CAM

Computer Aided Manufacturing spectraCAM Milling

Teachers Guide

CAM
Computer Aided Manufacturing spectraCAM Milling
Teachers Guide

1997 Light Machines Corporation and Intelitek

Manchester, NH, U.S.A.

September, 1997 34-7871-0000

 1997 Light Machines Corporation All Rights Reserved.

The information contained in this guide was accurate at the time of its printing. Light Machines Corporation and Intelitek reserve the right to change specifications and operational performance of its products without notice. Any changes or corrections to the information contained in this publication will be incorporated in future issues. This publication (34-7871-0000, September, 1997) corresponds to the spectraCAM software program.

Printed in U.S.A.

spectraCAM is a trademark of Light Machines Corporation. All other register marks or trademarks are of their respective holders.

Table of Contents

Introduction
About this Program ............................................................................................... iii About SCANS Skills ............................................................................................. iv SCANS Skills in this Program ...............................................................................v About the Activities Book .................................................................................... vi

Installing spectraCAM
System Requirements ........................................................................................... 1-1 Installation Procedure .......................................................................................... 1-1

PreTest
Pre Test ................................................................................................................ 2-1 Pre Test Answer Sheet ......................................................................................... 2-6

Worksheets
Worksheets ........................................................................................................... 3-1

Post Test
Post Test ............................................................................................................... 4-1 Post Test Answer Sheet ......................................................................................4-10

Answers
Activity 1 Answers ............................................................................................... 5-1 Activity 2 Answers ............................................................................................... 5-2 Activity 3 Answers ............................................................................................... 5-3 Activity 4 Answers ............................................................................................... 5-4 Activity 5 Answers ............................................................................................... 5-5 Activity 6 Answers ............................................................................................... 5-6 Activity 7 Answers ............................................................................................... 5-7 Activity 8 Answers ............................................................................................... 5-8 Activity 9 Answers ............................................................................................... 5-9 Activity 10 Answers ............................................................................................ 5-10 Activity 11 Answers ............................................................................................ 5-11 Activity 12 Answers ............................................................................................ 5-12
Teklink Activities Book Teachers Guide - i Computer Aided Manufacturing

Activity 13 Answers............................................................................................ 5-13 Activity 14 Answers............................................................................................ 5-14 Pre Test Answers ................................................................................................. 6-1 Post Test Answers ................................................................................................ 6-2

Teklink Activites Book

Teachers Guide - ii

Computer Aided Manufacturing

Introduction

About this Program

This manufacturing technology program is a flexible, four-semester course of study, based on hands-on activities. It is designed to provide students with a broad base of competencies in modern manufacturing technology. The curriculum systematically covers Computer Aided Manufacturing (CAM), allowing students to acquire the knowledge and skills greatly needed for success in industry. Students work in teams and are exposed to various core technologies on a rotation basis. This modular concept enables the program to be tailored to the needs of each class and student.

By rotating through individual modules, students master the technical skills and procedural techniques necessary for competent operation of each piece of equipment. Once the students are comfortable with the basics, design projects emphasize and develop the need to combine modules to form islands of automation, or Flexible Manufacturing Systems (FMS). Ultimately, students will be exposed to Computer Integrated Manufacturing (CIM) systems, where they need to complete a project, from concept, through design and all the way to production.

Teklink Activities Book

Teacher's Guide - iii

Computer Aided Manufacturing

About SCANS Skills

In 1990 the United States Secretary of Labor appointed a group called the Secretarys Commission on Achieving Necessary Skills (SCANS) to determine the skills necessary to succeed in the workforce. The Commission was composed of 30 representatives of education, business, labor, and state government and was charged with defining a common core of skills that constitute job readiness in the current economic environment. The environment being one of fierce economic competition, new technologies, and rapidly changing skill requirements. Specifically, the Commission was asked to: w Define the skills needed for employment. w Propose acceptable levels of proficiency. w Suggest effective ways to assess proficiency. w Develop a dissemination strategy for the nations schools, businesses, and homes. During the course of its work, SCANS produced several publications. The Commissions first report, What Work Requires of Schools, resulted from extensive meetings and discussions with a variety of organizations including business, industry, public employers, and unions. The report identified 36 workplace skills that high-performance workplaces require, and that high-performance schools should produce. These skills were divided into a Three-Part Foundation and the Five Competencies. The Three-Part Foundation includes: w Basic Skills, which include literacy and computational skills w Thinking Skills, described as necessary to put knowledge to work w Personal Qualities, described as making workers dedicated and trustworthy The Five Competencies include: w The ability to manage resources w The Interpersonal Skills necessary to work amicably and productively with others w The ability to acquire and use information w Skills needed to master complex systems w Skills needed to work with technology It was the finding of the Commission that these skills lie at the heart of job performance and are essential preparation for all students, both those going directly to work and those planning further education. The Commission found that the most effective way of learning skills is in context, teaching learning objectives within a real environment. They also believe that the SCANS foundation and competencies should be taught and understood in an integrated fashion that reflects the workplace contexts in which they are applied. Source: ScansLink: The National Scan Skills Concern, Get the Facts. http://144.162.10.248/ nlc/misc/scans/facts.htm

Teklink Activities Book

Teacher's Guide - iv

Computer Aided Manufacturing

SCANS Skills in this Program

The manufacturing technology program has been designed in recognition of the findings of the Secretarys Commission on Achieving Necessary Skills. The activities enable students to develop and reinforce both technical, occupational skills and the general (SCANS) skills which are required by all people, in any job or educational environment. Tasks enhance problem solving and decision making skills. Cooperative learning and team work promote interpersonal and leadership skills. Projects emphasize information and communication skills. Acquiring these skills will prepare students to successfully meet the social, economic and technological challenges of the 21st century.

Teklink Activities Book

Teacher's Guide - v

Computer Aided Manufacturing

About the Teklink Activities Book

The Teklink Activities Book is a lab manual which contains 15 Activities, each of which can be completed in one 45-minute lab session. Each activity begins with several lists: w Objectives are the goals students will achieve. w SCANS Skills are the competencies students will develop. w Materials are the specific items needed for each activity. The Overview section introduces the students to the subjects which will be explored in each activity. The Procedures contain series of Tasks, or operations. The first time an operation is to be performed, instructions are given in a tutorial manner. In subsequent tasks students should be able to perform these operations without guidance. Questions and tables for entering lab results appear within the tasks. Questions for discussion and review conclude each activity. All questions and tables are printed on a set of Worksheets supplied with this book. Students should record their answers in the worksheets, or as directed by the instructor. In teklinks which include hardware (e.g., vise, tooling), students will be directed to perform inventory and safety checks at the beginning of every working session, and to shut down the system properly at the end of each activity. In teklinks which utilize software, it is assumed that students are familiar with the PC and are comfortable working in the Windows/DOS operating environment. However, instructions for operating thespecific software are explicit and can be performed by novices.

Teklink Activities Book

Teacher's Guide - vi

Computer Aided Manufacturing

Installing spectraCAM
System Requirements To install and run spectraCAM, you must have the following items:
u u u u u

486 or 586 personal computer Windows 95 or NT 3.51, installed 4MB RAM, minimum 3.5" floppy drive, At least 10Mb of available hard drive space

Installation Procedure The following procedure explains how to install spectraCAM on your computer. Before you install the software, you must turn on your computer and start Windows. You should make sure no other programs are running during installation. To install spectraCAM: 1. 2. Insert Disk 1 into the floppy drive. Select Run from the Start Menu. The Run dialog box appears. 3. In the Open field, enter a:\setup.exe (if the floppy drive has the designation b:\, then enter b:\setup.exe), and click OK.

Teklink Activities Book

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Computer Aided Manufacturing

4.

The installation program starts. A Setup Wizard guides you through the simple procedure. You are given the opportunity select a Destination Directory prior to installation, and to view the Readme file for late breaking spectraCAM information after installation.

After installation is complete, you should see the following new Program Group.

You may start spectraCAD by double-clicking on the spectraCAM icon in the WCAMM Group, or by selecting WCAMM from the Programs Menu under the Start Menu.

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Pre Test

1.

What is CAM? A. Computer Aided Manufacturing B. C. Computer Allied Machining Computation And Metallurgy

D. Computers Assisting Machinists 2. Which of these is not something the right mouse button allows you to do? A. Start the tool path operation B. C. Change the cutting side of a selection Change the cutting direction of a selection

D. Select primary and secondary layers for selections 3. What is the purpose of the post processor file? A. Helps set layers for tool paths B. C. Selects tools for use in Machining Opens the NC browser Window automatically

D. Allows spectraCAM to generate NC code for different machines 4. When would you hide a tool path? A. When it is wrong B. C. When you need to select other geometries in the same area When you want to slow the rate that spectraCAM redraws the screen

D. When you need to change it 5. When spectraCAM generates an NC file from a session, what information is it using? A. Operations setup dialog box, NC Browser, Layer information B. C. Previous NC files, this session, the post processor file Tool paths, student files, CAD Drawings

D. The post processor file, the Operations Setup dialog boxes, and tool paths

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6.

What do tool numbers appear as in NC code? A. F codes B. C. T codes S codes

D. G codes 7. What does the Z Final value represent? A. How far into the workpiece the tool will cut during each operation B. C. Total depth of all the Z axis motions Last motion on the Z axis before cutting begins

D. Z axis start point 8. What is the difference between primary and secondary geometries in a ruled surface operation? A. The cutting direction and start point must be different B. C. The secondary must be smaller There is no real difference, either one can be primary

D. The primary must be on top 9. Do you have to select each component of the text during an engrave operation? A. Yes, CAM programs only recognize text that has been exploded in the CAD program. B. C. Sometimes, depending on the size of the text No, you can select part of the text and the CAM program will see all of it

D. Only if you are engraving invisible ink 10. What is one difference between a post processor file used for multiple tool programs and single tool programs? A. A single tool post file uses lower default values B. C. A single tool post file uses higher default values There is no difference

D. A multiple tool post file recognizes tool changes

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11. What happens if you decide not to accept a tool path operation? A. The tool path is created anyway, and you must change the drawing B. C. The tool path is not created, and you may go back and revise the operation The tool path is not created, and the program shuts down

D. The tool path must be deleted manually 12. What does wrapping geometry do? A. Deletes geometry from the drawing B. C. Places geometry on a different layer Moves geometry on the XY plane to the XZ or YZ plane

D. Moves geometry inside the box 13. A swept surface operation... A. Cuts a geometric shape into the workpiece along a path created on the XY plane B. C. Removes a layer of the material to create a smooth surface Is used to cut circular geometries into the workpiece

D. Always uses a high spindle speed 14. What does a Surface of Revolution operation do? A. Rotates existing geometry on the XY plane B. C. Turns the workpiece around on the Y axis Carves an image into the workpiece that corresponds to a tool path rotated around a center axis

D. None of the above 15. What is the workpiece origin? A. The point where the last tool path ends B. C. The point where the first tool path begins The point where the drawing begins

D. The point the X, Y, and Z axis all meet

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16. Why would you perform a Facing operation? A. To obtain a clean and level surface for the part B. C. To create a desired surface effect To shave the workpiece down to the desired size

D. All of the above 17. What does Contouring do? A. Moves the tool along a specified tool path adjacent to a part geometry by an offset amount B. C. Creates rounded corners on the part Carves an image into the workpiece that corresponds to a tool path rotated around a center axis

D. Cuts a geometric shape into the workpiece along a path created on the XY plane 18. In a Surface of Revolution operation, what does the geometry revolve around? A. The tool B. C. A centerline axis The origin

D. The primary geometry 19. A Ruled Surface operation must be performed between two closed geometries on the same plane. A. True B. False

20. What does the primary geometry define in a Swept Surface operation? A. The centerline axis B. C. The plunge rate The pocket

D. The swept area

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Name: _______________________________ Class: _________________ Date:__________

Pre Test
Pre-Test Answer Sheet. 20 Questions. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D

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Activites Book

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Name: _______________________________ Class: _________________ Date:__________

Activity 1

Getting Started
Q What is CAM?

Why would you perform a Facing operation?

In a Surface of Revolution operation, what does the geometry revolve around?

What does Contouring do?

A Ruled Surface operation must be performed between two closed geometries on the same plane. True or false?

What does the primary geometry define in a Swept Surface operation?

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Name: _______________________________ Class: _________________ Date:__________

Activity 2

Using spectraCAM
Q What are 3 of the 5 things the right mouse button allows you to do?

What is the purpose of the Status Bar?

What are the two major sections of the Help utility?

What does the Go! button on the Operations Bar do?

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Name: _______________________________ Class: _________________ Date:__________

Activty 3

Starting the LMC Project

Q What is the purpose of the post processor file?

What is the workpiece origin?

By selecting and defining the material, what important information is provided to spectraCAM?

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Name: _______________________________ Class: _________________ Date:__________

Activity 4

Generating Toolpaths
Q When would you hide a toolpath?

Why would you perform a facing operation?

What does the pocketing operation do?

Why are step values important when machining?

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Name: _______________________________ Class: _________________ Date:__________

Activity 5

Contouring and File Generation

Q When spectraCAM generates an NC file from a session, what information is it using?

In one activty we discussed hiding toolpaths, and in this activity, we show them all. What are some of the reasons for hiding Toolpaths? For showing toolpaths?

What is Contouring?

What is an NC file?

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Name: _______________________________ Class: _________________ Date:__________

Activity 6

Speaker Design Project

Q What do tool numbers appear as in NC code?

Why is it important to match the correct post file and machine?

If you select the wrong material for the CAM session, how does it affect the NC code generation?

How do the number of teeth on a cutting tool affect the feed rate?

Why is it necessary to set the workpiece origin?

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Name: _______________________________ Class: _________________ Date:__________

Activity 7

First Pocket Operation

Q What does the value in the Z Final field represent?

What is one reason for hiding a tool path?

In this activity, what does the contour operation do?

If you did not select the correct side during the contour operation, what would happen?

Why are you performing a pocketing operation instead of a facing operation?

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Computer Aided Manufacturing

Name: _______________________________ Class: _________________ Date:__________

Activity 8

Second Pocket Operation

Q What is the difference between primary and secondary geometries in a ruled surface operation?

What does a ruled surface operation involve?

What would the ruled surface tool paths look like if you entered positive values in the setup dialog boxes?

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Computer Aided Manufacturing

Name: _______________________________ Class: _________________ Date:__________

Activity 9

Engrave Text and Generate Code

Q Why do you have to select each component of the text during this engrave operation?

Why is it a good idea to view the NC code after you generate it?

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Computer Aided Manufacturing

Name: _______________________________ Class: _________________ Date:__________

Activity 10

Advanced Operations Setup

Q What is the between the post processor file used in this activity and the one used in previous activities?

If you were to select a single tool post file, what would happen when you generated the NC code?

How will the number of teeth on ball mill (2) affect the feed rate?

What is the difference between a ball mill and an end mill?

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Computer Aided Manufacturing

Name: _______________________________ Class: _________________ Date:__________

Activity 11

Advanced Operations
Q Why is the default feed rate, spindle speed and plunge rate higher than in previous activities?

What is the default XY step size for the contour operation?

Do you have to select spiral as the cutting method for all pockets?

What happens if you decide not to accept a tool path operation?

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Computer Aided Manufacturing

Name: _______________________________ Class: _________________ Date:__________

Activity 12

Ruled Surfaces
Q What does wrapping geometry do?

What are the 2 planes that the geometry is wrapped onto?

Does the geometry located on the XY plane always have to be the primary geometry?

Would the ruled surface tool paths look different if you set the cutting direction at opposite ends of the primary and secondary geometries?

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Computer Aided Manufacturing

Name: _______________________________ Class: _________________ Date:__________

Activity 13

Swept Surfaces
Q What does a swept surface operation do?

What defines the sweep path?

What does the secondary geometry define?

What is the purpose of using different tool (Ball Mill) for the last two Activities?

Activities Book

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Computer Aided Manufacturing

Name: _______________________________ Class: _________________ Date:__________

Activity 14

Final Steps
Q What does a Surface of Revolution operation do?

What is the default centerline axis?

If you had chosen the convex selection in the Surface of Revolution Setup dialog box, what would have been the difference in the tool path?

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Post Test

1.

Which of the following information is not reported on the Status Bar? A. The currently selected menu or tool bar selection B. C. Successful or failed geometry or tool path selection The size of the workpiece

D. The type of material currently selected 2. What is CAM? A. Computer Aided Manufacturing B. C. Computer Allied Machining Computation And Metallurgy

D. Computers Assisting Machinists 3. Which of these is not something the right mouse button allows you to do? A. Start the tool path operation B. C. Change the cutting side of a selection Change the cutting direction of a selection

D. Select primary and secondary layers for selections 4. What are the two major sections of the Help utility? A. Help Menu and Status Bar messages B. C. Context Help and Commands Balloons and Error messages

D. Commands and Step By Step procedures. 5. What is the purpose of the post processor file? A. Helps set layers for tool paths B. C. Selects tools for use in Machining Opens the NC browser Window automatically

D. Allows spectraCAM to generate NC code for different machines

Activities Book

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Computer Aided Manufacturing

6.

When would you hide a tool path? A. When it is wrong B. C. When you need to select other geometries in the same area When you want to slow the rate that spectraCAM redraws the screen

D. When you need to change it 7. What does the Go! button on the Operations Bar do? A. Generates tool paths when geometries are selected. B. C. Generates the NC file Accepts Operation parameters

D. Closes the session 8. When spectraCAM generates an NC file from a session, what information is it using? A. Operations setup dialog box, NC Browser, Layer information B. C. Previous NC files, this session, the post processor file Tool paths, student files, CAD Drawings

D. The post processor file, the Operations Setup dialog boxes, and tool paths 9. What do tool numbers appear as in NC code? A. F codes B. C. T codes S codes

D. G codes 10. By selecting and defining the material, what important information is provided to spectraCAM? A. Location of the tool paths B. C. The size and location of the material The type of machine that will cut the part

D. The type of material that is being cut and the cutting speed for that material

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Computer Aided Manufacturing

11. What does the Z Final value represent? A. How far into the workpiece the tool will cut during each operation B. C. Total depth of all the Z axis motions Last motion on the Z axis before cutting begins

D. Z axis start point 12. What does a pocketing operation do? A. Removes all the material inside an open geometry except selected islands B. C. Removes all the material to one side of a selected geometry Removes all the material inside a closed boundary except selected islands

D. Removes all the material outside an open boundary 13. What is the difference between primary and secondary geometries in a ruled surface operation? A. The cutting direction and start point must be different B. C. The secondary must be smaller There is no real difference, either one can be primary

D. The primary must be on top 14. Do you have to select each component of the text during an engrave operation? A. Yes, CAM programs only recognize text that has been exploded in the CAD program. B. C. Sometimes, depending on the size of the text No, you can select part of the text and the CAM program will see all of it

D. Only if you are engraving invisible ink 15. Why are step values important when machining? A. If you use a step value that is too great you can damage the tool B. C. If you use a step value that is too great you can damage the workpiece If you use a step value that is too great, along with a high feed rate, you run the risk of damaging the mill

D. All of the above

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16. What is one difference between a post processor file used for multiple tool programs and single tool programs? A. A single tool post file uses lower default values B. C. A single tool post file uses higher default values There is no difference

D. A multiple tool post file recognizes tool changes 17. What is an NC file? A. The file that determines whether you are using single or multiple tools B. C. The file the DXF file was created from The coded instructions the mill uses to cut the part

D. The file you create the Session file from 18. What happens if you decide not to accept a tool path operation? A. The tool path is created anyway, and you must change the drawing B. C. The tool path is not created, and you may go back and revise the operation The tool path is not created, and the program shuts down

D. The tool path must be deleted manually 19. If you select the wrong material for the CAM session, how will it affect the NC code generation? A. The NC code will be generated using the wrong feed rates and spindle speeds B. C. The NC code will not generate The NC code will cause the part to be cut twice as fast

D. An error message will be displayed telling you to correct the material 20. What does wrapping geometry do? A. Deletes geometry from the drawing B. C. Places geometry on a different layer Moves geometry on the XY plane to the XZ or YZ plane

D. Moves geometry inside the box

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21. A swept surface operation... A. Cuts a geometric shape into the workpiece along a path created on the XY plane B. C. Removes a layer of the material to create a smooth surface Is used to cut circular geometries into the workpiece

D. Always uses a high spindle speed 22. Why is it important to match the correct post file and machine? A. So the machine operators dont get confused B. C. Different machines have different operating parameters If you dont, the CAM program will crash trying to generate the NC file

D. It doesnt matter, the software checks for compatibility 23. What does a Surface of Revolution operation do? A. Rotates existing geometry on the XY plane B. C. Turns the workpiece around on the Y axis Carves an image into the workpiece that corresponds to a tool path rotated around a center axis

D. None of the above 24. How do the number of teeth on a cutting tool affect the feed rate? A. If you double the number of teeth, the feed rate quadruples B. C. If you increase the number of teeth, the feed rate decreases by a quarter If you double the number of teeth, the feed rate stays the same

D. If you double the number of teeth, the feed rate doubles. 25. What is the workpiece origin? A. The point where the last tool path ends B. C. The point where the first tool path begins The point where the drawing begins

D. The point the X, Y, and Z axis all meet

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26. If you did not select the correct cutting side during a contour operation, what would happen? A. The operation would fail B. C. The contour operation would remove all the material to the inside of the boundary It would only cut along the contour boundary

D. The contour cut would begin on the inside of the boundary and then move toward the outside 27. Why would you perform a Facing operation? A. To obtain a clean and level surface for the part B. C. To create a desired surface effect To shave the workpiece down to the desired size

D. All of the above 28. What does a ruled surface operation involve? A. A centerline axis, operations parameters, and the final tool paths B. C. A contour boundary, operations parameters, and the final tool paths A primary and secondary geometry, operations parameters, and the final tool paths

D. A swept surface, a contour boundary, and operations parameters 29. What does Contouring do? A. Moves the tool along a specified tool path adjacent to a part geometry by an offset amount B. C. Creates rounded corners on the part Carves an image into the workpiece that corresponds to a tool path rotated around a center axis

D. Cuts a geometric shape into the workpiece along a path created on the XY plane 30. In a Surface of Revolution operation, what does the geometry revolve around? A. The tool B. C. A centerline axis The origin

D. The primary geometry

Activites Book ?-6 Computer Aided Manufacturing

31. A Ruled Surface operation must be performed between two closed geometries on the same plane. A. True B. False

32. What does the primary geometry define in a Swept Surface operation? A. The centerline axis B. C. The plunge rate The pocket

D. The swept area 33. If your start depth was the part surface (Z=0) and you entered positive values in the setup dialog boxes (Z Final 0.5), what would the ruled surface tool paths look like? A. The tool paths would be raised up from the surface of the workpiece B. C. The tool paths would run along the surface only The tool paths would not generate

D. The tool paths would cut into the workpiece 34. Why is it a good idea to view the NC code after you generate it? A. To verify the header information B. C. To check the NC code for any obvious errors. To become familiar with NC coding

D. All of the above 35. What is the difference between a ball mill and an end mill? A. There is no difference, they both cut the same B. C. A ball mill has a rounded tip, which allows it to cut curved surfaces An end mill is better for roughing

D. A ball mill cuts faster

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36. If you were to select a single tool post file to generate a multiple tool program, what would happen when you generated the NC code? A. The file would not generate at all, and all your work would be lost B. C. The code would generate and would be fine You would get an error message telling you to select the multiple tool post file

D. The file will generate, however, when machining takes place there will be no call for the second tool to be installed, causing the part to be cut incor rectly 37. What is the default XY step size for the most operations? A. The width of the cutting tool B. C. Quarter of the width of the cutting tool Half of the width of the cutting tool

D. Three eighths of the width of the cutting tool 38. Do you have to select spiral as the cutting method for all pockets? A. Yes, and any other circular geometries B. C. No, only circular geometries No, you dont even have to select it for circular geometries

D. No, pockets require a linear cutting method 39. In a ruled surface operation, does the geometry located on the XY plane always have to be the primary geometry? A. No, you can select the primary geometry from any plane B. C. No, it can also be the XZ plane Yes, only the XY plane.

D. Yes, and the YZ plane is always the secondary geometry 40. In a swept surface operation, what defines the sweep path? A. The secondary geometry on the XY plane B. C. The primary geometry on the XY plane The secondary geometry on the YZ plane

D. The primary geometry on the XZ plane

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Name: _______________________________ Class: _________________ Date:__________

Post Test

Answer Sheet for Post Test. 40 Questions. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D

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Activites Book

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Activity 1

Getting Started
Q What is CAM?
Computer-Aided-Manufacturing (CAM) program that can take a drawing file from a CAD program and, with your help, turn it into NC code.

Why would you perform a Facing operation?

To establish a uniformly flat surface, or to create a desired surface effect.

In a Surface of Revolution operation, what does the geometry revolve around?

A user-defined centerline / the centerline axis.

What does Contouring do?

Moves the tool along a specified tool path adjacent to a part geometry by an offset amount.

A Ruled Surface operation must be performed between two closed geometries on the same plane. True or false?

False

What does the primary geometry define in a Swept Surface operation?

The swept area.

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Computer Aided Manufacturing

Activity 2

Using spectraCAM
Q What are 3 of the 5 things the right mouse button allows you to do?
Check which layer a selection is on Change the cutting side of a selection Change the cutting direction of a selection Select primary and secondary layers for selections Change start point of a cutting path for a selection

What is the purpose of the Status Bar?

The Status Bar indicates various messages, including: The currently selected menu or tool bar selection Successful or failed geometry or tool path selection The machine currently selected The type of material currently selected

What are the two major sections of the Help utility?

Commands and Step By Step procedures.

What does the Go! button on the Operations Bar do?

Generates tool paths when geometries are selected.

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Computer Aided Manufacturing

Activity 3

Starting the LMC Project

Q What is the purpose of the post processor file?
The post processor file allows spectraCAM to generate NC code for different machines.

What is the workpiece origin?

The workpiece origin is the point that the tool starts its motions from when cutting the part.

By selecting and defining the material, what important information is provided to spectraCAM?

The type of material that is being cut and the cutting speed for that material

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Computer Aided Manufacturing

Activity 4

Generating Toolpaths
Q When would you hide a tool path?
When you need to select and manipulate other geometries in the same area as the other tool paths. Numerous or complex tool paths can also slow the rate that spectraCAM redraws the screen when you change views.

Why would you perform a facing operation?

To obtain a clean and level surface for the part.

What does the pocketing operation do?

Removes the material inside the each letter of the LMC.

Why are step values important when machining?

If you use a step value that is too great, in conjunction with a high feed rate, you run the risk of damaging the tool, the workpiece, and the mill.

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Computer Aided Manufacturing

Activity 5

Contouring and File Generation

Q When spectraCAM generates an NC file from a session, what information is it using?
Information from the post processor file, Information entered in the Operations Setup dialog boxes, tool paths, save directory information.

In one activity we discussed hiding tool paths, and in this activity, we show them all. What are some of the reasons for hiding tool paths? For showing tool paths?

To make selecting geometries easier, to make the redraw go quicker.

To get a clearer picture of the cutting operations performed by the mill.

What is Contouring?

Moving the tool along a specified tool path adjacent to a part geometry by an offset amount.

What is an NC file?

The coded instructions the mill uses to cut the part

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Computer Aided Manufacturing

Activity 6

Speaker Design Project

Q What do tool numbers appear as in NC code?
T codes

Why is it important to match the correct post file and machine?

Since different machines have different operating parameters, it is important to match the right files with the right machines.

If you select the wrong material for the CAM session, how will it affect the NC code generation?

Because spectraCAM calculates default feed rates and spindle speeds appropriate for the material, the NC code will be generated using the wrong feed rates and spindle speeds.

How do the number of teeth on a cutting tool affect the feed rate?

The number of teeth affects the feed rate, which spectraCAM calculates automatically. If you double the number of teeth, the feed rate doubles.

Why is it necessary to set the workpiece origin?

The workpiece origin is the point that the tool starts its motions from when cutting the part. By giving the NC file an origin and the stock size, we are defining the work area. So that the tool has a start point.

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Computer Aided Manufacturing

Activity 7

First Pocket Operation

Q What does the value in the Z Final field represent?
Z Final depth, How far down into the workpiece the tool will cut.

What is one reason for hiding a tool path?

To see the other tool paths as you create them.

In this activity, what does the contour operation do?

The contour operation creates a raised face for the speaker enclosure and is responsible for the enclosures rounded corner appearance. This contour operation removes all of the material on the outside of the tool path, and off the edges of the stock.

If you did not select the correct side during the contour operation, what would happen?

The contour operation would remove all the material to the inside of the boundary.

Why are you performing a pocketing operation instead of a facing operation?

To avoid the islands of the part: the nameplate, the on/off switch, and the volume knob. A facing operation removes everything; the pocketing operation will leave the islands

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Computer Aided Manufacturing

Activity 8

Second Pocket Operation

Q What is the difference between primary and secondary geometries in a ruled surface operation?
Either one can be primary or secondary, there is no real difference. The cutting direction and start point can be different, although they are not for this activity.

What does a ruled surface operation involve?

A primary and secondary geometry, operations parameters, and the final tool paths

What would the ruled surface tool paths look like if you entered positive values in the setup dialog boxes?

The cone would be raised out from the surface of the workpiece.

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Computer Aided Manufacturing

Activity 9

Engrave Text and Generate Code

Q Why do you have to select each component of the text during this engrave operation?
CAM programs only recognize text that has been exploded (converted to geometry) in the CAD program.

Why is it a good idea to view the NC code after you generate it?

To check the NC code for any obvious errors.

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Computer Aided Manufacturing

Activity 10

Advanced Operations Setup

Q What is the difference between the post processor file used in this activity and the one used in previous activities?
It is a multiple tool post file, the previous were for single tool programs.

If you were to select a single tool post file, what would happen when you generated the NC code?

When machining takes place, there will be no call for the second tool to be installed, causing the part to be cut incorrectly, and wasting time and money for your company.

How will the number of teeth on ball mill (2) affect the feed rate?

If you reduce the number of teeth by half, the feed rate is cut in half.

What is the difference between a ball mill and an end mill?

A ball mill has a rounded tip, which allows it to cut curved surfaces

Teklink Activites Book

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Computer Aided Manufacturing

Activity 11

Advanced Operations
Q Why is the default feed rate, spindle speed and plunge rate higher than in previous activities?
Because you are using the 4 Tooth End Mill. The values are increased when there is more of a cutting surface (4 teeth).

What is the default XY step size for the contour operation?

0.0625. The default step is usually half of the width of the cutting tool (the radius).

Do you have to select spiral as the cutting method for all pockets?

No, you dont even have to select it for circular geometries. It just makes sense to do it for circles.

What happens if you decide not to accept a tool path operation?

The tool path is not created, you may go back and revise the operation, and then create a new tool path.

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Computer Aided Manufacturing

Activity 12

Ruled Surfaces
Q What does wrapping geometry do?
Change the orientation of a geometry on the XY plane to the XZ or YZ plane. Places a geometry on any of the sides of the part

What are the 2 planes that the geometry is wrapped onto?

XZ and YZ planes

Does the geometry located on the XY plane always have to be the primary geometry?

No, primary and secondary geometry are interchangeable. That is, either geometry can be primary or secondary. You can select geometries from any two planes.

Would the ruled surface tool paths look different if you set the cutting direction at opposite ends of the primary and secondary geometries?

Yes, the tool paths would cross near the bottom.

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Computer Aided Manufacturing

Activity 13

Swept Surfaces
Q What does a swept surface operation do?
A geometric shape (the secondary geometry) is cut into the workpiece along a path created on the XY plane (the primary geometry).

What defines the sweep path?

The primary geometry on the XY plane defines the sweep path

What does the secondary geometry define?

The secondary geometry defines the shape of the material that is removed

What is the purpose of using different tool (Ball Mill) for the last two Activities?

The ball mill will give a round finish to these surfaces, which is important in the flipnerk application.

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Computer Aided Manufacturing

Activity 14

Final Steps
Q What does a Surface of Revolution operation do?
The Surface of Revolution operation carves an image into the workpiece that corresponds to a tool path rotated around a center axis.

What is the default centerline axis?

Normally, the geometry rotates about the X axis at the location of the Y midpoint

If you had chosen the convex selection in the Surface of Revolution Setup dialog box, what would have been the difference in the tool path?

The tool path would rise up out of the workpiece.

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Computer Aided Manufacturing

Pre Test Answers

Pre-Test Answer Sheet. 20 Questions. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A A D B D B A C A D B C A D D D A B B D

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Computer Aided Manufacturing

Post Test Answers

Answer Sheet for Post Test. 40 Questions. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 C A A D D B A D B D A C C A D D C B A C 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 A B C D D B D C A B B D A D B D C C A B

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