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Contents

Using Tutorials

Tutorial 1in mm

Tutorial 1in inch

Tutorial 2

Tutorial 3

Tutorial 4

Tutorial 5

Tutorial 6

Tutorial 7

Tutorial 8

Tutorial 9

Using tutorials

The tutorials guide you through the actual programming process for a few sample parts. When you complete all the tutorials you will be able to use CAPSmill independently without any guidance.

To get the tutorials, click on the tutorials book in the help. A list of tutorials indicating the topics covered in it appears. Double click on the first tutorial. Perform the actions listed. At the end of each section, you will find a Back button, which leads you to the previous section, and a Next button, which leads you to the next. Clicking on underlined text leads to additional information on the topic. If you need information not available in the Tutorial, use the context sensitive Help in the software. The programming process consists of the following 8 steps:

Steps

Operation

Menu option

Step 1

Start new program

File

Step 2

Define work setup

 

Step 3

Draw the part

Geometry

Step 4

Define Blank

Geometry

Step 5

Perform Machining

Machining

Step 6

Select Machine

Machines

Step 7

View tool path

Tool path

Step 8

Generate NC program

NC program

Tool path Step 8 Generate NC program NC program You will notice that till View tool

You will notice that till View tool path the order of the steps is the same as in the main menu and icon bar. To do a program you will be following this order from Left to Right.

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Tutorial 1

In millimeters

Tutorial 1 In millimeters This tutorial illustrates: Creating the part and blank shapes Selecting tools Performing

This tutorial illustrates:

Creating the part and blank shapes

Selecting tools

Performing face milling, drilling and reaming operations

Viewing the tool path

Generating NC program

Generating documents

Part drawing in MM

View A-A 200 40 A 150 A 12 - f 10 holes at 30 pitch
View A-A
200
40
A
150
A
12 - f 10 holes
at 30 pitch on
PCD 100.
75

Material: Stainless steels, Austenitic. All dimensions are in MM.

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Start a new program

Steps to NC program

Start new program

Define work setup Draw the part Define Blank Perform

Machining Select Machine View tool path Generate NC program

Start CAPSmill. To do this, double click on the CAPSmill icon Or

Select Start ÆÆ Programs ÆÆ Cadem ÆÆ CAPSmill.

Select File ®®New

.
.

The Work setup dialog box appears.

Define work setup

Steps to NC program

Start new program

Machining Select Machine View tool path Generate NC program

Define work setup

Draw the part Define Blank Perform

The Work set up data is divided into Setup data and General data. Setup data is required for machining, and General data is documentation related to the program. Setup data must be entered, while General data is optional.

Select the Units as MM by clicking on it.

Select Stainless steels, austenitic, moderately difficult as the Workpiece material from the list.

Leave the Work coordinate system unchanged. The numbers 1 to 6 in the list correspond to the work offsets G54 to G59 on the

machine. Leave the Clearance height unchanged at 100 mm.

Enter the Tool change position as X=100, Y=100, Z=100.

Click on the General tab at the top of the dialog box and enter the general data as shown below.

Enter the Part number as 567-0099.

Enter the Part name as PLATE BOTTOM.

Enter the Setup number as 1.

Enter the Fixture name as FXT-9944.

Enter the Programmer name.

Enter the Remark as MODIFIED DUE TO DESIGN CHANGE NO. 7-A.

I

A fast way of moving between edit boxes is through the TAB key. Press TAB to move to the next edit box, or SHIFT+TAB (hold down the SHIFT key and press TAB) to move to the previous box.

Click on OK to exit from the Work setup dialog box.

Save the File

Select File ÆÆ Save

.
.

Enter the file name as PLATE.

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Draw the part

8 steps to NC program

Start new program Define work setup Generate NC program

Draw the part

Define Blank Perform Machining Select Machine View tool path

Select Geometry on the menu bar. The geometry menu appears, with options for drawing and editing the objects.

Draw the rectangle for face milling

Draw a rectangle of size 200 x 150

. The prompt Specify the center point appears in the status bar located at the

. The prompt Specify the center point appears in the status bar located at the bottom left hand corner of the screen.

Select Draw ÆÆ Rectangle ÆÆ Center – Length - Width

Breadth=150

Enter the coordinates 0,0 through the keyboard and press Enter.

A dialog box appears for entering the size of the rectangle. Enter the size as shown below against the respective prompts.

Length = 200

Corner radius=0 Rotation angle=0 Click on the OK button.

Draw the points for the ff 10 holes

The points lie on a pitch circle diameter of 100 mm. The coordinates for any hole machining operations should be defined as Points.

Select Draw ÆÆ Machinable objects ÆÆ Points on Circle . The prompt Specify the center

Select Draw ÆÆ Machinable objects ÆÆ Points on Circle

. The prompt Specify the center point appears in the status bar located at the bottom left hand corner of the screen. Enter the value 0,0

through the keyboard and press Enter. A dialog box appears for entering the points data. Enter the following values against the respective prompts.

Diameter=100

Angle of first hole=0 Number of holes=12 Click on the OK button.

Select Display ÆÆZoom All

12 Click on the OK button. Select Display ÆÆ Zoom All to see the entire part.

to see the entire part.

The part has now been defined. It should appear as shown below.

ÆÆ Zoom All to see the entire part. The part has now been defined. It should

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Define blank

8 steps to NC program

Start new program Define work setup Draw the part Generate NC program

work setup ‡ Draw the part ‡ Generate NC program Define Blank ‡ Perform Machining ‡

Define Blank Perform Machining Select Machine View tool path

The blank is always defined as a rectangular block. It is displayed during tool path simulation. To define it,

Select Define ®® Blank.

At the prompt Select rectangle <Press ‘Insert’ key for dialog input> that appears in the status bar, click on the 200 x 150 rectangle drawn

earlier. Enter the following data in the dialog box that appears and click on the OK button. Blank thickness = 80

Z coordinate at bottom = -75

The Minimum and Maximum X, Y coordinates are picked up automatically from the selected rectangle. Leave them unaltered. This ends the definition of Part (Rectangular block) and Blank.

I

The blank definition is optional. If it is not defined, it is automatically assumed as a rectangular block surrounding the area that is cut. The blank thickness entered here is 80 mm and the Z coordinate at bottom is -75 mm. This means that the blank

is

Z

at a height of 75 mm from the machine bed, which is the Z reference point for the program (i.e., the zero offset the along

axis).

Perform machining

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Generate NC program

Perform Machining

Select Machine View tool path

Select the tool for face milling

Click on Main to return to the main menu and then select Machining from the menu bar

.
.

I

I

If

you use the menu to change from Geometry to Machining, Machining to Tool path, etc., you must come to the Main menu

each time before you select an option. Clicking on an icon takes you straight to

each time before you select an option. Clicking on an icon takes you straight to the selected mode. Using icons is faster.

Select the face mill

Select Tool ÆÆ Face mill

Select Tool ÆÆ Face mill Against the prompt Manufacturer click on and select General - MM

Against the prompt Manufacturer click on

and select General - MM.

A dialog box appears with the default values. Enter the following data and leave the rest unchanged.

Enter Mill face against the prompt Process Name.

Against the prompt Tool material , click on

Against the prompt Tool material, click on

and select Carbide.

Against the prompt Tool name click on

and select Face mill Dia 80.0.

Click on the OK button.

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Perform face milling operation

Select Milling ÆÆ Face mill

Select Milling ÆÆ Face mill . At the prompt Select the area for face milling that

. At the prompt Select the area for face milling that appears on the status bar, click on the rectangle.

A dialog box with the default values appear. Enter the following data and leave the rest unchanged.

Against the prompt Process, click on Finishing Work Surface Z = 0 Material thickness = 5 Allowance after roughing = 0.5 Return to Z = 100 Click on Cutting parameters tab and enter Depth of cut = 3 Click on the OK button.

Notice that the cutting parameters are automatically selected from the database for the selected tool type, tool material and work piece material.

The prompt Select the machining start point appears in the status bar and also 4 symbols indicating the machining points and direction appear around the selected rectangle. Select the point at the top right corner as shown below.

Select
Select
Select
Select

Select

 

this point

Select   this point  
Select   this point  
 
 
 

Note : The Work surface Z to be specified for face milling is dependent on the blank definition. You had specified the blank thickness as 80

mm and the Z coordinate at bottom as -75 mm, while defining the blank. The remaining 5 mm over the blank is removed during the face milling

operation.

End the tool

A tool change is performed using the End option in the menu bar. To end the tool,

Click on End in the menu bar

Click on End in the menu bar . The dialog box for End of tool appears.

. The dialog box for End of tool appears.

Leave the data unaltered and click on the OK button.

This

completes the face milling operation.

 

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Select the tool for drilling

Select Tool ÆÆ Drill

Select Tool ÆÆ Drill Against the prompt Manufacturer , click on and select General - MM.

Against the prompt Manufacturer, click on

and select General - MM.

A dialog box appears with the default values. Enter the following data leaving the rest unchanged.

Enter PCD DRILLING against the prompt Process Name.

Against the prompt Tool material , click on and select HSS. and select Drill Dia

Against the prompt Tool material, click on

and select HSS.

and select Drill Dia 9.8.

 

Against the prompt Tool name click on

Click on the OK button.

Perform drilling operation

on Click on the OK button. Perform drilling operation . The prompt Select points to be

. The prompt Select points to be machined appears in the status bar. Click on one of the points in the hole pattern drawn earlier, as shown below.

Select Hole ÆÆ Drill

drawn earlier, as shown below. Select Hole ÆÆ Drill Select this point Since the hole is

Select

this point

Since the hole is part of a pattern, all the points in the pattern get selected.

Click the right mouse button and select Done.

The prompt Do you want to omit any holes? appear. Click on the No button.

A dialog box appears with default values for some of the prompts. Enter the following data and leave the rest unchanged.

Operation name = Drill on PCD Work surface Z = 0 Hole depth = 40 Return to Z = 100 Click on the OK button.

End the tool

This completes the drilling operation.

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Select the reamer

Select Tool ÆÆ Reamer

.
.

Enter the following data in the dialog box that appears leaving the rest unaltered :

Enter PCD REAMING against the prompt Process Name.

Against the prompt Manufacturer , click on and select General - MM. and select HSS.

Against the prompt Manufacturer, click on

and select General - MM.

and select HSS.

and select Reamer - Dia.10.

Against the prompt Tool material, click on

 

Against the prompt Tool name, click on

Click on the OK button.

Perform reaming operation

. The prompt Select points to be machined appears in the status bar. Click on

. The prompt Select points to be machined appears in the status bar. Click on one of the points in the hole pattern drawn earlier. Since the

Select Hole ÆÆ Ream

hole is part of point pattern, all the points in the pattern get selected Click the right mouse button and select Done.

The prompt Do you want to omit any holes? appears. Click on the No button.

A dialog box appears with default values. Enter the following data and leave the rest unchanged. Operation name = Ream on PCD Work surface Z = 0 Hole depth = 40Dwell at bottom = 1 Retract feed rate = 1 Return to Z = 100

Click on the OK button.

End the tool.

Save the file.

All the machining operations are now complete.

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Select machine

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Perform Machining Generate NC program

Select Machine

View tool path

The Work setup, Geometry definition, and Machining are independent of any machine. All functions after this are however dependent on the machine since they use the machine’s mechanical data like feed rate and spindle speed limits, spindle power, etc. The machine must be selected before executing the following functions:

View tool path

View power graph

Generate NC program

Generate Time study sheet

Generate Tool list

To select a machine,

Select Main ÆÆ Machines

Tool list To select a machine, Select Main ÆÆ Machines . A dialog box appears showing

. A dialog box appears showing the list of machines

Click on the machine you want to select.

Click on the OK button.

View tool path

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Perform Machining Select Machine Generate NC program

View tool path

To view the tool path,

Select Toolpath from the menu bar

Select Toolpath from the menu bar . The tool path menu appears.

. The tool path menu appears.

By default, simulation starts in solid mode and isometric view.

Select Simulation ÆÆ Start or click on

.
.

The mode can be solid or line mode. The view can be Isometric, XY, YZ or XZ. Simulation can be till the next motion, till the next tool, or till the end of the program.

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Generate NC program

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Perform Machining Select Machine View tool path

Generate NC program

 

To generate the NC program,

Click on Main to return to the main menu, then click on NC program on the menu bar.

Enter the program number in the dialog box that appears.

Select OK.

A status box indicating the location and file name of the program generated appears. The file gets saved with the main file name and .PRG

extension. Click on the Edit button to view the NC program.

Select File ÆÆ Exit to exit the editor.

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Generate the time study sheet

To generate the time study sheet,

Click on Documents ÆÆTime study sheet.

A Time study sheet format dialog box appears. Click on any format listed and click on the View button.

Note: The preview section displays the format selected. You can export the time study sheet to different formats through the Export button.

Click on the OK button to return to Time study sheet format dialog box and then click on OK to exit time study sheet.

Generate the tool list

To generate the tool list,

Click on Documents ÆÆTool list.

A Tool list format dialog box appears. Click on any format listed and click on the View button.

Note: The preview section displays the format selected. You can export the tool list to different formats through the Export button.

Click on the OK button to return to Tool list format dialog box and then click on OK to exit tool list.

Generate the power graph

To generate the power graph,

Click on Power graph on the menu bar.

A graph indicating the power consumed for each operation is displayed. Click on the Close button to exit power graph.

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Tutorial 1

In inches

The part is a rectangular block with twelve holes.

In inches The part is a rectangular block with twelve holes. This tutorial illustrates: Creating the

This tutorial illustrates:

Creating the part and blank shapes

Selecting tools

Performing face milling, drilling and reaming operations

Viewing the tool path

Generating NC program

Generating documents

Part drawing in inches

View A-A

8 1.2 A 6 A 3 12 - f 10 holes at 30 pitch on
8
1.2
A
6
A
3
12 - f 10 holes
at 30 pitch on
PCD 4.0

Material: Stainless steels, austenitic. All dimensions are in inches.

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Start a new program

Steps to NC program

Start new program

Define work setup Draw the part Define Blank Perform

Machining Select Machine View tool path Generate NC program

Start CAPSmill. To do this, double click on the CAPSmill icon Or

Select Start ÆÆ Programs ÆÆ Cadem ÆÆ CAPSmill.

Select File ®®New

.
.

The Work setup dialog box appears.

Define work setup

Steps to NC program

Start new program

Machining Select Machine View tool path Generate NC program

Define work setup

Draw the part Define Blank Perform

The Work set up data is divided into Setup data and General data. Setup data is required for machining, and General data is documentation related to the program. Setup data must be entered, while General data is optional.

Select the Units as INCH by clicking on it.

Select Stainless steels, austenitic, moderately difficult as the Workpiece material from the list.

Leave the Work coordinate system unchanged. The numbers 1 to 6 in the list correspond to the work offsets G54 to G59 on the machine.

Leave the Clearance height unchanged at 8 inch.

Enter Tool change position as X=8, Y=8, Z=8.

General data

Click on the General tab at the top of the dialog box and enter the general data as shown below.

Enter the Part number as 567-0099.

Enter the Part name as PLATE BOTTOM.

Enter the Setup number as 1.

Enter the Fixture name as FXT-9944.

Enter the Programmer name.

Enter the Remark as MODIFIED DUE TO DESIGN CHANGE NO. 7-A.

Tip: A faster way of moving between edit boxes is through the TAB key. Press TAB to move to the next edit box, or SHIFT+TAB (hold down the SHIFT key and press TAB) to move to the previous box.

Click on OK to exit from the Work setup dialog box.

Save the File

on OK to exit from the Work setup dialog box. Save the File Select File ÆÆ

Select File ÆÆ Save

. Enter the file name as PLATE.

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Draw the part

8 steps to NC program

Start new program Define work setup Generate NC program

Draw the part

Define Blank Perform Machining Select Machine View tool path

Select Geometry on the menu bar. The geometry menu appears, with options for drawing and editing the objects.

Draw the rectangle for face milling

Draw a rectangle of size 6.0 x 4.0

. The prompt Specify the center point appears in the status bar located at the

. The prompt Specify the center point appears in the status bar located at the bottom left hand corner of the screen.

Select Draw ÆÆ Rectangle ÆÆ Center – Length - Width

Breadth=4

Enter the coordinates 0,0 through the keyboard and press Enter.

A dialog box appears for entering the size of the rectangle. Enter the size as shown below against the respective prompts.

Length = 6

Corner radius=0 Rotation angle=0 Click on the OK button.

Draw the points for the ff 0.495 holes

The points lie on a pitch circle diameter of 4 mm. The coordinates for any hole machining operations should be defined as Points.

Select Draw ÆÆ Machinable objects ÆÆ Points on Circle . The prompt Specify the center

Select Draw ÆÆ Machinable objects ÆÆ Points on Circle

. The prompt Specify the center point appears in the status bar located at the bottom left hand corner of the screen. Enter the value 0,0

through the keyboard and press Enter. A dialog box appears for entering the data. Enter the following values against the respective prompts.

Diameter = 4 Angle of first hole = 0 Number of holes = 12 Click on the OK button.

The part has now been completely defined. It should appear as shown below.

Click on the OK button. The part has now been completely defined. It should appear as

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Define blank

8 steps to NC program

Start new program Define work setup Draw the part Generate NC program

work setup ‡ Draw the part ‡ Generate NC program Define Blank ‡ Perform Machining ‡

Define Blank Perform Machining Select Machine View tool path

The blank is always defined as a rectangular block. It is displayed during tool path simulation. To define it,

Select Define ®® Blank.

At the prompt Select rectangle <Press ‘Insert’ key for dialog input> that appears on the status bar, click on the 6 x 4 rectangle drawn

earlier. Enter the following data in the dialog box that appears and click on the OK button. Blank thickness = 3.3

Z coordinate at bottom = -3

Click on the OK button.

This ends the definition of the Part (Rectangular block) and Blank.

I

The blank definition is optional. If it is not defined, it is automatically assumed as a rectangular block surrounding the area that is cut. The blank thickness entered here is 80 mm and the Z coordinate at bottom is -75 mm. This means that the blank

is

Z

at a height of 75 mm from the machine bed, which is the Z reference point for the program (i.e., the zero offset the along

axis).

Perform machining

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Generate NC program

Perform Machining

Select Machine View tool path

Select a tool for face mill

Click on Main to return to the main menu and then select Machining in the main menu

.
.

I

I

If

you use the menu to change from Geometry to Machining, Machining to Tool path, etc., you must come to the Main menu

each time before you select an option. Clicking on an icon takes you straight to

each time before you select an option. Clicking on an icon takes you straight to the selected mode. Using icons is faster.

Select the face mill

Select Tool ÆÆ Face mill

Select Tool ÆÆ Face mill Against the prompt Manufacturer , click on and select General -

Against the prompt Manufacturer, click on

and select General - Inch.

A dialog box appears with the default values. Enter the following data and leave the rest unchanged.

Enter Mill face against the prompt Process Name.

Against the prompt Tool material , click on and select Carbide . and select Face

Against the prompt Tool material, click on

and select Carbide.

and select Face mill Dia 3.0.

 

Against the prompt Tool name, click on

Click on the OK button.

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Perform Face milling operation

Select Milling ÆÆ Face mill

.
.

At the prompt Select the area for face milling that appears in the status bar, click on the rectangle.

A dialog box appears with default values against some prompts. Enter the following data and leave the rest unchanged.

Process: Click on Finishing. Material thickness: 0.3 Allowance after roughing: 0.02 Return to Z: 4 Click on Cutting parameters tab. Depth of cut: 0.1 Click on the OK button.

Notice that the cutting parameters are automatically selected from the database for the selected tool type, tool material and work piece material.

The prompt Select the machining start point appears in the status bar and also 4 symbols indicating the machining points and direction appear around the selected rectangle. Select the point at the top right corner as shown below.

Select the point at the top right corner as shown below. Select this point Note: The

Select

this point

Note: The Work surface z to be specified for face milling operation is dependent on the blank definition. You had specified the blank thickness as 3.3 inches and the Z coordinate at bottom as –3 inch, while defining the blank. The remaining 0.3 inch over the blank is removed during the face milling operation.

End the tool

A tool change is performed using the End option in the menu bar. To end the tool,

Click on End in the menu bar

Click on End in the menu bar . The dialog box for End of tool appears.

. The dialog box for End of tool appears.

Leave the data unaltered and click on the OK button.

This completes the face milling operation.

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Select the tool for drilling

Select Tool ÆÆ Drill

Select Tool ÆÆ Drill Against the prompt Manufacturer , click on and select General - Inch.

Against the prompt Manufacturer, click on

and select General - Inch.

A dialog box appears with the default values. Enter the following data and leave the rest unchanged.

Enter PCD DRILLING against the prompt Process Name.

Against the prompt Tool material , click on and select HSS. and select Drill Dia

Against the prompt Tool material, click on

and select HSS.

and select Drill Dia 0.495.

 

Against the prompt Tool name, click on

Click on the OK button.

Perform drilling operation

.
.

Select Hole ÆÆ Drill

The prompt Select points to be machined appears in the status bar. Click on one of the points in the hole pattern drawn earlier, as shown

below. Select this point
below.
Select
this point

Since the hole is part of point pattern, all the points in the pattern get selected.

Click the right mouse button and select Done.

The prompt Do you want to omit any holes? appears. Click on the No button.

A dialog box appears with default values for some of the prompts. Enter the following data and leave the rest unchanged.

Operation name = Drill on PCD Work surface Z = 0 Hole depth = 1.2 Return to Z = 4 Click on the OK button.

End the tool

This completes the drilling operation.

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Select a reamer

Select Tool ÆÆ Reamer

.
.

Enter then following data in the dialog box that appears :

Enter PCD REAMING against the prompt Process Name.

Against the prompt Manufacturer , click on and select General - Inch and select HSS.

Against the prompt Manufacturer, click on

and select General - Inch

and select HSS.

and select Reamer Dia 1/2.

Against the prompt Tool material, click on

 

Against the prompt Tool name, click on

Click on the OK button.

Perform reaming operation

. The prompt Select points to be machined appears in the status bar. Click on

. The prompt Select points to be machined appears in the status bar. Click on one of the points in the hole pattern drawn earlier. Since the hole is

Select Hole ÆÆ Ream

part of point pattern, all the points get selected Click the right mouse button and select Done.

The prompt Do you want to omit any holes? appears. Click on the No button.

A dialog box appears with default values for some of the prompts. Enter the following data and leave the rest unchanged.

Operation name = Ream on PCD Work surface Z = 0 Hole depth = 1.2 Dwell at bottom = 1 Retract feed rate = 3 Return to Z = 4 Click on the OK button.

End the tool

Save the file.

All the machining operations are now complete.

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Select machine

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Perform Machining Generate NC program

Select Machine

View tool path

The Work setup, Geometry definition, and Machining are independent of any machine. All functions after this are however dependent on the machine since they use the machine’s mechanical data like feed rate and spindle speed limits, spindle power, etc. The machine must be selected before executing the following functions:

View tool path

View power graph

Generate NC program

Generate Time study sheet

Generate Tool list

To select a machine,

Select Main ÆÆMachines

Tool list To select a machine, Select Main ÆÆ Machines . A dialog box appears showing

. A dialog box appears showing the list of machines

Click on the machine you want to select.

Click on the OK button.

View tool path

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Perform Machining Select Machine Generate NC program

View tool path

To view the tool path,

Select Toolpath from the menu bar

Select Toolpath from the menu bar . The tool path menu appears.

. The tool path menu appears.

By default, simulation starts in solid mode and isometric view.

Select Simulation ÆÆ Start or click on

.
.

The mode can be solid or line mode. The view can be Isometric, XY, YZ or XZ. Simulation can be till the next motion, till the next tool, or till the end of the program.

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Generate NC program

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Perform Machining Select Machine View tool path

Generate NC program

 

To generate the NC program,

Click on Main to return to the main menu, then click on NC program on the menu bar.

Enter the program number in the dialog box that appears.

Select OK.

A status box indicating the location and file name of the program generated appears. The file gets saved with the main file name and .PRG

extension. Click on the Edit button to view the NC program.

Select File ÆÆ Exit to exit the editor.

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Generate the time study sheet

To generate the time study sheet,

Click on Documents ÆÆTime study sheet.

A Time study sheet format dialog box appears. Click on any format listed and click on the View button.

Note: The preview section displays the format selected. You can export the time study sheet to different formats through the Export button.

Click on the OK button to return to Time study sheet format dialog box and then click on OK to exit time study sheet.

Generate the tool list

To generate the tool list,

Click on Documents ÆÆTool list.

A Tool list format dialog box appears. Click on any format listed and click on the View button.

Note: The preview section displays the format selected. You can export the tool list to different formats through the Export button.

Click on the OK button to return to Tool list format dialog box and then click on OK to exit tool list.

Generate the power graph

To generate the power graph,

Click on Power graph on the menu bar.

A graph indicating the power consumed for each operation is displayed. Click on the Close button to exit power graph.

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Tutorial 2

Tutorial 2 This tutorial illustrates Face milling on a contour Using subprograms for hole machining Pocket

This tutorial illustrates

Face milling on a contour Using subprograms for hole machining Pocket milling a regular contour
Face milling on a contour
Using subprograms for hole machining
Pocket milling a regular contour
Side milling an irregular contour
The part drawing in mm
20
300
B
R15
75
75
125
R100
R200 (typ)
B
M10 X1.5 pitch
6 holes on 60
PCD, 60 pitch,
10 mm deep
30

All dimensions are in MM. Material: Cast iron, alloy, medium hardness.

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Start a new program

Steps to NC program

Start new program

Define work setup Draw the part Define Blank Perform

Machining Select Machine View tool path Generate NC program

Start CAPSmill. To do this, double click on the CAPSmill icon

Or

Select Start ÆÆ Programs ÆÆ Cadem ÆÆ CAPSmill.

Select File ÆÆNew

.
.

The Work setup dialog box appears.

Define work setup

Steps to NC program

Start new program

Machining Select Machine View tool path Generate NC program

Define work setup

Draw the part Define Blank Perform

Enter the data shown below in the work setup dialog box that appears. Select the Units as MM. Select Cast iron, medium hardness as the Workpiece material from the list. Leave the Work coordinate system unchanged. (The numbers 1 to 6 in the list corresponds to the work offsets G54 to G59 on the machine). Enter the Clearance height as 250 mm. Enter the Tool change position as X=0, Y=0, Z=400.

Click on OK, or enter the following General data and then click on OK (General data is optional). Enter the Part number as 540-103-00022. Enter the Part name as END PLATE. Enter the Setup number as 1. Enter the Fixture name as EP-540-808-011. Enter the name of the Programmer. Enter the Remark as IMPORTANT: CHECK THE COMPONENT HEIGHT.

Save the File

Enter the file name as END PLATE.

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Draw the part

8 steps to NC program

Start new program Define work setup Generate NC program

Draw the part

Define Blank Perform Machining Select Machine View tool path

Go to the Geometry menu.

Draw circles of radius 100 mm. and 150 mm.

Select Draw ÆÆ Circle ÆÆ Centre - radius . The prompt Specify center of circle

Select Draw ÆÆCircle ÆÆ Centre - radius

. The prompt Specify center of circle appears in the status bar. Enter 0,0 and press Enter.

The prompt Radius appears in the status bar. Enter 100. Circle c1 is drawn.

Draw the circle c2 with center point 300,0 and radius of 150 mm.

The part at this stage looks as shown below.

Note: Texts c1 and c2 are shown for clarity and do not actually appear on the screen.

shown for clarity and do not actually appear on the screen. Circle C1 Circle C2 .

Circle C1

clarity and do not actually appear on the screen. Circle C1 Circle C2 . At the

Circle C2

. At the prompt Select first object that appears in the status bar, select the

. At the prompt Select first object that appears in the status bar, select the circle c1 by clicking on its upper half.

To draw the circle c3 tangential to c1 and c2, Select Draw ÆÆCircle ÆÆ Tangent-Tangent-Radius

At the prompt Select second object, select the circle c2 by clicking on its upper half.

Enter 200 at the prompt Specify the Radius that appears in the status bar. Circle C3 appears on the screen, which is drawn tangent to the

circles C1 and C2. Similarly, draw the circle C4 tangential to C1 and C2, with the same radius of circle C3 (200).

Select Display ÆÆZoom all

Select Display ÆÆ Zoom all , to get all the objects within the screen.

, to get all the objects within the screen.

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The drawing at this stage appears as shown below.

Note: Texts c1, c2, etc. are shown for clarity and do not actually appear on the screen.

Circle C3 C2 C1 Circle C4
Circle C3
C2
C1
Circle C4

Trim the circles

Break the circles at their points of tangency and erase the unwanted arcs.

Break the circles at their points of tangency and erase the unwanted arcs.

Break the circle C3: Select Edit ÆÆ Break

. The prompt Select the object to break appears. Click on C3.

At the prompt Specify a point on the selected object that appears in the status bar, click on the right mouse button and select Intersection of.

Click on the intersection point of C1 and C3, at point P1 as shown in the figure below.

Another prompt Specify a point on the selected object appears in the status bar. Click on the right mouse button and select Intersection of.

Click at the intersection point of the circles C2 and C3, at point P2. C3 is now broken into two individual arcs.

To erase the upper arc of C3 select Edit ÆÆ Erase point shown in the figure below.

select Edit ÆÆ Erase point shown in the figure below. . The prompt Select objects [Press

. The prompt Select objects [Press W to select through window] appear. Click on the

Click here to erase after break

C3 C2 C1 C4
C3
C2
C1
C4
P1
P1
P2
P2
on the Click here to erase after break C3 C2 C1 C4 P1 P2 Click here

Click here to erase after break

Click on the right mouse button and select Done.

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Similarly, break the lower circle C4 at the tangential points with circles C1 and C2 and erase the unwanted portion.

Select Display ÆÆRedraw . The drawing will now appear as shown below. P3 P5 C2
Select Display ÆÆRedraw
.
The drawing will now appear as shown below.
P3
P5
C2
C1
P6
P4

Break the circle C1 at the points P5 and P6 as shown above and erase the inner arc.

Break the circle C2 at the points P3 and P4 as shown above and erase the inner arc.

The drawing now looks as shown below.

erase the inner arc. The drawing now looks as shown below. Define the part contour The

Define the part contour The drawing now is a combination of various arcs. For machining, it must be converted into a single contour (i.e., Machinable contour).

Select Define ÆÆ Machinable objects ÆÆ Auto . The prompt Specify the first point appears

Select Define ÆÆ Machinable objects ÆÆ Auto

. The prompt Specify the first point appears in the status bar. Click anywhere on the shape, as shown below.

The prompt Select any one of the highlighted objects to continue contour creation appears.

Click on the highlighted entities (entities in the form of dotted lines, as indicated below in the figure) till you get the message Do you want to

save the selected contour? Click on Yes.

The drawing will now appear as shown below.

Select this point for contour creation. Click here to continue contour creation.
Select this point for
contour creation.
Click here to
continue contour
creation.

The part shape is now converted to a single contour.

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Draw points for the tapped holes

The holes lie on a pitch circle diameter (PCD) of 60 mm.

Select Draw ÆÆ Machinable objects ÆÆ Points on circle.

Specify the center point as 0,0 against the prompt that appears in the status bar.

Enter the data shown below in the dialog box that appears:

Diameter = 60 Angle of first hole = 0 Number of holes = 6 Click on the OK button.

Draw the rectangle for the pocket

Select Draw ÆÆ Rectangle ÆÆ Centre – Length - Width.

Specify the center point as 300,0 at the prompt that appears in the status bar and press the Enter key.

Enter the following data in the dialog box that appears:

Length = 125. Breadth = 75. Corner radius = 20. Rotation angle = 0. Check Save in machinable contour. Click on the OK button.

The drawing will now appear as shown below.

the OK button. The drawing will now appear as shown below. Tip: Select Display Æ Zoom

Tip: Select Display ÆZoom All

Tip: Select Display Æ Zoom All to shift the part you have drawn to the center

to shift the part you have drawn to the center of the screen

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Define blank

8 steps to NC program

Start new program Define work setup Draw the part Generate NC program

work setup ‡ Draw the part ‡ Generate NC program Define Blank ‡ Perform Machining ‡

Define Blank Perform Machining Select Machine View tool path

To draw the blank,

Select Draw ÆÆ Rectangle ÆÆ Centre – Length - Width.

Enter the center point as 175, 0 against the prompt that appear in the status bar and press Enter.

Enter the data shown below, in the dialog box that appears, leaving the remaining entries unchanged:

Length = 550 Breadth = 300. Check Save in machinable contour. Click on the OK button.

To define the blank,

Select Define ÆÆ Blank

Select the 550 x 300 rectangle drawn earlier.

Enter the data shown below, in the dialog box that appears:

Blank thickness = 35 Z coordinate at bottom = 70 Leave the maximum and minimum X, Y coordinates unaltered. Click on the OK button.

Save the File

.
.

The drawing will appear as shown below.

Save the File . The drawing will appear as shown below. This ends definition of the

This ends definition of the part and blank.

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Perform machining

8 steps to NC program

Start new program Define work setup Draw the part Define Blank Generate NC program

Perform Machining

Select Machine View tool path

Click on Main to return to the main menu and then Machining in the menu bar Machining involves:

.
.

1.

Face milling the plate with a 50 mm diameter face mill.

2.

Drilling with 9.8 mm diameter drill.

4.

Countersink with 16 mm diameter countersink cutter

5.

Tap with M10 x 1.5 tap

6.

Pocket mill the inside rectangle with 20 mm diameter end mill.

7.

Side mill contour with 20 mm diameter end mill

Performing a machining operation involves 3 steps:

Select a tool

Perform operation or operations

End the tool

Here, we will first define the subprograms for hole machining operations. The hole machining operations to be performed on this part are Drilling, Countersinking and Tapping.

The operations are performed on the same six hole locations. These hole locations can be defined in a subprogram and which is called for different operations.

Define the Subprogram:

Select Subprogram ÆÆ Define from the menu bar.

Enter Tappoints as the subprogram name.

Leave the machining face as the Standard Face.

Select Subprogram of point patterns as the subprogram type.

Click on the OK button.

The subprogram menu appears. Select Hole pattern ÆÆ Select / Deselect.

Click on any one of the points at the prompt Select points to be machined. All the points get selected.

Click the right mouse button and select Done.

At the prompt Do you want to omit any holes? Select No.

Click on Machining to return to the machining menu.

The subprogram Tappoints with six hole locations has now been defined.

Note: If you have made a mistake in entering the data for any process, it can still be modified through the Edit

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menu in Machining.

Perform face milling operation

Select the tool : Select Tool ÆÆ Face mill Process name: MILL FACE Manufacturer: GENERAL-MM

Select the tool : Select Tool ÆÆ Face mill Process name: MILL FACE Manufacturer: GENERAL-MM Tool type: Face mill Tool material: Carbide Tool name: Face mill Dia 50.0

. Enter or select the following parameters in the Face mill selection dialog box that appears:

Click on the OK button.

Perform the operation : Select Milling Æ Face mill.

Click on the 550 x 300 rectangle at the prompt Select the area for face milling. Enter the data shown below in the dialog box that appears. Leave the rest of the data unchanged. Operation name: Face mill profile. Process: click on Finishing. Work surface Z: 100. Material thickness: 5 Allowance after roughing 0.4. Return to Z: 200. Click on Cutting parameters tab. Depth of cut: 5.

Click on the OK button. Four ‘+’ signs appear around the selected rectangle. Select a suitable start point at the prompt Select the machining start point, by clicking on any one of the ‘+’ signs.

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Select a drill

Select the tool : Click on Enter the data shown below in the dialog box that appears:

Process name: Drill 9.8 Dia. Holes Manufacturer: GENERAL-MM Tool type: Drill Tool material: HSS Tool name: Drill Dia. 9.8

Click on the OK button.

Perform drilling operation

The location for the drilling operation will be specified as the subprogram Tappoints instead of actually selecting points.

The following data in the Perform the drilling operation : Select Hole ÆÆ Drill

.
.

At the prompt Select the points to be machined select Subprogram ÆÆCall.

Select the subprogram Tappoints and click on OK.

Click the right mouse button and select Done.

Select No at the prompt Do you want to omit any holes?

Enter drilling dialog box that appears, leaving the remaining entries unchanged.

Hole depth = 20 Return to Z = 200 Click on the OK button. End the tool.

Countersink the holes:

Select the tool : Select Tool ÆÆ Countersink

Select the tool : Select Tool ÆÆ Countersink . Select the appropriate tool from the GENERAL-MM

. Select the appropriate tool from the GENERAL-MM manufacturer.

Perform the operation : Select Hole ÆÆ Countersink

Perform the operation : Select Hole ÆÆ Countersink . Call the subprogram Tappoints for the points

. Call the subprogram Tappoints for the points to be machined, from the Subprogram

menu. Click on the right mouse button and select Done.

Enter the following data in the countersink dialog box that appears, leaving the remaining entries unchanged.

- Work surface Z = 100

- Chamfer diameter = 16

- Dwell at bottom = 1

Return to Z = 200 Click on the OK button. End the tool.

-

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Tap the holes:

Select the tool : Select Tool ÆÆ Tap

. Select the appropriate tool from the GENERAL-MM manufacturer.

. Select the appropriate tool from the GENERAL-MM manufacturer.

Perform the operation : Select Hole ÆÆ Tap

Perform the operation : Select Hole ÆÆ Tap . Call the subprogram Tappoints for the points

. Call the subprogram Tappoints for the points to be machined, from the Subprogram menu.

Click on the right mouse button and select Done.

Enter the following data in the Tap dialog box that appears, leaving the remaining entries unaltered.

Work surface Z = 100 Hole depth = 10 Return to Z = 200 Click on the OK button. End the tool.

Perform Pocket milling operation

Pocket milling operation is to be performed using an End mill.

Click on Tool ÆÆEnd mill.

Select a 20 mm diameter end mill from the GENERAL-MM manufacturer.

The remaining tool selection parameters are automatically selected from the database.

Click on the OK button.

Select Milling ÆÆ Pocket.

Select the smaller rectangle as the area for pocket milling, against the prompt that appears in the status bar.

At the prompt Do you want to specify islands?, Select No.

Enter the data shown below, in the pocket milling dialog box that appears. Do not alter any other data. Work surface Z: 100 Pocket depth: 20

Allowance after roughing

Bottom: 0.2

Side: 0

Return to Z: 200 Click on Cutting method tab Cutting method: Select ZigZag Click on Cutting parameters tab Depth of cut: 4

Click on the OK button.

At the prompt Select the start point of ramping INSIDE the pocket ‘ click inside the rectangle as shown below.

the pocket ‘ click inside the rectangle as shown below. Click here This completes the pocket

Click here

This completes the pocket milling operation. Do not End the tool now. The same tool can be used to perform Side milling operation along the contour.

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Perform side milling operation

Select Side mill from the Milling pull down menu.

The prompt Select the contour/shape/line for side milling appears in the status bar. Click on the defined machinable object.

The prompt Select the machining start point appears. Select a convenient start point on the contour.

At the prompt Do you want to mill the whole contour?, select Yes.

The prompt Click on the circle to specify the side for milling appears and also two circle appears on the selected contour. Click on the outer

circle to indicate side milling on the outer side of the contour. Enter the data shown below in the side milling operation dialog box that appears. Leave all the other entries unaltered. Process: Click on Side finish Cutting method: Select the first option (Multiple depth multiple width) Work surface Z: 100 Material width: 3 Material depth: 30

Allowance after roughing Return to Z: 200 Check Output CRC for finishing?

Bottom: 0.2

Side: 0.2

Click on Tool entry / exit tab Entry type: Select Line tangent Entry distance: 12

Exit type: Select Arc tangent Exit arc angle: 80

Exit distance: 12

Click on Cutting parameters tab Depth of cut: 4 Click on the OK button.

End the tool.

Save the file.

This completes all the machining operations on the part. We have however made a mistake. The material thickness is 5 mm for the face milling operation and the depth of cut too is 5 mm, which means that the entire material is removed in a single cut. Modify the operation to reduce the depth of cut to 3 mm. To modify the process,

Click on Edit . The Edit box appears with the list of all the tools

Click on Edit

. The Edit box appears with the list of all the tools selected and operations performed so far.

Click on the operation Face mill profile, and then click on the Modify button.

The prompt Do you want to reselect the machining area appears. Select No.

The face milling dialog box appears with the data entered earlier. Change the depth of cut to 3.

Click on the OK button.

Click on the OK button to return to the Machining menu.

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Simulated part

Simulated part Modify a process Click on Edit . An edit box appears with the list

Modify a process

Click on Edit.

An edit box appears with the list of all the tools selected and operations performed so far.

Select the tool or operation that you want to modify by clicking on it. Click on the Modify button.

If you have selected a tool for modification, the tool dialog box appears. Make the necessary changes and click on the OK button.

If you have selected an operation for modification, a prompt Do you want to reselect the machining area appears.

- Select yes if you want to change the machining area for that operation. Reselect the machining area at the respective prompts. - Click on No if you want to change only the dialog box entries and not the machining area. Click on the OK button after making the necessary changes.

After all the changes are made, click on the OK button to return to the Machining menu.

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Tutorial 3

Tutorial 3 This chapter illustrates: Milling a pocket with an island. Milling a groove. The part

This chapter illustrates:

Milling a pocket with an island.

Milling a groove.

The part drawing is in mm

R 6 R 5 200 200
R 6
R 5
200
200

Material : Soft low carbon steel All dimensions are in MM.

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is in mm R 6 R 5 200 200 Material : Soft low carbon steel All
50
50

20

is in mm R 6 R 5 200 200 Material : Soft low carbon steel All
is in mm R 6 R 5 200 200 Material : Soft low carbon steel All

10

35

Draw the part

Start a new file and define the work setup.

Save the file as Block.

Go to the Geometry menu.

First draw the rectangle of dimension 200 x 200 (Refer the drawing for the coordinates).

To draw the polygon,

 

Select Draw ÆÆ Polygon.

Specify the center point of the polygon against the prompt that appears in the status bar. To do this, click on the right mouse buttonÆ

Select Centre of. Click on the rectangle drawn earlier.

Enter the following data in the dialog box that appears, leaving the rest unchanged:

Length of side: 60 Number of sides: 8 Corner radius: 5 Check Save in machinable contour Click on the OK button.

Draw the second rectangle of dimension 60 x 60 (Refer the drawing for the coordinates).

To draw the groove,

- Select Draw ÆÆ Machinable objects ÆÆGroove

.
.

- Specify the center point as 0,0

- Enter the data shown below in the dialog box that appears:

Length: 60 Breadth: 15 Click on the OK button.

This completes the part shape.

Define blank

The rectangle of dimension 200 x 200 can be defined as the blank.

Select Define ÆÆ Blank.

Click on rectangle (200 x 200).

Specify Blank thickness as 50 and Z coordinate at the bottom as 0.

Observe that the Work surface Z specified is 50 mm and the Z coordinate at the bottom is 0. This means that the zero offset on the machine along Z axis is the machine bed. This completes the Geometry part.

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Perform Machining

Go to the Machining menu. The machining operations involve:

1. Mill pocket with 20 mm diameter end mill.

2. Mill groove with 12 mm diameter end mill.

First, select an end mill of dia. 20 mm. The tool is available in GENERAL-MM tool manufacturer. To perform pocket milling operation,

Click on Milling ÆÆPocket.

Select the octagon for pocket machining.

At the prompt Do you want to specify islands? Select Yes.

Click on the smaller rectangle (This rectangle is selected as the island).

Operation name: Mill pocket excluding islands

Click the right mouse button and select Done.

Alter only the following data in the dialog box that appears:

Work surface Z: 50 Pocket depth: 20

Allowance after roughing

Bottom: 0.3

Return to Z: 100 Click on Cutting method tab Select Cutting method: ZigZag. Click on Cutting parameters tab Select Depth of cut: 2 Click on the OK button.

Click inside the polygon drawn earlier, at the prompt Select the point of ramping INSIDE the pocket

Click on End on the menu bar to end the operation.

Perform groove milling operation

Select an end mill of dia. 12 mm. The tool is available in GENERAL-MM manufacturer. To perform pocket milling operation,

Select Milling ÆÆGrooving

.
.
 

Click on the groove at the prompt Select the object for grooving.

Alter only the following data in the dialog box that appears:

Operation name: Groove milling Process: Click on Side finish. Work surface Z: 50 Groove depth: 10

Allowance after roughing

Bottom: 0.3

Return to Z: 100 Click on Tool entry / exit tab Entry distance: 10 Exit distance: 10 Click on Cutting parameters tab Depth of cut: 2

Click on the OK button.

Select End on the menu bar to end the operation.

Save the file

End on the menu bar to end the operation. Save the file This completes all the

This completes all the machining operations.

.

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Simulated part

Simulated part CAPSmill ver 7.0 3 8

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Tutorial 4

Tutorial 4 FACE 1 FACE 2 This tutorial illustrates performing machining operations on two faces of
Tutorial 4 FACE 1 FACE 2 This tutorial illustrates performing machining operations on two faces of

FACE 1

FACE 2

This tutorial illustrates performing machining operations on two faces of a job. Depending on whether the part is being machined on a Vertical Machining Center (VMC) or a Horizontal Machining Center (HMC), the part definition in CAPSmill varies.

On a VMC, after machining FACE 1, FACE 2 is placed beside FACE 1 and then machined using a different work offset number. There is no table rotation in this case.

On an HMC, the component is clamped on the table that can rotate along an axis, Say B axis. After machining FACE 1, the table is rotated through 180º, and then FACE 2 is machined using a different work offset number.

The part is a regular contour having operations on two faces.

Part drawing 200 15 30 Face 1 Face 2 50 100 150 200 10 8
Part drawing
200
15
30
Face 1
Face 2
50
100
150
200
10
8 holes of dia.
20 with 25 dia
counterbore
60
100

Material: Low Alloy Cast iron. All dimensions are in MM.

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Draw the part

Create a new file and define the work setup.

Save the file as FIXED PLATE.

Go to the Geometry menu.

Draw the first face (Face 1) of the part in the standard face (Default face). Draw the rectangle of dimension 200 x 200 (Refer the drawing for the coordinates). To draw the points for the holes,

Select Draw ÆÆMachinable objects ÆÆPoints on Parallelogram.

Enter -75, -75 at the prompt Specify start point that appears in the status bar.

Enter the data as shown in the dialog box that appears, and click on the OK button. Length: 150 Breadth: 150 Number of holes along length: 4 Number of holes along breadth: 2 Angle of length side: 0 Included angle: 90

Define the rectangle (200 x 200) as the blank. Specify the Blank thickness Z as 105 and the Z coordinate at the bottom as -100 (Facing allowance of 5 mm is provided on the blank, which will be machined during Face milling).

This completes drawing the part on Face 1.

Define FACE 2

Before drawing the part, the second face (Face 2) must be defined.

To define FACE 2 on a VMC,

Select Machining faces ÆÆ Add.

Enter the data as shown below in the Machining faces dialog box that appears:

Face name: FACE-2 Work offset number: 2 (The numbers 1 to 6 in the list corresponds to work offset numbers G54 to G59 on the machine). Table rotation angle: 0 Retract Z: 120

To define FACE 2 on an HMC,

Select Machining faces ÆÆ Add.

Enter the data as shown below in the Machining faces dialog box that appears:

Face name: FACE-2 Work offset number: 2 (The numbers 1 to 6 in the list corresponds to work offset numbers G54 to G59 on the machine). Table rotation angle: 180 Retract Z: 120

Do not alter any other data. This completes defining Face 2.

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Draw the part on Face 2

First the face (FACE 2) must be made as the active face. To do this,

Click on Machining faces on the menu bar.

From the dialog box that appears, select FACE-2.

Click on Set active and then select Done.

FACE-2 is now the current machining face and it represents the face opposite to the standard face.

Draw the rectangle of dimension 200 x 200 (Refer the drawing).

Draw the second rectangle of dimension 100 x 100.

Draw the circle of dia. 50 mm (The circle must be defined as a machinable object).

Define the rectangle (200 x 200) as the blank. Specify the Blank thickness as 100 and the Z coordinate at the bottom as –100 (No material is left for face milling in this case).

Perform machining

Perform machining operations on FACE 1

Click on Main to return to the main menu and then go to the Machining menu. The geometry on the Standard Face (Face 1) appears. Perform the machining operations as explained below. All the tools are available in GENERAL - MM tool manufacturer database. Follow the prompts that appear on the status bar for all the machining operations and refer the drawing for entering the machining parameters.

Select a 50 mm diameter face mill

Perform Face milling operation

End the tool.

Select a 20 mm diameter drill

Perform Drilling operation on 8 holes

End the tool.

Select a 25 mm diameter end mill

Perform Counter boring operation