A thousand words could be used to describe CAD.

Entire books and educational curriculums have

been created around it. In its simplicity, CAD is a word used to describe the “design” aspect of what
our industry does. It stands for:

“Computer Aided Design.”

Our software systems offer CAD functionality that

allows the customer to design or draw their parts
from start to finish. Primarily it is drawing
software that allows the customer to create
blueprints with dimensions that they can then print
out and use for the manufacturing stage of
making the part as well as models that can be
viewed as if you were looking at the actual
finished part for inspection and evaluation which
is also a part of the manufacturing process.

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.

3 dimensional design/drawing Rendered Model

A wireframe is a 2 or 3 dimensional frame of a part or drawing that represents the part and can also
be used to create toolpath for machining. Here is a 3D wireframe drawing of a guitar:

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:

Sphere: Cube: Cone:

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.

Everything around you has a surface to it. Surfaces do

not have to be flat. In fact, surfaces that are not flat like
the bottom area of this guitar and the edges of the top
and bottom are referred to as contours or contoured
surfaces. In manufacturing, the last step of completing a
part is to machine “Finish Surface Toolpath.” This
usually produces a nice smooth surface finish when the
finish machining is done.

BobCAD-CAM not only allows you to design surfaces

but you can also create finishing toolpath for surfacing
and the g-code program. BobCAD-CAM software offers
a complete series of surface features for constructing
and working with various surface types.
Here are other surface-creation features that BobCAD-CAM software offers:

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.

Here are some solid models of manufactured parts:

This is a solid model of a rubber dog bone that you

would buy at the local pet store for your dog. It was
designed in a CAD system as a solid model and
consists of many surfaces that were created and
stitched together to form a solid model.

Molds are designed as solid models for machining. Here are the negative and positive mold plates.

Negative Mold Plate: Positive Mold Plate:

Once the solid model is created, the CNC programmer can generate the right toolpath directly from
the model. Then the G-Code program is generated by a CAM system like BobCAD-CAM software.

In order to make an accurate mold for

the part, a solid model is first created
to represent the actual part itself along
with its physical size, area and
volume. Then the solid model is used
to construct a mold. Solid modeling is
typically used for more complex parts
that require 3D design, 3-axis toolpath
and corresponding g-code programs to
be written. 2D wireframe drawings are
typically used for flat 2D part
programming with a CAD-CAM
system.

Here, you can see that 3D toolpath

was created for the inside of the mold
cavity.

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.

The wireframe geometry was

extracted from this model for the
purpose of toolpath containment.

Here you can see an example of

generating 3D toolpath inside of
geometric boundaries. This is called
toolpath containment or Boundary
Machining and is a special feature that
our BobCAD-CAM software provides.

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.

Here is a solid tapered extrusion with finishing

toolpath on the inside tapered wall.
“2D” is a shortened term for two dimensions or a two dimensional drawing or part. 2D is described in
the American Heritage dictionary as something that has no range or depth to it. Basically something
that is flat.

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 of how this term would be used:

“The machinist cuts mainly 2D parts.”

“We do a lot of 2D type work.”
“We are looking for a CAD-CAM system for making 2D parts.”
“Our machine can only handle 2D jobs.”
“We are looking to get out of just 2D and into more complex machining.”
“BobCAD-CAM software allows you to design 2D parts and machine them easily.”

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.

Here are some examples of how this term would be used:

“I am looking at a few different 3D CAD-CAM systems.”

“Right now all we do is 2D but would like to get into 3D.”
“Do you offer any sort of 3D machining capabilities?”
“We don’t do any 3D at all.”
“BobCAD-CAM offers both 2D & 3D design and machining capabilities.”
“I need something to take my 3D drawings and machine them.”

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.

Dxf files: We can read and write/save this file type.

Iges files: We can read and write/save this file type.
Step files: We can read and write/save this file type.
Sat files (also known as ACIS). We can read and write/save this file type.
AutoCAD .dwg files; Wireframe, Surfaces & Solids (native file format). We can read and
write/save this file type.
SolidWorks .sldprt files (native file format). Read only.
Parasolids X_T & X_B files. Read only.
RhinoCAD .3dm (native file format). We can read and write/save this file type.
Stl files: We can read and write/save this file type.
Bbcd files (native to BobCAD). We can read and write/save this file type.

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 is a recognized SolidWorks Solution Partner. Therefore we have permission to use

the logo below on our website and our promotional materials.
This also is a word that has been written about, discussed a taught. Millions of dollars have been
thrown at it for development and use! In its simplicity, CAM is a word used to describe the
“manufacturing” aspect of what our industry does. It stands for:

“Computer Aided Manufacturing.”

Our software systems offer CAM functionality

that allows the customer to machine their parts
from start to finish. Primarily it is manufacturing
software and is the aspect of our software that
allows the customer to determine how the part
will be machined and finished. CAM software
also creates a numeric language that is sent to
the machine from the computer that basically
tells the machine how to cut the part with a
cutting tool.

In the end, CAM offers all of the necessary

machining and communication functions to get
the part machined and delivered to the end
customer on time. This is the second most fundamental term that you must know.

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.

When you hear the term, “2D Toolpath” you now

know that the toolpath is simple. It is flat. Here are
some examples of how this term would be used:

“The machinist needs to be able to create 2D

toolpath.”
“I’m looking for a software system to help me
with 2D toolpath.”
“I would like to generate my 2D toolpath
faster with a CAD-CAM system.”
“Right now I do all my 2D toolpath by hand.”
“BobCAD-CAM software allows you to
generate your 2D toolpath easily and
quickly.”

An example of 2D Toolpath:

Here you can see the tool is moving back and

forth across an area without going up or
down while traveling along the path. This is
also known as 2D cutting.

Just about every CAD-CAM system on the

market today offers the ability to create 2D
toolpath for machining. In many cases, you
can expect that if the manufacturer that you
are talking to says he already has a CAD-
CAM system, this means that he can already
create 2D toolpath and may be looking for a
faster and easier way to do it. Or, They may
be looking for something more advanced. It
is important for you to know that 2D
toolpath is also referred to as 2-Axis
toolpath (X and Y).
The 3D Toolpath offers tool movements that include going up or down while traveling along a path.
Here is an example of 3D toolpath shown in a 3D view.

You can clearly see that the toolpath is not flat. It

actually follows along a 3D contour that has depths
that the tool travels along while cutting.

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:

“I’m looking for something to help me with creating 3D toolpath.”

“Does your software offer 3D Toolpath capabilities?”
“I need to create 3D toolpath from my models.”
“What sort of 3D toolpath options does BobCAD-CAM offer?”
“BobCAD-CAM offers 3D toolpath generation directly off of a solid model.”

Here are some examples of 3D/3 Axis toolpath:

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:

2D/2.5 Axis Strategies:

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

3D/3 Axis Strategies:

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:

4th Axis Indexing

4th Axis Wrapping

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:

“Numeric” means having to do with numbers.

The “G” in G-Code stands for Geometric (having to do with geometry).
The word “Code” has to do with systematic collection of numbers or symbols that are put
together as a language to give an instruction.

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.

Here is an example of G-Code with the sequence being shown:

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:

“Computer Numeric Control”

This is the term used to describe a machine that is computer driven.
CNC machines have what is called a “Controller.” The controller is
what our software communicates with to make the machine cut the
part or program that the CAD/CAM software created. There are two
types of machines. There are Manual machines and then there are
“CNC machines.” BobCAD-CAM software and all other CAD-CAM
software systems are used for programming “CNC” machines ONLY.
The picture of a machine to the left is a manual machine with hand
cranks.

The bottom picture on this page is what is called a “CNC Machine.”

Next to the machine itself is a CNC Controller that reads in the NC
(numeric code) program from the CAD/CAM software and allows the
machinist to go ahead and cut the part without having to do it
manually with hand cranks etc. There are many different brands of CNC machine and CNC
controllers. In the end, CNC machines have changed the way the world used to manufacture parts.
Now, parts can be made much faster than when there were only manual machines that didn’t have
CNC controllers.

You can have both 2 and 3-Axis CNC Machines.

You have already learned what CNC is. Let’s take this a step further here.
A milling machine is a standard piece of equipment that is used for cutting material. Milling machines
are used for a wide variety of machining actions.

For example:

Hole drilling, Pocket Milling and Profile Milling.

Prototyping or other custom manufacturing.
A wide range of 3D/3 Axis milling.
General CNC Machining in 2-4 Axis and even higher (5th Axis etc).

The 3 axis mill is common in job

shops and any manufacturing facility
that makes parts. Just about every
manufacturer that you talk to will
have a machine like the one you see
here. There are varying sizes of this
machine. The smaller images show
the tool cutting out of material.
Usually coolant is used when cutting
metal so that the tool and material do
not over heat while the
cutting/machining process is done.
The table that the material sits on,
moves in the X and Y directions.
The tool and “head” move in the Z
axis (up and down) directions. All 3
axes’ can be moving at the same
time while the tool is cutting. This is
really the basics of this type of
machine. Now let’s take a look at
what BobCAD-CAM software
systems would work best with this
machine and what functions would
benefit a manufacturer that has a
machine like this. This machine is
also referred to as a “Tool Room
Mill.”

A CNC Milling machine has a CONTROLLER attached to it.

A CNC Machining Center is basically a milling machine that is enclosed and has doors that are
opened and closed to access the material/finished part or tools or to do repairs to the machine itself.

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.

There are limited CAM systems on the market

today that can program CNC Grinders.
BobCAD-CAM software is not one of them at this
time.
There is a difference in a tool room mill or machining center and a mini-mill or table top milling
machine. Have a look at one of these mini-mills/table top mills below. They are also called “Micro-
Mills”, Table Top Mills or “Desk-Top Mills.”

Here is a prime example of one. They stand about 3-4

feet tall and are small enough to sit on a table top or
bench.

Some are CNC and some are manual which means that
the manual mills do not have controllers or motors.

BobCAD-CAM software will allow someone with this CNC

mill to make small parts. They will be able to design their
parts in BobCAD and then generate the toolpath and
numeric program to machine the part. For example, this
is used in making jewelry or small prototypes. They can
be full 3 axis or even set up with a 4th axis allowing the
part to turn as the other 3 axes’ move as well. An
example of this would be making rings or engraving and
machining on a pool stick.

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.

Industries that would have a CNC router:

Any type of Sign Making

Custom Cabinet Makers
Guitar Makers
Surfboard Makers
Furniture Makers
Any manufacturer that does 2D programming

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.

Plasma cutting is a process that is used to cut steel and other

metals (or sometimes other materials) using a plasma torch. In
this process, an inert gas (in some units, compressed air) is
blown at high speed out of a nozzle; at the same time an
electrical arc is formed through that gas from the nozzle to the
surface being cut, turning some of that gas to plasma. The
plasma is sufficiently hot to melt the metal being cut and moves
sufficiently fast to blow molten metal away from the cut. Plasma
can also be used for plasma arc welding and other applications.

BobCAD-CAM works with most CNC

Plasma machines. It is best to ask if
the machine accepts standard G-
Code to machine parts. Some of
these machines will take a 2D DXF
file and machine them directly. The
BobART add-on may be an
acceptable solution for creating these
from pictures but may not be able to
create a g-code file for some
controllers. Check first.
This is a Wire Electrical Discharge Machine. It is a specific type of CNC machine that uses a wire
with electricity running through it to cut material.

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.

This type of part required a 4 axis wire EDM to cut it as it has

a taper radius around the outside and the inside. This is a
perfect example of why a wire EDM is important to
manufacturing. With this type of machine you can get a near
perfectly smooth part with precision accuracy. Not all wire
machines are 4 Axis. Some are 2 and most are 2 & 4 Axis
type EDM machines.

BobCAD-CAM offers the “BobWIRE” software that will

accommodate both 2 &4 Axis types for a manufacturer that
needs to program this type of machine.
 Sinker EDM consists of an electrode and workpiece
that are submerged in an insulating liquid such as oil
or dielectric fluid. The electrode and workpiece are
connected to a suitable power supply. The power
supply generates electricity between the two parts.
As the electrode approaches the workpiece,
dielectric breakdown occurs in the fluid forming an
ionization channel, and a small spark jumps. The
resulting heat and cavitation vaporize the base
material, and to some extent, the electrode. These
sparks strike one at a time in huge numbers at
seemingly random locations between the electrode
and the workpiece. As the base metal is eroded, and
the spark gap subsequently increased, the electrode
is lowered automatically by the machine so that the process can continue uninterrupted. Several
hundred thousand sparks occur per second in this process, with the actual duty cycle being carefully
controlled by the setup parameters. These controlling cycles are sometimes known as "on time" and
"off time". The on time setting determines the length or duration of the spark. Hence, a longer on time
produces a deeper cavity for that spark and all subsequent sparks for that cycle creating a rougher
finish on the workpiece. The reverse is true for a shorter on time. Off time is the period of time that
one spark is replaced by another. A longer off time for example, allows the flushing of dielectric fluid
through a nozzle to clean out the eroded debris, thereby avoiding a short circuit. These settings are
maintained in micro seconds.

A CNC Punch Press is a machine for processing

sheet material (usually metal) that performs the
operation of stamping / forming. The punch enters
the material, and pushes it through the die,
obtaining the required shape of the punch and die
set. This will form a piece of material that is ejected
through the die and bolster plate and collected
underneath the machine in a scrap container. At
this time, BobCAD-CAM software is not developed
to work with CNC punch press machines. There
are 2 types of punch machines: Turret Punch and
Hydraulic Punch machines.

As a metal forming process, the punch press is

used for the highest volume production.
A CNC Lathe is the most common piece of equipment in a job shop. It has been reported that CNC
lathe sales are 3 to 1 over milling machines in the manufacturing industry.

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:

4th Axis Indexing

4th Axis Wrapping

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 picture to the left shows 4th Axis Wrapping. This is

where something is drawn flat in the software and then the
CAM wraps it for machining around the diameter of the part
for machining.

BobCAD-CAM software works for both wrapping and

indexing but is not full simultaneous 4 axis machining.
5 Axis machining is necessary for very complex part making. Generally you have 2, 3 and 4 axis
milling which are all capabilities with the BobCAD-CAM software. However 5 axis requires X, Y, Z, A
and B axis to be in motion at once.

In this picture you can see the cutting tool

is machining at an angle.

5 Axis Precision Machining allows

machining of all 5 sides in one Set up.
While this can certainly be a cost saving
factor, 5 Axis machining is used more often
for complex contour work, which may need
simultaneous movement of all 5 Axes.
Current generation 5 Axis machines offer
excellent tolerances.

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.

The Job Tree lists all of the machining features/strategies as

you load them into the tree for use. Each machining
strategy has special parameters that define how the toolpath
will be created. The machining feature is then associated
with CAD geometry. This means that if the CAD geometry
needs to be changed, it can and then simply be reselected
and assigned to the same cutting feature so that the
toolpath is updated.

It works the other way as well. For example, if you make a

change to the parameters of the cutting feature then the
toolpath can automatically be updated as well.

You can blank and un-blank toolpath that is displayed on the

screen through the job tree. You can rearrange the
machining order as well as other things. This is where you
define stock/material as well as tools. Basically, all CAM
related operations are performed through the tree, including
the generating of the G-Code. This is a very big feature in
BobCAD-CAM software as it keeps things so simple and
organized and allows us to just keep adding cutting features
to the software.
Roughing is the standard machining process for removing layers of material, stepping down in the Z-
Axis while cutting until all the material except for the part is removed. Have a look at the image
below.

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.

Z-Level/Water-line toolpath is used for roughing

and finishing as well. However, basic roughing
should not be confused with Z-Level or Water-
line path.

Remember, roughing toolpath is used for

removing the most amount of material before
finishing toolpath is used to make the part
contour as perfect as possible.
Finishing is the process of cutting toolpath that will produce a smooth or polished final part. Finishing
toolpath is usually used with a smaller tool than you would use for roughing. Have a look at the two
example images below. One of them is a representation of a surface after roughing and the other is
the same surface after finishing.

After Roughing:

As you can see, this block has a rough

surface that has high ridges. These
ridges are also known as “scallops.” In
order to smooth out the scallops you have
to create and machine finishing toolpath.

After Finishing:

You can see that after finishing,

the scallops are almost gone
providing the machinist with a
much smoother finish. You could
take this a step further by
creating toolpath for an even finer
finish. This is called polishing
and is common in the mold
industry because there has to be
an almost mirror-like finish.

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.

The Z-Level Finish toolpath was used as a semi finish

to remove the remainder of the material before a
super fine finishing toolpath was used.

BobCAD-CAM software has many 3D machining

features/strategies available in the PRO version that
gives the machinist/user freedom to machine their
parts the way they want to.
Profiling is a standard 2D machining strategy that is very commonly used in machining whereas the
toolpath that is created simply follows around the outside or inside of a part profile and the tool cuts in
a counter clockwise or clockwise direction. Have a look at the example below.

The toolpath simply follows along the profile

of the part. Generally the tool cuts along
the center of this profile path.

Profile milling toolpath sometimes requires a

lead-in and lead-out for the tool so that when
the tool comes into contact with the material it
doesn’t leave a mark or gouge. This is a
standard type functions that should always be
a feature for profile milling in CAM systems.
BobCAD-CAM offers automatic profile milling
with lead-in and lead-out options.
This is the method by which a programmed toolpath can be altered to allow for the difference
between the actual path and the tool that will be used to cut the part. In BobCAD-CAM software,
compensation variables are available for the operator to pick and choose from. If the programmer is
using a half inch tool, the cutter compensation offset will need to be a quarter inch around the outside
of the toolpath just as an example. We allow the user to step his tool over a percentage of the size of
the tool being used. This way the tool will not cut more than the desired amount of material. See the
example below.

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 what is happening in the image above:

1. The tool does a rapid approach along the dashed line.

2. When the tool meets the Tool Lead-In line the tool will begin cutting along the first level pocket
toolpath.
3. When the tool has cut the first level of the pocket toolpath it will plunge down into the material
and begin cutting the first level roughing toolpath and so on.
4. When the tool is finished with the last roughing level toolpath it will retract from the pocket and
rapid back to its starting position away and above the
pocket altogether.

This is also known as a 2.5 or 2 ½ axis program because the

toolpath is mostly 2D/2 Axis toolpath but the tool does
movement down in the Z axis, but NOT while traveling in the
X or Y Axis at the same time. 3 Axis would be X, Y and Z
simultaneously.
 In the machining process there may be
areas of a part that still have left over
material after a finish that still needs to be
cleaned out. Therefore, the machinist has
to go in and machine the REST of the part
that needs it with a smaller tool. This is an
automatic CAM machining strategy that is
popular. There can be both rest roughing
and also rest finishing type toolpaths. In the
future, BobCAD-CAM software will offer
REST Machining capabilities. At this time it
does not.

You will see in the image to the left that there

is both green and red toolpath on the model.
These are both pencil milling type paths. The
red in a single pencil machining path that
goes around the joints/intersection areas of
the model and drives the tool around these
areas to provide a very clean and smooth
transition finish from one surface to another
joining surface. The green paths are called
parallel offset pencil toolpaths that further
accomplish the goal of pencil milling and
making sure these surface areas are clean
and smooth. This is a finishing type toolpath
operation.
 This type of toolpath cycle allows users
to define curves that will guide the tool
to produce a smooth, consistent finish.
This type of toolpath cycle uses a 3D
projection algorithm to create a finish on
any number of surfaces or solids.

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:

Ball End Mill tool

Flat End tool
Bull Nose tool
V Carving tool

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.

RS 232 Communications is what we use to send the G-Code

program to the machine controller through a cable. This
cable is called an RS 232 cable and can be purchased at
any Radio Shack type store. This cable is plugged in to the
back of the PC and the other end is plugged in to the
machine controller.

BobCAD-CAM software has built-in RS 232 Communications

settings for sending the g-code program through the RS 232
cable to the machine controller.

This is really all you need to know about RS 232. You

simply need to know what it means as it will come up.
Now that you know what G-Code is, what a CNC Machine is and what a CNC Controller is we can
discuss what a “Post Processor” is. A Post Processor is like a built-in translator that creates the
special style of G-Code that communicates the same type of numeric language that a specific
machine controller reads in and understands.

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.

Known machine types that will work with BobCAD-CAM:

2,3and 4-Axis Mills

2 axis Lathes
2 Axis Water-jet
2-Axis Plasma/Laser

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.