Project report on subtractive manufacturing. Used Surfcam software suite to create a machining process on a CNC machine.

1. 8/18/16
MET 328 Class Credit Subtractive Manufacturing Project
Joseph Legan

2. 2
Executive Summary
This project is being performed in an effort to use life experience and experience gained from an
internship as a substitute for the MET 328 class.
The purpose of this report is to document the processes and technologies that can be used in
modern subtractive manufacturing.
This project used a 3D Systems Capture scanner that uses white/blue light to digitize an artifact.
This was followed by the use of Geomagic Design X to manipulate the scan data and to model
the solid. The last software used was Surfcam Traditional 2016 R2. This is a CAM software that
is more closely related to Mastercam than the new Surfcam Evo. Originally Surfcam Evo was
going to be used for this project. In an effort to show an entry level working knowledge of a
CAM software had been achieved, a decision was made to use the traditional version instead.
This project is an example of some of the technologies and their respective processes that are
available to the manufacturing industry. The scanning and modeling processes are not exclusive
to subtractive manufacturing and are often used in additive as well. I believe that this project has
been a success in demonstrating thoroughly the technologies and processes used.

3. 3
Introduction
This project is being performed in an effort to use life experience and experience gained from an
internship as a substitute for the MET 328 class.
The purpose of this report is to document the processes and technologies that can be used in
modern subtractive manufacturing. More specifically the processes of reverse engineering a
given artifact, modeling a solid and using a CAM software to create a G-Code. This project used
a 3D Systems Capture scanner that uses white/blue light to digitize an artifact. This was followed
by the use of Geomagic Design X to manipulate the scan data and to model the solid. Then
Surfcam Traditional 2016 R2 was used to create the G-Code for the artifact.
Each of these steps is covered in more detail in the following section.
Procedures
The process involved in this project have been segmented into 7 functions. These are:
1. Scanning the artifact
2. Mesh manipulation
3. Modeling a solid from the mesh
4. Preparation of required views, fixtures and tooling
5. Defining machining steps as driven by part geometry, machine capability, and tooling
6. Tool path verification
7. Post processing and G-Code creation
The first step to all of this is setting up the scanner. The scanner chosen for use with this artifact,
a remote oil filter base, is the 3D Systems Capture scanner. The Capture scanner is a desktop
scanner that is intended for use with items no larger a softball or large grapefruit. It uses white
and blue light displayed in a series of patterns along with 2 cameras to digitize portions of the
artifact. After each image is captured a synced turn table rotates the artifact to next position and
the process is repeated.
The actual steps used for this project are fully defined in the Additive Manufacturing Report that
has been submitted as well.
The next step or process is manipulating the meshes of the individual scans. This must be done in
order to combine the data from multiple artifact positions into a single cohesive mesh. There may
be as few as 2 artifact positions and up to as many as needed for the scanner to fully digitize the
artifact. For this artifact a total of 3 scans were required.
Again the actual steps used are fully defined in the Additive Manufacturing Report that has been
submitted as well.
The next process is the modeling of a solid for use in later procedures. The actual steps used are
summarized in the Additive Manufacturing Report.

4. 4
The remaining processes all use the Surfcam Traditional 2016 R2 software.
The first operation, after opening the software and loading the part file, is to prepare additional
C-Views that are needed for use in machining steps. This is done by referencing the geometry of
the desired face and assigning it as a new orthogonal view. Theses C-Views are really new
coordinate system references for use with specific fixtures and operations. A picture guide with
captions for creating C-Views is in the Appendix.
For this particular model, a remote oil filter base, a total of 3 additional views are required.
Along with the 3 additional views a total of 6 fixtures would have to be created. This is due to
the part geometry and the limitations of a 3 axis CNC mill. For this reason, we have to assume
that the workpiece and fixtures are being mounted to a sine table and that the axis of rotation of
the table matches that of the work piece. The fixtures have not been designed or defined as that is
believed to be beyond the scope of this project. A picture guide of the each required fixture view
is located in the Appendix.
Next the tooling required needs to be selected and assign tool locations. The tooling required for
the project are assigned as follows:
1. 0.5” End mill
2. 1.0” Carbide insert face mill
3. 0.375” End mill
4. 0.375” 118 degree split point mill
5. 0.125 End mill
6. 0.125 Ball mill
The tooling is described in depth on the set-up sheet that is located in the Appendix.
The next process is the defining of the machining operations. Before each operation can be
defined by geometry a fixture position and tool must be selected. In the process of defining the
first operation, the size and type of the stock is automatically determined by use of a bounding
box. The order of operations is as follows.
Fixture Position 1
 Rough cut of the base – Tool 1
 Final cut of the base – Tool 1
 4 pockets finish cut – Tool 1
 Central hole finish cut – Tool 1
Fixture Position 2
 Right angle finish face mill – Tool 2
 Right Angle hole contour finish mill –Tool 1

5. 5
Fixture Position 3
 Left angle face mill – Tool 2
 Left angle hole contour finish mill – Tool 1
Fixture Position 4
 Front contour finish mill – Tool 1
 Rear contour finish mill – Tool 3
Fixture Position 5
 Front pressure/temperature port hole operation – Tool 4
Fixture Position 1
 Rear mounting hole finish mill – Tool 5
 Rear mounting hole finish mill – Tool 5
 Rear mounting base profile contour finish mill – Tool 1
 Mounting base pocket mill – Tool 5
 Mounting base pocket mill – Tool 5
Fixture Position 6
 Bottom oil path 3 axis Z finish mill – Tool 6
Each tool path is pictured individually in the Appendix.
The next process involved is the verification of the toolpath. This ensures that the operations are
being executed in the desired order and to the correct geometry. The Surfcam software has a
feature that automates the entire sequence. Pictures of the automated verification are listed in the
Appendix.

6. 6
Once the tool path has been verified, the final steps are the post processing and the creation of a
G-Code. The post process is an adaptive process that conditions the G-Code for use with each
specific CNC machine. A CAM software with a strong post processing utility can alleviate the
need to manually edit the NC code, will support most or all the features of the selected CNC
machine and verifies that the tool path data will not damage the CNC machine.
The CNC machine chosen for use with this project was the FANUC 15MB. The actual G-Code
is an attached file as well as a text version of the code. In the Appendix there is a picture of the
back plot that illustrates the execution of the G-Code.
Data
The data for this project is the actual G-Code file. It could be used with a FANUC 15MB CNC
machine and the appropriate workpiece, fixtures and tooling to create a finished product.
Results/Analysis
The results of this project is the G-Code. The pictures used are done so in an effort to document a
digital process contained within a closed computer system, a difficult task to do when the
audience may not have access to the software used in order to verify the product.
Conclusions
I feel as though this project has been a success. The creation of the final G-Code product could
have been done in fewer steps by the use of automated options within Surfcam. This was avoided
when possible to display a working knowledge of the basic steps of traditional CAM software.
Having only dabbled with CAM software before this project, it has been an intensive learning
experience.

7. 7
Appendices
Create additional C-Views
Select the Create tab and then from the drop down menu select View. Next, select the 3 Points
method.
The first point will represent the intersection of the X and Y axis, the 2nd is positive X, and the
3rd is positive Y. The Z axis will be normal to the new reference plane.

8. 8
The new plane is created and with it an associated C-View for use with specific operations.

9. 9
Fixture Views
Assume that you, the viewer, are the spindle of the mill looking along the Z axis towards the
workpiece.
Fixture 1
Fixture 2

10. 10
Fixture 3
Fixture 4

11. 11
Fixture 5
Fixture 6

12. 12
Tool Setup Sheet
See the attached PDF document of the same name.
Tool Paths
Tool path 1

13. 13
Tool paths 2 and 3
Tool paths 4 and 5

14. 14
Tool paths 6 and 7
Tools paths 8 – 10

15. 15
Tool paths 11 and 12
Tool path 13

16. 16
Verification of tool path.

17. 17

18. 18

19. 19

20. 20
G-Code Back Plot