QuickCAM Pro

Advanced Milling CAM Software

F1 in Schools
Training Guide QuickCAM Pro (V1.13)
VR Milling (V5.58)
Product Code
Contents

About 4
Introduction 4
Launching QuickCAM Pro 5
Navigating QuickCAM Pro 6
Opening your Model 6
Orientate Model 8
Set Cut Depth 9
Set Billet Size 10
Set Model Size 11
Set Model Position 12
Set Boundary 13
Setup Tools 14
Machining Plans 15
Raster Roughing 16
Creating a Custom Border 17
Raster Finishing 20
Toolpath Simulation 21
CNC File Output 22
Saving the CNC File 23
F1 in Schools Car Manufacturing Fixture 23
4th Axis F1 in Schools Conversion Kit 24
Machining the F1 in Schools Billet 25
F1 in Schools Car Manufacturing Fixture 25
4th Axis F1 in Schools Conversion Kit 29
Running the Program 33

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About QuickCAM Pro
QuickCAM Pro is an advanced, yet simple to use, wizard based CAM package, which is used
to create cutter paths for machining 3D parts on a milling machine or router. Both STL files
and image files can be imported into QuickCam Pro, and a comprehensive set of machining
plans can be used individually or in combination to produce complex 3D surfaces and
lithophanes.

Introduction
The aim of this training guide is to show you how to navigate your way around QuickCAM Pro
and instruct you how to operate this software to manufacture an F1 in Schools balsa wood
blank.
This guide will cover all the steps required to convert the STL file of your car into a machined balsa car
body.

This guide makes use of screen shots where possible and will use the following conventions:
Instructions will be in this format
Text to be typed will be in this format
Any software buttons to be pressed, a picture of the button will follow the instruction

This guide assumes that your software has already been installed and your machine has
been commissioned.
If any of the features described in this guide are not operating as described please check
that the version number you are using is the same as that shown on the front cover.
Version is written on the title bar of the main software window.

Denford provide machine training and it is recommended that you undertake the training
and use this guide as a revision guide after completion of the machine training.

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Launching QuickCAM Pro
Open the "Denford Applications" folder.
"Double click" on the QuickCAM Pro icon.

The screen shown on the right will be displayed and

the software will take a minute or 2 to open.
You can force the software to open quicker by
following the next instruction.

"Double click" on the area circled below.

The software will open and you will be greeted with the screen below.

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Navigating QuickCAM Pro
QuickCAM Pro is very easy to use, the main screen displays what is going on and the
navigation panel on the right is how you select options and move around this wizard based
program.
The left mouse button allows you to rotate the main display and the right mouse button
allows you to zoom in and out.

The 3 buttons here are:

The toolbar has
various options, you
should not need to
use them for this For this tutorial you will be
tutorial. using the
button
This information box contains
instructions on each screen.
The next and previous buttons allow you to move
backwards and forwards through the wizard

Information hear tells you the dimansions of

your model and dimensions of your billet.

Opening your Model

Select the 3D Model button

Select the .STL file you wish to machine and click the open button
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Your model will now be displayed in the main screen.
You can hold the left mouse button to rotate your model, holding the right mouse button
zooms in and out.
A new button has appeared, this is the invert button
We do not use it for this tutorial.

Click the next button

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Orientate Model
There are a number of ways to orientate the model, there is no right or wrong way as long
as the fixture in the machine is aligned in the same way.
For this tutorial we will orientate the model so that the cartridge hole is on the left and the
bottom of the model is facing us so that we machine the right hand side of the car first.
In the illustration below you can see a large red arrow has appeared in the main display, this
represents the direction that the cutting tool will be coming from.

We need to rotate the model 180 degrees along the Y axis to orientate the model correctly.
Click on of the Y axis buttons twice
As you can see these buttons rotate
the model in 90 degree increments

Whether or not the model will need rotating will depend on which planes you used when
creating the model.
When your model is correctly orientated, click the Next button

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Set Cut Depth
This screen allows you to set the cut depth

As we will be machining the car from the left and the right hand sides we could set this to
the centre, but as we will be using a ball­nose cutter this would leave a ridge down the centre
of the model.
For this tutorial set the cut depth to the bottom and we will create a custom offset later in
the tutorial.
Click the Bottom button
Click the Next button

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Set Billet Size
This screen is where we set the size of the billet.

Whilst the physical balsa billet is 220mm x 50mm x 65mm, we cannot use this full size as
part of the billet is lost to the aluminium fixture.
Click in the X dialogue box and type
210
Click in the Y dialogue box and type
50
Click in the Z dialogue box and type
65
Click the Next button

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Set Model Size
This screen allows you to set the size of the model.

Having designed your model to a certain size you should cut it out the same size.
Check that the scale is set to 100%

Click the Next button

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Set Model Position
This screen is where you set the position of your model within the billet.

It is very important to get this correct as the cartridge hole is already in the billet and has an
aluminium post inserted into it, getting the model position wrong may cause damage to the
fixture and possibly break a tool.
The Z position is up and down but as your model is on its side it is best to think of this as
moving the model left and right. As the cartridge hole is in the centre the model should be in
the centre.
Ensure that the values in both of the Z dialogue boxes are equal

The X position moves the model left or right, as the cartridge hole is on the left the model
should be moved as far to the left as possible.
Ensure that the value in the left X dialogue box reads 0
The Y position controls where the base of the model is,
as the balsa blank has the tether line guide already
machined in it the model should line up with it.
Ensure that the bottom Y value reads 0
This model is the same size as the billet in the Y and Z
directions making it easier to position.
Click the Next button
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Set Boundary
This screen is where you can set the boundary.

For this tutorial we will be using a custom offset so we will set the boundary to be the same
as the billet.
Click the Billet button

Click the Next button

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Setup Tools
Manufacture of the F1 in Schools cars is best done with the 1/4" (6.35mm) Long series
Ball­nose cutter as it has a 40mm flute and will have about 50mm of length sticking out
from the spindle nut. Using this cutter should prevent any clearance issues, the last thing
you want to do is run the spindle nut into either your billet or the F1 fixture.
The screen below is where you set­up tools.

This screen takes the tooling information from VR Milling V5, as long as you have set the
1/4" Ball­nose in VR Milling V5 it should be showing here.

Click on the 1/4" (6.35mm) Ball­nose

The tool number should highlight in light blue
Click the next button

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Machining Plans
The screen below is where you create your machining plans having already instructed
QuickCAM Pro on the size of your billet and the position and orientation of your model within
it.

Click the Add button

The window below will pop up.

Here you have a choice of 3 roughing plans, 6 finishing plans, and 3 fine finishing plans.
For this tutorial we are going to use a Raster roughing and a Raster finishing plan.

Click the Raster Roughing button

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Raster Roughing
The window below will appear, this is where you set the parameters for Raster roughing.

Enter the details shown below

Click the Custom button

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Creating a Custom Border
A custom border window will appear and the main display will change so that your model has
a shaded box over it as shown below

The shaded area is the area that will be cut with this machining plan.
X Minimum
Do not change this from 0, increasing it will miss part of your model, decreasing it may
cause the tool to hit the aluminium post which is inserted in the cartridge hole.
X Maximum
This should be the same length as your model, modify your model before exporting the .STL
to include a tail­stock so that it will not break when making the 2nd side of the model, as can
be seen in the image below.

Tailstock modelled into the nose of the model to

prevent it from breaking away during machining.
X Maximum has been reduced so part of the
model protrudes from the shaded border, this
ensures the tailstock will not be parted off.

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Y Minimum
As you are rastering in the Y direction it is a good idea to extend this boundary by at least
the tool diameter so that the tool is accelerating / decelerating / and changing direction in
fresh air. Make this ­8mm.
Y Maximum
As you are rastering in the Y direction it is a good idea to extend this boundary by at least
the tool diameter so that the tool is accelerating / decelerating / and changing direction in
fresh air. Make this 58mm.
Z Minimum
As you are cutting from both sides you want to cut down to the centreline of the billet which
is 32.5mm, but as you are using a 1/4" (6.35mm) Ball­nose you need to go beyond the
centreline by the tools radius so make this ­35.675mm.
Z Maximum
This is the top of the billet so should be 0mm

Click the OK button

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QuickCAM Pro will now calculate the Raster Roughing plan using the parameters you have
entered.
Depending on the speed of your PC this may take some time.
On completion your screen should look like the image below.

You are now ready to add a finishing plan.

Click the Add button
Click the Raster Finishing button

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Raster Finishing
The window below will appear, this is where you set the parameters for Raster Finishing.

Enter the details shown below

Click the OK button

Like the Raster Roughing this may also take some time to calculate depending on the speed
of your PC.
Once the calculation has completed.
Click the Next button

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Toolpath Simulation
The Navigation panel on the right of your screen now has the video control buttons shown
below

Click to Play
simulation

Click the Play button to run a simulation of your toolpath

It should look something like the one image below.

Click the Next button

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CNC File Output
This is the final screen where we create the CNC file which is a .FNC file.

Setting the DATUM

For the F1 in Schools models we set the DATUM as the axis of rotation which is in this case
the centre of the cartridge hole.
Set the DATUM to the values below
X0
Y29
Z-32.5
Post Processor
QuickCAM Pro includes a number of Post Processors to enable you to create programs for
makes of CNC machines.

For Denford Mills and

Routers select Denford
(Metric) - Milling

Select Denford (Metric) ­ Milling

Click the Post Process button

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Saving the CNC File
A "Save As" dialogue box will have popped up.
As you will be machining your model from at least 2 sides it is a good idea to create a new
folder with the name of your model, as you can see from the image below I have created a
folder called "New Model".
How you save the file depends on which fixture you are using.

F1 in Schools Car Manufacturing Fixture

You have just created the toolpath for the right hand side of your model so name this file
RHS
Type "RHS"
Click the Save button
Wait while VR Milling V5 opens
Your CNC file is now showing in the editor window, we are going to make some changes.
Highlight line 1 and change it to the text below
(File: LHS.fnc
Hit the Enter button to create a new line
Type "M71"
M71 is a miscellaneous function which mirrors the Y axis
From the Toolbar select >File>Save As
Save the file as LHS
Type "LHS"
Click the Save button
You have now created the Right
and Left programs for your model
and are ready to start machining

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4th Axis F1 in Schools Car Manufacturing Conversion Kit
Follow the instructions for the F1 in Schools Car Manufacturing fixture
Open the folder which contains the files RHS.fnc and LHS.fnc
Rename RHS.fnc to 0001.fnc
Rename LHS.fnc to 0002.fnc
We now need to create a subcall routine which will automatically rotate the 4th axis and call
the programs 001.fnc and 0002.fnc
In VR Milling V5 you need to create a new file
From the Toolbar select >File>New
Type the following:
M70
G00 A90
M98 P0001
G00 A270
M98 P0002
G00 A360
M70 is another miscellaneous function, it mirrors the X axis. This is required as on the 4th
axis the cartridge hole is on the right hand side.
G00 A90 instructs the 4th axis to turn 90 degrees
M98 P0001 calls program 0001.fnc and executes it
G00 A270 instructs the 4th axis to turn a further 180 degrees
M98 P0002 calls program 0002.fnc and executes it
G00 A360 returns the 4th axis to the start position
Save this file in the same folder as program 0001.fnc and program 0002.fnc
Save this file as
Subcall.fnc
This is the file which you will run when using the 4th axis to machine an F1 in Schools billet.

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Machining the F1 in Schools Billet
If using the 4th Axis go to page 29, the instructions from
pages 25 to 28 are for the F1 in Schools Car Manufacturing
Fixture only.

F1 in Schools Car Manufacturing Fixture

The billet should be positioned in the machine as shown in the image below.
Note that the tether line guide slot is facing you, this is set up for the right hand side to be
machined
When tightening the bolts circled in the image above always tighten the right hand side
before the left to prevent the billet from being twisted.

Ensure that this cutout is at the

bottom. As the bolts are tightened
onto the aluminium bar that goes over
this bracket the cutout closes up and
secures the aluminium post which is
inserted into the cartridge hole.

On the left hand side the bar which is inserted into the cartridge hole has an aluminium block
around it with a cutout, ensure the cutout is to the bottom as shown in the image below.
Set the datum to the left hand side of the billet with Y and Z on the centreline of the
aluminium bar as shown on the next page.

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Setting the DATUM
X Axis
Touch the tool onto the left hand side of the billet as shown in the image below
In the Tool and Offset Editor window select the X
axis datum offset button

Type the value shown below into the offset amount

3.175
Click the X Minus button

Click the OK button

You have now set the X axis

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Y Axis
Touch the tool onto the front of the aluminium bar as shown in the image below

In the Tool and Offset Editor window select the Y axis

datum offset button

Type the value shown below into the offset amount.

9.175
This is the radius of the tool and the radius of the bar

Click the Y Minus button

Click the OK button

You have now set the Y axis

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Z Axis
Touch the tool onto the top of the aluminium bar as shown in the image below.
In the Tool and Offset Editor window select
the Z axis datum offset button

To do this the Y axis must be at 0

Go to the MDI tab in the Control Panel
Type "Y0"
Press the Start button

Go to the jog tab and lower the tool onto the top of the bar

Type the value shown below into the offset amount.

6
This is the radius of the bar

Click the Z Plus button

Click the OK button

You have now set the Z axis and can run the program
RHS.fnc, when this is finished simply rotate the billet and
run the program LHS.fnc
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4th Axis F1 in Schools Conversion Kit
The billet should be positioned in the machine as shown in the image below.

Note that the tether line guide slot is at the bottom closest to the bed of the machine and
the cartridge hole is on the right, the cartridge hole should have the aluminium cartridge
fitted into it and this mates up to the tail­stock of the 4th axis.
Aluminium cartridge inserted into the cartridge
hole in the billet. Note the hole in the centre, this
locates onto the 4th axis tail-stock.

The tail-stock must be aligned with the chuck of the 4th axis.
To do this fit the spiked drive into the 4th axis and slide the
tail-stock up to it, adjust the 4th axis so that the centre point
of the drive and the point from the tail-stock align with each
other.

Use these bolts to loosen the tail-stock in

order to align it with the chuck.

The aluminium block which holds the billet fixes into the
chuck of the 4th axis.
The 4th axis does not have a datum switch, this means
that whatever position it is in when you connect to the
router is taken as 0 degrees.
Use an engineers square to set the aluminium block so
that it is parallel to the bed of the machine and then
tighten the chuck on the 4th axis.

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Setting the DATUM
X Axis
Touch the tool onto the right hand side of the billet as shown in the image below
In the Tool and Offset Editor window select the X axis datum

offset button
Type the value shown below into the offset amount
3.175
Click the X Plus button

Click the OK button

You have now set the X axis

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Y Axis
Touch the tool onto the front of the aluminium bar as shown in the image below

In the Tool and Offset Editor window select the Y axis

datum offset button

Type the value shown below into the offset amount.

15.675
This is the radius of the tool and the radius of the bar
behind the aluminium block which holds the left hand
side of the billet

Click the Y Minus button

Click the OK button

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Z Axis
Touch the tool onto the top of the aluminium bar as shown in the image below.
In the Tool and Offset Editor window select
the Z axis datum offset button

To do this the Y axis must be at 0

Go to the MDI tab in the Control Panel
Type "Y0"
Press the Start button

Go to the jog tab and lower the tool onto the top of the bar

Type the value shown below into the offset amount.

12.5
This is the radius of the bar

Click the Z Plus button

Click the OK button

You have now set the Z axis and can run the program
Subcall.fnc which will automatically rotate the 4th axis and
execute program 0001.fnc and 0002.fnc
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Running the Program
F1 in Schools Car Manufacturing Fixture
Open the "RHS.fnc" file that you created on page 23 of this guide.

4th Axis F1 in Schools Conversion Kit

Open the "Subcall.fnc" file that you created on page 24 of this guide.

Running the Program

On the Control Panel, ensure that you are in Auto mode
Be sure that Turbo Mode is turned on
Make sure that Material Overide is turned off
Chek that the Feed Rate Overide on the front of the
router is set to 100%

With the file control buttons select Stop, Rewind, then Start

Whilst you could just press Start, the above method is safer as it will ensure that you do not
start a program part way through which could cause damage to the fixture and the tool.

F1 in Schools Car Manufacturing Fixture

When the first side has finished turn the billet over, instructions for fixing the billet are
on page 25
4th Axis F1 in Schools Conversion Kit
When the program has finished remove the finshed design

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