 2 11. Click the Extract Machinable Features button on the CAMWorks toolbar. Click the ‘Automatically extract sync curves’ button. The Insert 4 Axis EDM Feature dialog box displays. Loop 1 will be selected in the Curve-1 area. Before Automatically Extracting Sync Curves After Automatically Extracting Sync Curves 3-6 Learning 4 Axis Contour Cutting . rotate the part and pick the bottom face. Did You Know . the ‘Automatically extract sync curves’ button is disabled. Insert the 4 Axis EDM feature interactively: 1. CAMWorks extracts the sync curves. 5. Click the Punch button for the Feature type. pick the top face of the part. Running AFR sets up information for associativity that is necessary for the Rebuild function. Pick the top face on the part and click OK. Right click Part Setup1 in the tree and select Insert 4 Axis EDM Feature on the shortcut menu. 2. 12.

4-Axis Contour 2 Generating the 4 Axis Contour Operation and Toolpaths Generate operations and toolpaths: 1. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. Expand 4 Axis Contour1 in the tree. The Glue stop option controls whether a tab is created automatically. Click the operation in the tree to view the toolpath. When No Glue Stop is selected. Notice that there is no Tab cut. On the EDM tab. then click 4-Axis Punch1 to expand it. Double click 4 Axis Contour1 in the Operation tree. Learning 4 Axis Contour Cutting 3-7 . 2. 3. 6. Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the shortcut menu. 5. 4. then click OK. a tab is not created and the NC program will not contain a glue stop. set the Glue stop to No Glue Stop.

Right click Wire EDM Mode–inch in the tree and select Edit Settings on the shortcut menu. make sure TUTORIAL is selected for the Make and TUTORIAL for the Model. On the Posting tab. In the Available machines list. then click OK. 14. 11. Click the Reverse selected entity button. 8. 3. You should run AFR even when you know AFR cannot find any features on a part. you select a sketch to define the top of the 4 Axis EDM feature. click the Select button. In the Manage Stock dialog box. 9. 5. In the Machine Selection dialog box. 10. Double click Stock Manager in the Feature tree. 7. highlight Wire EDM Mode–inch. then click OK. 2. 4. Double click the Machine item in the CAMWorks Feature tree. since the top face on the part is not parallel.SLDPRT in the \Examples\EDM folder. Click the CAMWorks Feature Tree tab. set the Process order for Punch to By Complete Feature. Right click Wire EDM Mode–inch in the tree and click Select Machine on the shortcut menu. then click OK. Using Sketches to Define a 4 Axis EDM Feature 1. and then click OK. Expand EDM4AX_3 in the graphics area and pick the Front reference plane. 12. Right click Stock Manager in the Feature tree and select Insert Part Setup on the shortcut menu. In this exercise. Running AFR sets up information for associativity that is necessary for the Rebuild function. Open the part file EDM4AX_3. Click the Extract Machinable Features button on the CAMWorks toolbar. click OK to use the default bounding box and material. 13. 3-8 Learning 4 Axis Contour Cutting . 6.4-Axis Contour 3 4-Axis Contour 3 What You'll Learn Faces and loops can be used to define a 4 Axis EDM feature if the faces/loops are on a plane that is parallel to the setup axis.

4. Rotate the part and notice the top and bottom start points are not lined up. Click the Move Start Point Location button under Curve-1 until the points line up as shown in the figure on the right hand side. Click Insert. Pick Sketch2 for Curve-1. Learning 4 Axis Contour Cutting 3-9 . pick the bottom face anywhere on the right side as shown in the figure. 7. Click the Punch button for the Feature type. the start position for Curve 1 or Curve 2 is moved from end point to end point. 2. and then click Close. 6. Each time you click the button. Right click EDM Part Setup1 in the tree and select Insert 4 Axis EDM Feature on the shortcut menu.4-Axis Contour 3 Insert the 4 Axis EDM feature interactively: 1. 5. The start point is used when Curve 1 and Curve 2 contain the same number of entities. Rotate the part so that the bottom face is visible. For Curve-2. 3.

Right click 4-Axis Punch1 under the operation and select Edit Leadin Point on the shortcut menu. 2. Set the display:  Stock. Click the + sign next to 4 Axis Contour1 in the tree to expand the item. 8. Click the Simulate Toolbar button of the CAMWorks toolbar or right click Part Setup1 in the tree and select Simulate Toolpath. The entry point marker displays at the midpoint of the selected edge. 11. 3-10 Learning 4 Axis Contour Cutting . Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the shortcut menu. Change the Select profile option to Bottom and pick the segment shown in the figure. The toolpath is automatically updated. Use the current settings in the Lead in Location dialog box and pick the segment shown in the figure. 4. 3. The Lead in Location dialog box displays and a round marker on the feature identifies the current leadin point. 9.4-Axis Contour 3 Changing the Leadin Point Generate the operation and toolpath: 1. Click OK. 7. Tool Holder and Target Part = Translucent Display  Tool = Shaded Display Click the Run button. 6. Click the X button in the upper right corner to cancel the simulation and return to the SolidWorks/CAMWorks Solids display. 10. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. 5.

13. click the Select button. make sure TUTORIAL is selected for the Make and TUTORIAL for the Model. 6. you insert a 4 Axis EDM feature that has an unequal number of entities in the top and bottom curves. however. 4. Right click Wire EDM Mode–inch in the tree and select Edit Settings on the shortcut menu. set the Process order for Punch to By Complete Feature. You should run AFR even when you know AFR cannot find any features on a part. 3. Double click the Machine item in the CAMWorks Feature tree. Learning 4 Axis Contour Cutting 3-11 . 5. Right click Stock Manager in the Feature tree and select Insert Part Setup on the shortcut menu. 10. In the Machine Selection dialog box. Running AFR sets up information for associativity that is necessary for the Rebuild function. Pick the top face on the part and click OK. then click OK. Picking Sync Curves to Define a 4 Axis EDM Feature 1. you used the automatic synchronization to insert a 4 Axis EDM feature that had an unequal number of entities in the top and bottom curves. highlight Wire EDM Mode–inch. 11. In the Available machines list. 7. Open the part file EDM4AX_4. 2. 8. 12. On the Posting tab.SLDPRT in the \Examples\EDM folder. you pick each of the sync curves instead of using the automatic function. Double click Stock Manager in the Feature tree. Click the CAMWorks Feature Tree tab.4-Axis Contour 4 4-Axis Contour 4 What You'll Learn In exercise 4-Axis Contour 2. then click OK. In this exercise. 9. click OK to use the default bounding box and material. Click the Extract Machinable Features button on the CAMWorks toolbar. Right click Wire EDM Mode–inch in the tree and click Select Machine on the shortcut menu. then click OK. In the Manage Stock dialog box. Because you use sketches for the curves.

In the Insert 4 Axis EDM Feature dialog box. Click the Simulate Toolbar button of the CAMWorks toolbar or right click Part Setup1 in the tree and select Simulate Toolpath. 6. Right click EDM Part Setup1 in the tree and select Insert 4 Axis EDM Feature on the shortcut menu. Pick the four segments shown in the figure to define the sync points. Click Insert. In most cases. 4. Set the display:  Stock.4-Axis Contour 4 Insert the 4 Axis EDM Feature interactively: 1. 5. 2. Sketches were used for demonstration purposes. Click in the Sync Curves list box to set the focus. picking the segments in sequential order is recommended. Click the Generate Operation Plan button on the CAMWorks toolbar or right click NC Manager or Part Setup1 in the Feature tree and select Generate Operation Plan on the shortcut menu. 5. pick Sketch2 for Curve-1. Click the Punch button for the Feature type. 3. The ‘Automatically extract sync curves’ button is disabled since a sketch was used for Curve-2. Generate the operation and toolpath: 1. however. 3. the order you pick the segments does not matter. and then click Close. 2. Tool Holder and Target Part = Translucent Display  Tool = Shaded Display Click the Run button. 3-12 Learning 4 Axis Contour Cutting . Click the X button in the upper right corner to cancel the simulation and return to the SolidWorks/CAMWorks Solids display. Pick Sketch1 for Curve-2. 6. 4. 7. Click the Generate Toolpath button on the CAMWorks toolbar or right click the Part Setup1 or NC Manager items in the Operation tree and select Generate Toolpath on the shortcut menu. Note that you can also insert this feature by picking the top and bottom faces or edges and using automatic synchronization.

3-9. 2-11 4 Axis EDM feature inserting Die 3-3 inserting Punch 3-6. 3-11 EDM Part Setup 1-8. 2-15. 2-6. 2-2. 2-12. 3-6. 3-8. 2-13. 2-2. 2-10. 2-14. 1-12. 2-11 defining 4 Axis EDM feature interactively 3-3. 3-7. 2-10. 2-8. 2-6. 3-5. 3-9 M Auto save option 1-13 Automatic Feature Recognition 1-7. 2-12. 3-10 editing leadin/leadout 1-10. 3-6. 3-12 Move Start Point button 3-3. 3-11 EDM Setup PropertyManager 2-11 Extract Machinable Features command 1-7. 3-6. 3-3. Machine tab 1-5 Machine Selection dialog box 1-5. 2-2. 2-15 2. 2-4. 2-14. 3-10. 2-8. 2-15. 2-10. 2-6. 3-3. 3-11 selecting make/model 1-5. 3-2. 2-2. 2-4. 3-12 using sketches 3-9 A Insert 4 Axis EDM Feature command 3-3. 3-8. 2-10. 3-5. 3-8. 3-8. 3-8. inserting 2-10. 215. 2-2 interactively inserting Die feature 2-7. 2-8. 2-15 i . 3-5. 3-11 Manage Stock dialog box 1-7 N Feature Definition dialog box 2-7. defining interactively 2-11 Operation tree 1-9 operations changing machining parameters 1-10. 2-15. 2-15 defining interactively 2-6. 2-6. 2-2 C CAMWorks machining trees 1-3 menu 1-4 Message Window 1-8. 2-5. NC program file extension 1-14 2 Axis Contour dialog box 1-10. 2-2. 2-14. 212.5 Axis EDM Feature command 2-6. 2-2. 3-9. 2-12. 3-3. 3-9. 3-2. 215. 3-9.5 Axis EDM feature interactively 2-6. 2-8. 2-2.5 Axis EDM feature defining automatically 1-7. 2-3 toolbar 1-4 Configurations 1-3 E Edit Leadin Point command 2-8. 3-8 EDM Settings dialog box 1-5. 3-3 interactively inserting Open Profile feature 2-11 interactively inserting Punch feature 2-7. 1-9 EDM Part Setup. 1-4. 3-12 Generate Toolpath command 1-10.txt. 3-12 Machine editing settings 3-2. 2-6. 2-11 Open Profile feature. 3-2. 3-10 Edit Settings command 3-2. 3-12 Insert 4 Axis EDM Feature dialog box automatically extract sync curves 3-6.Index Index . 3-2 setup options 1-6 Machine dialog box. 3-12 defining automatically 1-7. NC program 1-14 G NC program file 1-13 generating 1-13 generating 2 files 2-6 setting machining order 2-14 steps to generate 1-2 O Generate Operation Plan command 1-9. 3-3 editing leadin point 2-8. 3-5. 3-3 generating 2 Axis Contour 1-9. 3-7. 3-5. 2-12. 3-2 F machinable features customizing AFR 2-3 defining 2. 3-11 identifying type 1-3. 3-6. 2-6. 2-15 features recognized automatically 1-7. 2-10. 3-12 glue stop option 3-7 I Insert 2. 3-10. 2-11 Feature tree 1-8 file.

2-5. 2-8. 3-7.sldprt 3-2 edm4ax_2. 2-15. 3-4 Post Process Output dialog box 1-14. 2-5. 2-13. 3-4. 2-5. 2-13. 2-5. 2-5. 3-11 Punch feature. 2-6. inserting interactively 2-7 R Recycle Bin 1-4 S Save/Restore part option 1-13 shortcut menus 1-4 Simulate Toolpath command 1-11. 3-5. 2-10. 3-12 Options dialog box EDM Features tab 1-8. setting 1-6 workpiece See Stock parts used in exercises edm2ax_1. 3-12 Step Thru Toolpath command 1-12 steps to generate NC program 1-12 Stock 1-3. 2-13. 3-4 setting machining order 2-14 simulating 1-11. 3-10. 2-2. 2-9. 2-5. 3-4. 2-15 General tab 1-13 P T toolpaths generating 1-10. 3-10. 3-3. 3-12 generating toolpaths 1-10. 2-5. 3-7. 3-11 viewing code 1-14.sldprt 2-6 edm2ax_4. 2-3.sldprt 3-8 edm4ax_4.Index generating 4 Axis Contour 3-3. 3-12 stepping through 1-12 W wire diameter. 2-5. 2-9.sldprt 2-2 edm2ax_3.sldprt 2-14 edm4ax_1.sldprt 1-3 edm2ax_2. 3-12 post processing 1-13. 2-14. 3-3. 3-10. 3-4 selecting processing order 1-6. 3-10. 3-5. 2-8. 2-2. 2-13. 3-2. 3-8. 2-10. 2-5. 2-4 File Output tab 2-9. 2-15 Post Process command 1-13. 2-9. 3-4 simulating toolpaths 1-10. 3-4. 2-6. 2-14. 2-9. 2-15.sldprt 3-11 Perimeter punch feature 2-3 Post Output File dialog box 1-14. 2-5. setting 1-6. 3-4 Processing order. 2-13.sldprt 2-10 edm2ax_5. 3-8. 3-10. 3-12 glue stop option 3-7 post processing 1-13. 2-14. 2-13. 1-7 ii . 3-7. 3-10. 2-14. 2-5.sldprt 3-5 edm4ax_3. 3-2. 3-4 post process generating NC program 1-14.

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