Documente Academic
Documente Profesional
Documente Cultură
In the end, CAD offers all of the necessary drawing and design functions to get the part laid out in
order for the manufacturer to their job. This is probably the first most fundamental term that you must
know.
BobCAD-CAM software includes CAD design capabilities that are simple and that are easy to learn
and use. This is another reason why our software is an effective product for manufacturers to use.
Below you can see a 3 dimensional design and a solid render view of the same part.
Basically a wireframe is the lines and arc or drawn geometry segments that make up a model or part.
You could literally relate it to an outline or skeleton of something. A wireframe can be used to create
surfaces that toolpath can be applied to for 3D/3 Axis machining. Once again, a wireframe can be
constructed in 2D or 3D. Not all parts are 3D. Below you can see a image of a model that is actually
a 2D part that only contains hole types in it.
In CAD, a “Solid” is a standard series of shapes that are used to design something. They are:
Cylinder: Torus:
These are the 5 basic solids. They are also referred to as “Primitives.” These shapes have depth,
area and used together in conjunction with Solid Editing operations are used to create models. Here
is an example part below that was created using some of these primitive solids along with special
editing operations.
This is a word that is used in CAD-CAM software to generally describe the outer face or
exterior of an object. CAD-CAM software is used to create the toolpath that will make the
finished surface of a part. Surface toolpath usually has some sort of peak or valley type finish
to it and is sometimes very complex. The example below shows the actual surfaces of the
guitar used in the wireframe example.
As you can see, there are many types of surfaces. BobCAD-CAM software also allows the customer
to import various types of files that contain surfaces in them. Other CAD design software systems
such as Solid Works or AutoCAD or PRO Engineer are all CAD design systems that can create
surfaces as well. You can draw or construct a surface in another CAD system, save it as an IGES or
STEP or STL file and bring it into BobCAD. You will learn more about other CAD systems and their
native file types as well as which ones we support and which ones we do not support later in this
training book.
BobCAD-CAM software offers advanced design and manufacturing capabilities and to this point we
have discussed toolpath, types of machines and some CAD basics in terms of what a wireframe is
and what a surface is. This leads us to, “Solid Modeling.” Solid Modeling is possibly the most
revolutionary approach to modern engineering and manufacturing that has ever existed. This is the
designing and creation of a part using wireframe design, surface creation and/or primitive solids to
create a model. Solid Modeling is the term used to describe this activity. A solid model itself is the
designed part when it is finished. There are many benefits to solid modeling. Some are:
The ability to visually see the product as you would see it when it is done.
The ability to check and verify aspects of the part before spending machine time and money on
material.
You can inspect the product before manufacturing takes place.
The manufacturer can present the product to a customer for approval before manufacturing
has taken place.
You can use advanced CAM systems to create toolpath directly from a solid model to machine
the part itself. This saves a lot of time.
These are just a few good reasons why solid modeling is important.
Molds are designed as solid models for machining. Here are the negative and positive mold plates.
BobCAD-CAM software is a complete solid modeling CAD-CAM system capable of solids based
design, toolpath and g-code creation for both 2D and 3D models. This is advanced technology that
over the last several years has become more common and more desirable for the manufacturer
because of how fast new products can be created and manufactured for the market place.
What used to take months of engineering, design and manufacturing can now take a matter of hours.
There are higher levels of CAD and CAM functionality that have to do with solid modeling. However,
this is the basics and is actually a prime example of how technology drives the economy.
The word “Hybrid” in CAD software is used to describe a system that has two kinds of methods that
when used or put together produce the same result. This being said, we can discuss the use of both
wireframe and surface creation functions to make a solid model. Have a look at the chart below.
As a hybrid system you can work with Wireframe, Surfaces or Solids in any order. For example, if
you had a solid model and needed to extract edge geometry in order to create pocket toolpath, you
could. See the example below.
There is more to this. In some cases the engineer may want to extract or get the wireframe geometry
from a model. The reason for this is because the extracted wireframe geometry can be used in
containing the toolpath that is created. Have a look at the example image below.
This adds a new term: Toolpath Containment or Boundary Machining. This is important because
some complex parts require different toolpath strategies to get the job done. This is another reason
why BobCAD-CAM software fits the bill. We can do it.
In the end, Hybrid Modeling is the ability to work with wireframe, surfaces and solids in any order
necessary to accomplish the program.
Here is another concept that is important to CAD Design. To “Extrude” something means to force out
or to force through a die. A die is a tool used for stamping or shaping something. An example of this
would be the childrens toy where the child loads the clay and turns the crank to make what looks like
spaghetti. Well, the piece that has the little holes that the spaghetti goes through would be the die
and the process would be called, Extrusion. Get it? It’s literally that simple.
Now, in CAD you can perform extrusions that are slightly different but still fall under the same
concept. Have a look at the example image below.
Here you can see a flat surface and then the result of extruding the surface with a tapered angle.
This would be called a “Tapered Extrusion” and is a function that BobCAD-CAM software offers. This
is an important concept because you will talk to engineers that make extrusion dies and need
functionality for both designing them and then machining them.
The term “2D” is used in our industry to refer to flat type work or machining flat parts that do not have
complex curves to them. They are mostly flat. This requires simple machining and is something that
BobCAD-CAM software can handle.
Examples 1: This would be considered a 2D part because it is basically flat and has no complex
curves to it.
Example 2: Here is another part that is flat. This is a 2D part. Making this part would require flat 2D
machining.
“3D” is a shortened term for three dimensions or a three dimensional drawing or part. Three
dimensional is described in the American Heritage dictionary as having or appearing to have an
extension in depth.
The term “3D” is used in our industry to describe parts or anything having to do with parts that has
extended depths involved. The images below are perfect examples of a 3D part.
You can see that there are curved areas that are not flat, even though there are also flat 2D areas of
this part. Because this part has those curved depths, you would consider this to be a “3D Part.”
Machining 3D parts is a more complicated task than machining a 2D part and requires that a CAD-
CAM system have functions allowing a programmer or machinist to create 3D toolpath.
There is more to the concept of 2D & 3D. Aside from the toolpath aspect, you have a viewing aspect.
You can have a 2D part being viewed in a 3D view or a 3D part being viewed in a 2D view. When
you look at something in life you are seeing it in 3 dimensions. It has height, length, width and depth.
This is 3D. In engineering and design, when you are drawing something in a CAD system, you want
to be able to see it as closely defined as if the real thing was right there in front of you. This has a
great benefit in the design process. In present times, most of the CAD-Design systems on the market
allow you to draw and create as well as view the part as a model in 3D on the screen. BobCAD-CAM
software offers these capabilities.
It is important to understand what types of CAD Files that BobCAD-CAM can open and work with.
The following is a list of file types that we can read into our software. File names will appear with the
name of the file, then a “.” and the file extension. Here is a list of extensions.
These files can contain CAD geometry such as points, lines, circles, solids, surfaces and other entity
types. Refer to this section as needed when you are asked about these files.
The idea is that a customer who buys BobCAD-CAM software can use it with their existing CAD
software. This is a BIG added value to their entire operation. If they have a CNC Machine they can
open and machine the file directly without having to send the work out to another shop with a CAM
system. Therefore, once again, some customers will receive a CAD file from one of their customers
and will need to import one of these file types into BobCAD-CAM just for the machining capabilities
that we offer.
BobCAD-CAM software includes CAM functionality in it that will allow the manufacturer to create the
part with the machine.
First of all, “Toolpath” is the path in which a cutting tool takes whether it is simple or complex, while
cutting, to remove material from a block. Thus, you end up with a flat finished part.
Here you can see the tool is traveling along the flat
2D toolpath. The toolpath is only flat and has no
curves that would make the tool travel up or down
while moving in a direction.
An example of 2D Toolpath:
In the next image below, you can see the same model
from a side view. The tool travels along the contour
of the part going in a specific direction. The contour
defines what the part will look like when it is finished
and the toolpath goes up and down while the tool
travels along it in what is called the “Z-Axis.”
Whereas 2D toolpath is only X and Y, 3D toolpath incorporates the Z axis while the tool is traveling
along its path (toolpath). Thus, we get what is called, “3D Toolpath.” BobCAD-CAM software has the
ability to create 3D toolpath for machining. There are other CAD-CAM systems on the market that
offer 3D toolpath capabilities. This is the basics regarding this type of toolpath. Therefore, now you
know that, if asked, we do offer 3D design and machining capabilities. It is important for you to
know that 3D toolpath is also referred to as 3-Axis Toolpath because it has to do with the Z-
Axis.
Here are some examples of how the term “3D Toolpath” would be used:
In each of the 4 example images you can see that the toolpath in them has Z-Axis movements along
the contour that the toolpath follows. Once again, this is 3D or 3-Axis toolpath.
In the end, this is how a machinist or CAM programmer decides the best way to machine a part. It
includes what toolpaths will be used and in what order depending on the part. It would be the best,
most efficient way to cut away the material to get the final finished part. Certain parts would require
certain toolpaths to be used. Generally, you would have a “Roughing” toolpath cycle first. Then a
“Semi-Finish” type toolpath and lastly, a “Finishing” type toolpath. Sometimes you would want to use
more than just 1 type of finishing toolpath. Here are the various 2D & 3D toolpath strategies that
BobCAD-CAM software has to offer:
Profile Milling
Single Cut
Side Rough / Spring
Passes
Pocket Milling
Lace/Horizontal
Parallel Offset In / Out
High Speed
Face Milling
Plunge Roughing
Thread Milling
Chamfer Milling
Engraving
Slice Planar
Slice Spiral
Slice Radial
Z-Level Roughing
Z-Level Finishing/Semi-Finish
Plunge Roughing
Equi-Distant Offset
3D Engraving
V-Carving (BobART)
4 Axis Strategies:
In our software they are known as Machining Features but they are all direct strategies that the
machinist can use to machine a completed part.
G-Code is simply the language that communicated to the machine so that the machine can cut the
part. G-Code is also known as “NC Code.” NC stands for Numeric Code. Here are some basics:
In manufacturing with CNC machines, Numeric Code and G-Code are the same thing. You will hear
the term “G-Code” used far more often. This is a basic term that you absolutely need to know. You
don’t need to know what the code means when looking at it, but you need to know that G-Code is the
language produced by a CAM system that is sent to the machine to make the machine cut the part.
G-Code is basically an instruction that the machine reads and adheres to. It doesn’t make the
machine run, nor does it drive the machines motors. It is simply instruction to tell the machines
controller where to go and what to do.
The G-Code tells the controller what to do with the tool, the speed in which the tool travels and spins,
when to change to a different tool etc. Once again, G-Code does not drive the machines motors, it is
simply instructions for the machines controller that consists of X, Y and Z locations, depth of the tool
and other commands all pertinent to machining the part. G-Code is based primarily off of the
toolpath. CAM software automatically writes the G-Code program which is then sent to the machine.
The big reason that CAD-CAM software companies develop their systems is because of this thing
called, “CNC.” CNC Stands for:
For example:
In the image above you can see the milling area as well as the CNC Controller on the left. The doors
to the machine are closed during the milling process so that chips/material waste and coolant are
contained and easy to clean up and coolant is easy to collect and recycle.
CNC Grinding Systems are widely used to produce parts for aerospace, medical, automotive, and
other industries. Extremely hard and exotic materials are generally no problem for today's grinding
systems and the multi-axis machines are capable of generating quite complex parts.
Some are CNC and some are manual which means that
the manual mills do not have controllers or motors.
You will also find that this type of mill is used by the
hobbyist. Because they are small you can only make
small parts on them.
A Knee mill or knee-and-column mill refers to any milling machine whose x-y table rides up and down
the column on a vertically adjustable knee. This includes Bridgeports. This is considered a 3 Axis
machine.
The term Bed mill refers to any milling machine where the spindle is on a pendant that moves up and
down to move the cutter into the work. These are generally more rigid than a knee mill. This is
considered a 3 Axis machine.
CNC Routers are different than a mill yet still have the same basic concept in mind. CNC Routers still
have X, Y and Z movement. With a mill, the table moves in the X and Y direction and the tool moves
up and down in the z-axis direction. With a CNC Router, the table doesn’t move. The tool head
moves up and down and is on what is called an “Overhead Gantry.” This moves the length of the
table and the head/tool part moves across the width of the table. Have a look below.
Routers are used by manufacturers that do a good amount of flat work. In other words, 2D type work
that includes cutting out patterns, doors, fixtures and that do a lot of what is known as “production”
machining.
BobCAD-CAM software is a great match for programming parts with a CNC Router because the
software provides a lot of 2D functions as well as 3D for those manufacturers generating 3D
programs with this type of machine.
A Water Jet is a machine that combines water and an abrasive material (similar to fine sand) and
shoots it from a nozzle at high enough pressure to cut metals. Have a look at the example image
below.
A Water Jet is used for flat 2D cutting only. The machine itself is setup just like a CNC Router where
the head moves along the overhead gantry that travels the length of the table itself and the table
remains stationary. This is good for pattern cutting in volume.
The upper and lower guides are called such because they hold the wire in place. Electricity is then
put through the wire, enough so that the wire heats up to the appropriate temperature to cut the
metal. The entire process takes place under water. If the upper and lower guides stay fixed, this is
called 2 Axis wire programming. Because there is no Z movement up or down, the upper and lower
guides move together while the wire is cutting in the
X and Y axis only. This is also known as 2D Wire
Programming.
If the upper and lower guides become independent of each other, meaning that they move
separately, you get what is called a taper angle and it becomes 4 Axis wire programming. Have a
look at the example image below.
An example of 4 Axis wire programming would be a square on the bottom and a circle on the top.
Have a look at the example image below of a nozzle.
A lathe is a type of machine that is different from the milling machine. The primary axis that are used
with a lathe are X and Z. A lathe is also sometimes called a “turning center” because it turns or
rotates the material while the tool comes in from the side (Z axis) to cut the material away.
Hold er
Material
Tool
CNC Lathes can be very large or they can be small enough to sit on a table top as well. This
example is a mid sized lathe. Some are inside of a complete casing with doors and can be called
“Turning Centers.”
BobCAD-CAM software also includes 2 axis lathe programming capabilities for roughing, finishing,
grooving, slotting and facing. These are just different types of toolpath. We offer a built-in tool library
for the customer and can help the programmer complete their G-Code programs.
4th Axis is a method of machining parts
around a fixed axis. The BobCAD-CAM
software offers 2 types of 4th axis
machining features.
They are:
This picture shows 4th Axis Indexing where the part will
rotate and then stop so that the tool can machine. Then
the part rotates again to another position and stops so the
tool can come in and machine again. This is not full
simultaneous 4th axis machining. It is indexing.
The benefits of five-axis machining is the machines ability to machine complex shapes in a single set-
up. This reduces the machinist setup time and increases production rates . By eliminating multiple
set-ups, time and errors are reduced. Additionally, the feature-to-features accuracy is improved
because the same zero or datum reference frame is used throughout the manufacturing process.
Other advantages of five axis machining is the since simultaneous movement is allowed along the X
and Y axis, shorter and more rigid tools may be used. Also, higher spindle/cutting tool speeds may be
achieved while reducing the load on the cutting tool.
Shorter and thicker cutters also reduce vibration when machining deep pockets or contoured features
with three-axis machines. Example applications for five axis CNC machining are complex three
dimensional profiles. These geometric are common for impellers, turbine blades, and plastic mold
tools. BobCAD-CAM software is not set up for 5 axis machining at this time.
The job tree allows the operator to keep all of their machining strategies organized. It also allows the
user to make edits to machining parameters fast and easy.
There is also what is called, “Z-Level Roughing.” This is another term for roughing that is typically
used for roughing type toolpath. The goal with roughing is to remove the most amount of material in
the most efficient amount of time. Typically, a larger tool is used when roughing to remove more
material than the size tool that is used for finishing toolpath. This term is not to be confused with “Z-
Level or Waterline” toolpath. Below is an example of Z-Level or Water-line toolpath.
After Roughing:
After Finishing:
The result of a toolpath has mostly to do with the size of the tool used and the toolpath that is created
to cut the part. One important aspect of this is what is called “Tool Compensation” or “Step Over”
for the tool itself.
A semi finishing toolpath is generally going to be after roughing and before a final finishing toolpath.
This is used as a machining strategy when needed for complex 3D/3 Axis type machining. For
example, in the image below you can see the first stage of the machining process was accomplished
using plunge roughing, the second was Z-Level Finish and the last was the equi-distant offset contour
toolpath.
In the picture, you can see that there was a .25 offset created around the outside of the original
profile. This is because the tool that was being used was a .5 tool. You can see that the tool
simulation did not cut any farther than the original path. This is cutter compensation.
In the picture above you can see the tool compensation options that we have in the Profile machining.
of a part. Sometimes pocket toolpath is created around a piece of geometry on the screen to leave
that geometry standing after the other material has been moved. If that is done, the item that was
pocketed around is called an “island.” Have a look at the example image below.
Here is another example below of a flow line or Flow style machine toolpath. You will see in the
picture below that the tool paths flow along the general contour of the shape that they are being
applied to. This type of toolpath can be roughing or a finishing type of strategy.
It is important to understand that the cutting action of a Milling tool varies depending upon the
direction of feed or motion. Have a look at the example diagram below.
Notice how the top image shows the tool sort of scooping the material with the tool edge. This is the
conventional cutting method of a tool. Now notice the bottom part where the cutting edge sort of
climbs into the material and cuts. This is climb milling. Sometimes you can remove more material at
a faster rate by using the climb milling method. However, by doing this method you will produce more
tool wear and it isn’t recommended except for very light finishing cuts.
You may be asked from time to time if our software supports climb milling. The answer is yes.
system or manual programming operation. BobCAD-CAM software supports tools where the
operator selects the tool in some cases from a list, but in all cases, enters in basic tool information
when creating the toolpath. They are:
These are the 4 primary tools supported in our software to the Version 20 level. Have a look at each
of the example pictures of these tools below.
The Ball End Mill: In this picture you can see that the bottom of the tool
is basically round like a ball. The “L” in the picture represents the “Length”
and the “D” represents the “Diameter.”
The Flat End: In this image you can see that the bottom of the tool is
basically flat. Once again, the “L” in the picture represents the “Length”
and the “D” represents the “Diameter.”
The Bull Nose End Mill: In this example picture you can see that the
bottom is flat while the bottom edge is rounded. This tool is defined by
the “L” which represents the “Length” and the “D” which represents the
“Diameter” and the “R” that represents the corner “Radius.”
The V Carving Tool: You can see that this tool has a tapered end down
to a point and is used for carving and engraving.
When the operator is creating toolpath, the tools diameter is always entered as well as how much that
tool will be stepped over to compensate for the tool.
There are many different types of tools for producing different cuts. It is not important at this point for
you to know every type of cutting tool or their attributes. This is to give you an idea of what BobCAD
software supports at this time. There are many tools for machining. These are just a few of the basic
ones we support in BobCAD-CAM software.
DNC stands for Direct Numeric Control.
This is a system used to send G-Code program from the CAD-CAM system to the machine controller
or to receive G-Code from the machine to the CAM end of the software. Basically it is sending and
receiving. A machine controller is like a computer and can, in most cases, store existing g-code
programs in it. When the controller is full and cannot store any more systems, DNC functionality is
used to transfer those programs to a CAM system on a PC that can store them. Controller memory
isn’t like a normal computer, where the PC/computer has a lot more room for these programs.
2D part programs are typically smaller in size. 3D programs have a lot more code and can be very
large. Therefore it is a benefit to have a CAM system with DNC capabilities like BobCAD-CAM.
In BobCAD-CAM software we have added a feature called ARC FIT that turns the tiny line segments
into arc segments. This reduces the amount of G-Code in a 3 axis program and can even allow the
machinist to end up with a better smoother finish.
It is a configuration setup where the operator opens the CAM side of our software by selecting this
configuration first. When the CAM opens, everything in the menus and the code generator is
configured to communicate that required language. This Post Processor configuration is what is set
up in the software before the actual G-Code is written. Some CAD-CAM systems allow you to
customize your own and some CAD-CAM companies charge money for them. Never the less, you
must have the correct post processor created to meet the specifications of the CNC controller before
making the g-code program. Otherwise the G-Code will not match the machine. The controller will
not read it. We call these post processor configurations the same name as its corresponding
machine controllers name.
NOTE:
If you are asked about a post processor and do not know if we have one that is available to support
the customers machine, you can visit our website at www.bobcad.com to see the list of posts on the
technical support page. There are many different CNC controllers in the industry today. You will here
the following:
We have a conversational type controller. “Conversational” means that the NC code is proprietary to
that machine control. ALWAYS check this. There are only a few controllers that we can work with
that have conversational type controls. Our software CAM side will output G-CODE. Not HPGL
language or conversational type language to cut toolpath created in BobCAD-CAM. Always ask to
make sure that we can work with the machine unless you know before hand. If the customer says he
works with “G-CODE” then we are most likely good to go.
The ultimate question to ask a customer….Does your machine accept a standard G-Code? If yes,
you are fine. If not, get help from a technician or your manager to make sure that we can support the
machine.
In the world of manufacturing software, some providers offer a “core” system and then modules that
can be added on to that core system. An example of this would be a core CAD system that has an
available Mill module, Lathe module, Punch Press module, ART module etc. This is the way
BobCAD-CAM software works. We offer a standard 2D & 3D solid modeling CAD Design package
that allows a customer to design their parts in 2D or 3D or construct simple or complex 3D solid
models. This is technically our core system. From there the customer can add mill, lathe, art and
wire EDM. Each of these will be explained to you in this training document. It is important to
understand the most basic fundamentals first. This way you understand the various modules that we
have to offer.
A hard lock is a device used for software security that plugs into the USB port of a computer. This is
designed to activate the software so it can be used. BobCAD-CAM software is designed so that a
password can be typed in and activate the software as well as the use of a hard lock for protection.
Together with your trainer or sales manager point out which one of the three parts below has 2D
toolpath.
CHALLENGE 2
Together with your trainer or sales manager point out which of these 3 parts below has 3D toolpath.
CHALLENGE 3
Together with your trainer or sales manager point out which of these 3 parts below shows both 2D &
3D toolpath on the same part.
CHALLENGE 4
Together with your trainer or sales manager point out which of these parts below shows a 2–Axis
toolpath and which one shows 3-Axis toolpath.