Lathe Module

GibbsCAM

Gibbs and Associates323 Science Drive

Moorpark, CA 93021

May 2006

ProprietaryNotice

This document contains propriety information of Gibbs and Associates and is to be used onlypursuant to and in conjunction with the license granted to the licensee with respect to theaccompanying Gibbs and Associates licensed software. Except as expressly permitted in the license, nopart of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, ortranslated into any language or computer language, in any form or by any means, electronic,magnetic, optical, chemical, manual or otherwise, without the prior expressed written permissionfrom Gibbs and Associates or a duly authorized representative thereof.

It is strongly advised that users carefully review the license in order to understand the rights andobligations related to this licensed software and the accompanying documentation.

Use of the computer software and the user documentation has been provided pursuant to a Gibbs andAssociates licensing agreement.

© Copyright 1996-2006 Gibbs and Associates, Inc. All rights reserved. The Gibbs logo, GibbsCAM, GibbsCAM logo, Virtual Gibbs, Gibbs SFP, MTM, SolidSurfacer, and “Powerfully Simple. Simply Powerful.” are either trademark(s) or registered trademark(s) of Gibbs and Associates in the United States and/or other countries. Windows is a registered trademark of Microsoft Corporation in the United States and other countries. All other brand or product names are trademarks or registered trademarks of their respective owners. Contains Autodesk® RealDWG by Autodesk, Inc., Copyright © 1998-2006 Autodesk, Inc. All rights reserved.

Acknowledgements:

Written by Wil Gaffga

Thanks to Bill Gibbs, Charles Kindall, Bob Dunne and the entire Gibbs development Team for theirinput and assistance.

Printed in the United States of America

Modified: May 31, 2006 11:02 am

Table of Contents

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Table of Contents

INTRODUCTION 1

How to Learn the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Balloons and Prompting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Text Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

PART SET-UP 5

Document Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Part Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Machine and Stock Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TOOL CREATION 13

Tool Creation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Lathe Tool dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Tool Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Cutter Radius Compensation (CRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Tool List Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

MACHINING 23

Machining Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Creating an Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25What is a Cut Shape? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Multiple Process Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Modifying an Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Machining Palette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Process Dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Contour Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Cut Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Entry Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Exit Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Contour Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Rough Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Cut Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Rough Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Pattern Shift Rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Thread Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Holes Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Thread Dimensions - Defining the kind of thread to cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Cut Information - Defining how to cut the thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Depth Of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Thread Location - Defining where to cut the thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Cutting standard NPT Pipe Threads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.5" - 8 NPT EXTERNAL PIPE THREAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442.5" - 8 NPT INTERNAL PIPE THREAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

American National Standard Taper Pipe Thread (NPT) Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Pre-Defined Process Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Clearance Moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Auto Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Fixed Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Clearance Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Approaches from Tool Change Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

OD Approach From Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Face Approach From Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50ID Approach From Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Exits To Tool Change Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51OD Exit To Tool Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Face Exit To Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51ID Exit To Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Same Tool Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52OD To Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52OD To OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Face To ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Face To OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Face To Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54ID To Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55ID To ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Canned Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Machining Markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

How Machining Markers Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Start and End Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Selected Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Material Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Operation Tiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Operation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Printing the Toolpath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Touch-Off Point Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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CUT PART RENDERING 63

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Rendering Palette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Cut Part Rendering context menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Optional Stop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Current Display Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Fast Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Flash Cut Part Rendering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Flash CPR Context Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Flash CPR Rendering Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Printing the Cut Part Rendered Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

POST PROCESSING 73

Post Processing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Post Processor Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Posted Output Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Post Output Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Lathe Post Label Definitions and Code Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 772-Axis Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Code Issues: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3 & 4-Axis Mill/Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Label Definitions:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Code Issues: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

COMMUNICATIONS 81

Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Adding a Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Changing a Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Removing a Protocol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Communicating with a CNC Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Communications Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Sending a File to the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Sending Other .NCF Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Receiving a File from the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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LATHE TUTORIAL 87

Exercise #1: Lathe Tutorial. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89This tutorial explains how to: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Custom Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Creating the Operations - OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Creating Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Multiple Process Group Op 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Multiple Process Group Op 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Creating the Operations - ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Multiple Process Group Op 9-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Op 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Cut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Op 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Post Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Exercise #2: Form Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Form Tool Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

INDEX 131

INTRODUCTION

Introduction

❖

3

CHAPTER 1

: I n t r o d u c t i o n

HOW TO LEARN THE SYSTEM

Congratulations on your purchase of the most productive programming system available! The mosteffective way to learn the system is to look through the Getting Started Guide to become familiar withthe system and how it works. After going through Getting Started you should complete the exercisesin the Geometry Creation manual followed by the tutorials contained in this manual. For simpleexplanations of on-screen items and their purpose, use

Balloons

and

Prompting

provided in the

Help

menu. The Common Reference Guide will help you with items contained in the menu bar.

This manual is intended for users of a basic 2-Axis Lathe; however, the lessons learned are appliedacross more advanced C-Axis and Multiple Turret Machines. This manual covers information specificto Lathe machines; however, most of the interface concepts are similar to other types of machining.After learning the concepts of creating geometry, this manual proceeds with information on part set-up, tools, toolpath generation, Posting and communications with a CNC.

BALLOONS AND PROMPTING

Balloons

and

Prompting

are built-in documentation and training information, also known as C.A.T.(Computer Aided Training). They are accessed from the

Help

menu or with a shortcut key (

Ctrl+B

).They provide reference information, rules, and assistance in using the system. For more detailedinformation on

Balloons

and

Prompting

, see the Common Reference guide.

TEXT CONVENTIONS

In this and all other GibbsCAM manuals you will find a number of standards used in the text, knownas conventions.

Screen text

: Any text you see

like this

is referring to text you will see in GibbsCAM or on your monitor.Typically this is a button or text for a dialog.

Keystrokes:

Words that appear

like this

refer to a keystroke or mouse action, such as

right-click

or

Ctrl+C

.

Term:

Words that you see followed by a colon

like this

refer to a word or phrase used in GibbsCAM.

❖

Introduction

4

PART SET-UP

Part Set-Up

❖

7

CHAPTER 2

: Pa r t S e t - U p

DOCUMENT DIALOG

Clicking on the Document button will bring up the Document dialog. This dialog isactually a combination of two linked dialogs. The top dialog contains general information

about the part such as the

Machine

and

Material

information. In addition, the top dialog provides filemanagement options which give the user control over where the file is stored on the computer. The

❖

Part Set-Up

8

bottom dialog provides specific information about the part such as stock size, clearance moves and

Tool Change

positioning.

PART DETAILS

This part of the dialog contains a part’s basic parameters including the type of machine to be used, thematerial the part is made of, whether the part is metric or imperial. This section of the dialog alsocontains commands for opening, closing and saving part files.

File Control:

The buttons used for file management described below are also available under the

File

menu.

1 - File Control2 - Machine Type menu3 - Part Material4 - Measurement Units5 - Stock Size Diagram6 - X Dimension Style7 - Auto Clearance Option8 - Fixed Clearance settings9 - Tool Change Position10 - Lathe Shank Size11 - Mill Tool Holder Menu12 - Part Comment

Part Set-Up

❖

9

Open (Ctrl-O) :

Clicking on the

Open

button will bring up the

Open

dialog which allows the user to selectwhich file to open. If a file is currently open, it will be closed and the selected file will be opened.

New (Ctrl-N) :

This button will create a new file by opening a dialog and asking for a file name and alocation to save the new file. If there is a file open, it will be closed.

Save (Ctrl-S) :

If there have been any changes made while the file was open, this button will save thechanges.

Save As :

This button will open a dialog asking for a file name and a location to save the current file.The changes made since the last

Save

command will be written into the new file. The original file willnot be affected. The new file will become the current, open file.

Save Copy :

This button is very similar to the

Save As

button. The system will create a duplicate copy ofthe open file. The original file remains the current, open file. The name of the duplicate file can bechanged.

Close :

This button closes the current file. If the file has not been saved before clicking on the

Close

button, a dialog will come up asking if the file should be saved.

Machine list:

Clicking on the

Machine

pop-up menu will produce a list of all machines the software is setup to handle. The shank size refers to the standard tool holder size on a lathe. These shank sizes areused to limit the number of inserts and holders in the tool database. A copy of the Machine Typeselection is stored with the part file. Thus, if you have a custom MDD (machine type file) you mayeasily transfer the part file to another system. If the Mill, Advanced Mill or Multi-Task Machiningmodules have been installed, there will be additional choices.

Part Material:

The information in this box is used to specify the material of the part. If the CutDATAMaterial Database (which is an option that can be purchased with the system) has been installed, therewill be multiple selections. If not, there will be one default selection. A custom material database canalso be created. Refer to the “Material Database” section on page 57 for more information.

Measurement Units:

These two radio buttons determine whether values input will be based on anEnglish or metric standard and entered in inches or millimeters. The measurement type used togenerate the posted output is determined by the post processor itself. There are English and metricpost processors. If an English post is used on a metric part, the posted numbers will be converted frommillimeters to inches. Likewise, metric posts will convert values from inches to millimeters.

MACHINE AND STOCK DETAILS

The bottom section of the Document dialog is specific to the type of part being made. This section ofthe dialog will change to reflect the part definition requirements as different machine types areselected. Thus, a horizontal or vertical turning part’s setup is different from a 3-axis mill part which isdifferent from a 4-axis mill part which is different from a Multi-Task Machining part. In this manual wewill strictly concern ourselves with the turning settings.

❖

Part Set-Up

10

Stock Size diagram:

This section of the dialog is used tospecify the starting size of the part stock. The stocksize entered here will be used by the system todetermine positioning moves when using the

AutoClearance

function. The stock dimensions will alsobe taken into account when generating toolpathswith the

Material Only

option selected in the Processdialog. If custom stock has been created, the systemwill use the custom stock size for toolpath andpositioning moves. In that case, the values enteredhere will only be used to draw the stock outline andorigin marker correctly. The text box for the Xdimension will be a radius or diameter value depending on which option is selected for the XDimension Style.

X Dimension Style:

These two radio buttons determine whether the X values for the part are input asradii or diameters. Some text boxes in particular dialogs specify that the value entered is either a radiusor a diameter value, regardless of the selection made here.

Tool Change:

If the

Tool Change

option is turned “on.” the turret will be sent to the X and Z dimensionsspecified when a tool change occurs. If

Tool Change

is not on, it is assumed that either fixture offsetsare being used or the operator will hand input the tool change moves.

Recommended Settings for Tool Change:

Tool Change On:

Best for newer machines which use generic offsets or Work Fixture Offsets.

Tool Change Off:

Best for older machines which use G50 offsets.

Auto Clearance:

When the

Auto Clearance

option is turned on, the system will calculate positioningmoves between operations. These positions will be dynamically calculated, meaning that they willchange as the material conditions of the part change. The value entered is an offset amount from thecurrent part stock that the system will use to maintain adequate clearance from the material. Refer to“Clearance Moves” on page 47 for more information.

Fixed Clearance Positions:

Fixed Clearance positions must be entered when the

Auto Clearance

option isturned off. When the

Auto Clearance

option is on, the fixed clearance position text boxes will be grayedout. The X and Z values entered specify the location the tool will rapid to and from during a toolchange. This position will also be used when moving from one approach type to another. Refer to“Clearance Moves” on page 47 for more information.

Holders:

The items here describe the size or class of the tool holders found on the current machine.

1 - Part Diameter2 - Stock +Z dimension (past origin)3 - Stock –Z dimension (behind origin)

Part Set-Up

❖

11

Shank:

This is the shank size of lathe tool holders for the current machine. This setting controlswhat tool holders are actually available when defining tools.

Mill Class:

This is the class or standard size of the mill tool holder on the current machine.

Comment:

Any text entered as a part comment will be shown in the part preview section of the Opendialog and in the posted output.

❖ Part Set-Up

12

TOOL CREATION

Tool Creation ❖

15

CHAPTER 3 : To o l C r e a t i o nTOOL CREATION OVERVIEW

The tools button in the main palette will open the Tool List. The Tool List can hold upto 999 tools in a part file. To create a tool double-click on an empty tile location toopen a Tool Creation dialog. This dialog is used to create and modify tools. Once thetool information has been entered and the dialog closed, a Tool Tile will be created inthe Tool List which displays the tool type and insert width. To index through thevarious tools that have been created, click on the scroll arrows located at the top andbottom of the Tool List.

Tools can be reorganized in the list at any time, even after operations have beencreated, without reprocessing the operations. To reorganize the order of tools, clickonce on the Tool Tile to be moved and drag it to an insertion point. The system willautomatically adjust the operations to reflect the change in tool order and number. Formore information on Tile Lists, refer to the Getting Started Guide.

Tool specifications can be modified at any point during part creation. However, ifoperations have been created using the tool, those operations must be reprocessed. Toreprocess an operation, double-click on the Operation Tile in the Operation List andclick on the Redo button. The new tool specifications will be incorporated into theoperation toolpath.

❖ Tool Creation

16

LATHE TOOL DIALOGIn order to define lathe tools a Lathe machine type must be selected in the Document dialog. Thebasic turning tools are created using the Tool Creation dialog shown below. Each of the itemscontained in the dialog is described in the following section.

Tool Type: This button is used to toggle between mill tools and lathe inserts. Mill toolsshould only be used with the drilling function unless you have the Mill/Turn or Multi-Task Machining module(s) installed.

Insert Types: This area is used to select the type of insert used with the tool holder. The Insert Specs willchange depending on the selected insert.

1 - Tool Types2 - Insert Types3 - Insert Specifications4 - Insert Orientation diagram5 - Tool Diagram6 - Holder Specifications7 - Spindle Direction8 - Turret Shift9 - Custom Tool Holder

Definition

Tool Creation ❖

17

Form Tools: The system supportscustom form tools for Latheparts. Unlike Mill parts, Latheform tools must be a closedshape. Be sure to create the shapewith the part origin in mind. Theorigin is used as the touch-offpoint for the tool. All postedoutput with this tool is relative tothis point. The Touch-off point isshown as a red cross in the tooldiagram.

Insert Specs: This information willchange depending on the currently selected insert type. Each of the pop-up menus will limit theselections available in the pop-up menus that follow it. For example, selecting a Tip Radius will limitthe number of available Inscribed Circles and Thicknesses. Selecting an IC will further limit thenumber of Thicknesses available. These settings will limit the number of available tool holders andboring bars in the holder diagram. If no tool holders or boring bars are available, the None choice willbe automatically selected. When the Other checkbox is checked, the user can enter any toolspecifications they wish. When Other is selected, the holder diagram is automatically set to None.

Full Radius: When enabled, this option will limit the inserts available to only those with a full radiustip.

Other: If this item is on, the insert specs will switch from pop-up menus to text boxes. Any valuecan be entered in the text boxes. The type of tool holder will automatically be set to None(although there might be tool holder or boring bar selections available).

TIP

The Steps To Make a Form Tool:

1 - Create the profile geometry, taking into account the touch-off point.

2 - Select the geometry (double click it).3 - Create a new tool, designate it as a

Form Tool.4 - Click on the Apply button.

❖ Tool Creation

18

Tip Rad. : The tip radius of the insert.

Inscribed Dia: The inscribed circle of the insert.

Thickness: The thickness of the insert.

Insert Width: The width of the insert.

Length: The length of the insert.

Size: The IC size of the rectangle. If the Otherbutton is turned on with this type of insert,the length and width of the insert need to beentered instead of the size.

Tip Width: The width of the tip of the insert.

Face Angle: The angle of the inserts cutting face.

TPI: The threads per inch that the blueprint calls for.

Style: The thread style of the insert.

Insert Type: The type of insert.

Included Angle: Used to define the touch off point of Round tools and Face Relief and Diameter Reliefsettings.

Face Relief: The angle of the inserts approach, changing affects the Diameter Relief.

Diameter Relief: The angle the tip is approaching, changing affects the Face Relief.

Insert Orientation: This diagram is used to specify the orientation of the insert in thetool holder or boring bar. Changing the information will not affect the availability ofother items in the dialog, but it will change the orientation of the drawing in theHolder diagram.

Tool Diagram: The tool diagram provides information about the touch off and type ofholder or boring bar that will be used for the insert. The None choice is used for holders not in thesoftware’s database. Use the scroll bar to scroll through the list of available holders. The holderselection is used to determine the diameter relief and face relief angles. The red circle on the insertshows the location of the Touch-off point. The radio buttons below the holder diagram designatewhether the holder will be shown at its actual size, or at a calculated size that is scaled to fit in the box.

No Holder: If None is selected, the insert will be drawn without a holder. This is automaticallyselected if there are no tool holders or boring bars available in the database for the selected insert.The face and diameter relief angles must be entered. The cross hair marker indicates the Touch-

1 - Tip Length2 - Tip Width3 - Tip Radius4 - Insert Width5 - Face Angle6 - Inscribed Diameter

Tool Creation ❖

19

off point of the insert. The radio buttons below the holder diagram designate whether the holderwill be shown at its actual size, or at a calculated size that is scaled to fit in the diagram.

Holder Specs: Detailed information appears to the right of the diagram displaying the holder data.

Forward/Reverse: Forward will turn the spindle in the forward or normal direction. Selecting Reverse willreverse the spindle.

Offset #: Normally, the offset number of the tool is determined by its location in the Tool List. This boxallows the user to override that default with a different number.

Tool ID #: Enter the tool ID you wish to use instead of the tool list position.

Insert Material: This is a pop-up menu used to specify the material of the tool. The information givenhere is used by the Material Database as another factor in determining speeds and feeds. The defaultsetting for Lathe parts is Carbide Insert, Coated.

Comment: This is a comment associated with the tool. It will be output in the finished code at thebeginning of every operation that uses this tool.

Turret Shift: Enables a Turret Shift (see below). It is used to specify the preset point for the tool.It can also be used to set up different tool change positions for each tool.

Turret Shift Dialog: Thisdialog is used to specifythe distance from thepreset point (also knownas the Touch-off point orthe theoretical tip of thetool) of the tool to thecenter of the turret. It canalso be used to specify adifferent tool changeposition for the tool.

Preset Point: Thisinformation is onlyrequired on some older machines. The two boxes are for entering the Xr and Z distances from thepreset point to the default tool change position. They are absolute values. These vales are uniqueto each tool This function is useful for pre-programming G50 offsets in the office usingGibbsCAM rather than on the floor.

Turret Shift: These numbers are used to set up a different tool change position than the default. Thetwo boxes are for entering the Xr and Z offset from the default tool change position. These valueshave polarity.

❖ Tool Creation

20

Default Tool Change: This is a reference to the setting from the Document dialog.

Tool Holder Definition: This option isonly recommended if you need tocreate a custom holder shape.Holders can be defined by ageometry profile (similar to creatinga custom tool shape), by a solidmodel of the holder or by numericvalues (Custom). By default the holderis set to None, meaning a holder willnot be used. To use a geometryshape, select the geometry, selectProfile and click OK. To use a solidmodel, select the solid, select the Solidoption and click OK. The Apply ToAll Selected Tools option will apply thecurrent tool holder definition to allthe tool tiles currently selected. The Show Solid option will show the solid model that is currently setto be the holder. Clicking the Make Profile button will create a geometry profile from the Custom toolholder definition.

TOOL OFFSETWhen roughing or contouring, the system calculates a tool offset amount based on the tip radius ofthe insert. This is the amount the finishing pass of the toolpath (the only pass if contouring) will beoffset from the selected part geometry. If a stock amount is entered for the process, that stock amountwill be added to the tool radius offset.

CUTTER RADIUS COMPENSATION (CRC)In the File > Preferences > Machining dialog there is an option to control CRC with Contouringoperations only. From Tool Center is the recommended option because that is the method used by thesystem to display the toolpaths and cut part rendered images regardless of the setting of the ContourCutter Comp, which only affects the posted output.

!

• The overall tool length set in the tool dialog defines the distance from the tool tip to theface of the tool holder.

• Note that if a tool holder is not defined, the overall length of a tool in the tool dialog is thetool’s distance out of the holder.

• Note that holders on vertical mills will need to be re-oriented to lie along the Z axis.

Tool Creation ❖

21

When the From Tool Center item is selected, the numbers generated in the posted code will be thegeometry offset by a tip radius (providing the Stock amount is 0). From Tool Center is therecommended selection for this preference. When the From Tool Edge item is selected, the numbersgenerated in the posted code will be the same as the blueprint numbers.

Roughing operations will always be calculated from the tool center. If the From Tool Edge item isselected for this preference, CRC should be turned off in all roughing operations.

When using From Tool Center, the offset in the CRC register at the control should be the differencebetween the tip radius of the actual insert used and the tip radius of the insert programmed in thesystem. If the inserts are identical, the CRC offset number should be zero. If the actual insert issmaller, a negative value can be used.

When using From Tool Edge, the tip radius of the actual insert used should be entered in the CRCregister.

WARNING: The system does a much better job offsetting the tool than the majority of controlscurrently available. Regardless of the setting made in this preference, all toolpath drawing and cut partrendering will be calculated and displayed using the system’s offsetting mechanism. Therefore, it ispossible for the cut part rendered image produced by the system to look good while the tool, cuttingaccording to the posted code, will not cut well. If the control’s offsetting mechanism is less advancedthan the system’s, it is possible that when the control produces the offset values, errors andinterference will result.

TOOL LIST SUMMARYSelecting Tool List Summary from the Window menu displays the Tool List Summary dialog whichprovides information in spreadsheet form about each tool contained in the Tool List. The informationin the dialog can either be saved as a text file or printed out. To save the summary as a text file, selectthe Tool List Summary item from the Save Special submenu in the File menu. To print the summary,select the Tool List Summary item from the Print submenu in the File menu.

❖ Tool Creation

22

MACHINING

Machining ❖

25

CHAPTER 4 : Mach i n i n gMACHINING OVERVIEWClicking the Machining button will bring up the Process List, the Machining palette, and theOperation List. The Process List is used to create sets of operations to be performed on cutshapes. The Machining palette contains Function Tiles that when used in conjunction with Tool Tilescreate Process Tiles. The Process List is a “staging area” that is used to generate finished operationswhich contain the toolpaths for cutting the part. When an operation is finished and placed in theOperation List, the items in the Process List can be thrown away or reused with a different cut shape.The Operation List contains the completed operations that will be output during post processing.

CREATING AN OPERATIONEach tile in the Process List will beapplied to the selected geometry. AProcess Tile is created by dragging aFunction Tile from the Machining paletteand a Tool Tile from the Tool List to thesame location in the Process List. Theycan be dragged in any order. When aProcess Tile is complete, a Process dialogspecific to the chosen machining functionwill appear. This dialog contains detailedinformation about the way theoperation’s toolpath will be created.

Contouring and roughing functionsrequire that geometry be selected to actas the cut shape for the operation.Machining Markers are used to select theportions of the geometry to be used asthe cut shape when creating a toolpath.The markers will appear on the geometrywhen it is selected. If a drilling orthreading function is being used, nogeometry is required to create anoperation.

After the information in the Process dialog has been entered, place the machining markers in thecorrect locations on the geometry. Machining Markers are not used for drilling and threadingfunctions. Clicking on the Do It button will create an operation(s). The operation(s) will be placed inthe Operation List. If any completed operations are selected (in yellow), the Do It button becomes the

1 - Tool List2 - Process List3 - CAM palette

❖ Machining

26

Redo button. If the Redo button is depressed, the selected operations will be replaced by the newoperations. Clicking on an empty operation location or an insertion point between operationlocations will deselect all the operations.

Operations contain the finished toolpaths. A toolpath consists of the actual moves the tool will make.The toolpath is based on the cut shape. The data contained in the operation is what the post processorwill use to make G-code.

WHAT IS A CUT SHAPE?A cut shape is used to generate a toolpath. It is not drawn on the screen, but can be visualized as thefinished shape left after the removal of material by the toolpath. A cut shape (not the originalgeometry) is used to create a toolpath because programming the toolpath to the geometry as it isdefined on the blueprint will usually gouge the part. The software automatically generates the cutshape. Various specifications and limitations are taken into consideration in the creation of the cutshape.

The machining markers (the start and end point and start and end feature markers) allow the user tospecify the portion of geometry (or the entire shape) that will act as the initial outline of the cut shape.The system then takes into account the physical attributes of the tool being used in the process, suchas insert type, tool holder, relief specs, etc. in order to prevent possible tool interference whenapplying the tool to the cut shape being machined. The cut shape is further governed by informationentered in the Process dialog, such as Entry/Exit Radius, Stock, Shape Axes, etc. The system employsthe concept of a cut shape so that it is not necessary to create different geometry for differentoperations in order to avoid gouging the part.

MULTIPLE PROCESS PROGRAMMINGThe Material Only option available in the Contouring and Roughing Process dialogs is particularlyuseful when doing multiple process programming. Material Only provides for “no air cutting.” Whenselected, the system optimizes the toolpaths created by only making feed moves where there ismaterial that needs to be removed. The system takes into account the material conditions in terms ofwhat has already been cut in previous operations, including those contained in the same Process List.

MODIFYING AN OPERATIONDouble-clicking on an item in the Operation List will recreate all of the information in the ProcessList. It will also select the geometry and place the markers exactly as they were when the Do It buttonwas pressed. Any operations that were created at the same time as the selected operation will becomeselected and their information will also be placed in the Process List. The Do It button will be replacedby a Redo button. Click on the Redo button after the changes have been made. This will replace allselected operations in the Operation List with the newly created operations.

Machining ❖

27

MACHINING PALETTE Each tile in the Machining palette has a different function. The Contouring function is used for takinga single finish pass. The Roughing function is used for taking multiple passes. The Threading functionis used for making different types of threads. The Drilling function is used for drilling a hole at X = 0.

The order of machining in the finished NC program is the same as in the Operation List. This meansthat the order of Operation Tiles in the Operation List is very important. Efficient use of multipleprocess programming may produce operations in a less-than-optimal machining order. TheOperation List can be organized as the part is being created or when all operations to cut the part havebeen completed. Clicking on the Sort Ops button reorganizes the operations by tool number andcreation order. Operations created in the same Process List will maintain their order to ensure thatfinishing passes cannot be moved in front of roughing passes, etc. The Operation List can also bemanually rearranged by moving tiles to different locations in the list.

While the Operation List can be reorganized to create a more optimal machining order, there aresome other considerations. When using the Auto Clearance option and/or the Material Only option, thesystem takes into account the material conditions when it creates the positioning moves and toolpathfor each operation. Changing the order of operations has the potential to change the initial materialconditions for existing operations. If the order of operations is changed or operations are added orremoved from the list, the toolpaths and positioning moves should be checked. Rendering the part is agood way to check if changes need to be made to the tool moves due to tool interference orunnecessary incorrect positioning moves. If adjustments need to be made, the operations must bereprocessed. Reprocessing all operations in a part file is very easy using the Redo All Ops item under theEdit menu. When the operations are reprocessed, the system will recalculate all of the toolpaths andpositioning moves based on the new order of operations.

PROCESS DIALOGSProcess dialogs appear on the screen when a Function Tile from the Machining palette and a Tool Tilefrom the Tool List are placed in a Process List location. There are four types of Process dialogs thatcorrespond with the four types of functions available in the Machining palette. The options availablewith each of these processes are described in this section.

❖ Machining

28

CONTOUR PROCESSThe Contourprocess is usedto take a singlepass along ashape. When aContouringFunction Tile iscombined witha tile from theTool List, thefollowingProcess dialogwill appear.

Cut OptionsApproach Type:This should bethe firstselection madein any Processdialog. TheApproach Typeselectiondesignates theaxis (Z or X)along which thetool will approach the part. The OD and Front ID options specify that the tool approach and retractalong the X axis, while the Front Face option requires that the tool approach and retract along the Zaxis. Also, selecting one of these radio buttons will change the Clearance Diagram that appears in themiddle of the Process dialog.

Clearance Diagram: This picture will change depending on the Approach Type selection and on theClearance selection made in the Document dialog. The Approach Type selection will change the axisof approach.

If Auto Clearance is selected in the Document dialog, the diagram will disable the clearance positionvalues because they are calculated based on the Auto Clearance value.

Entry Clearance specifies the diameter or radius location the tool will make a rapid move to beforefeeding to the operation start point. The Exit Clearance position specifies the location the tool mayrapid to after completing its toolpath for that operation. Both boxes are labeled with arrows goingtowards and away from the part, respectively.

Machining ❖

29

Forward: This indicates the direction the tool will move along the designated cut shape. If the Forwardoption is selected, the tool will move from the start point to the end point of the selected cut shape asdesignated by the machining markers. Left unchecked, the tool will move from the end point to thestart point of the selected cut shape.

Square Corners: This checkbox determines the external corner moves for a cut shape. When this optionis turned on, the system does not add a radius move at the corners of the cut shape. Instead, the toolonly makes sharp moves when going around a corner and will leave contact with the finished shape,possibly creating a burr at the corner. If this option is not selected, the system automatically makes aradius move when rounding a corner so that the tool always stays in contact with the part.

No Drag: A checkbox that indicates how the contour will be cut. When this option is selected, thechosen cut shape is automatically broken up into segments that will be cut along the positive insertangle direction. All cutting will be “pushing” the insert, not “pulling” it.

Cut Off: A checkbox for use with cut off tools. If the post processor has been appropriately customized,turning this option on will trigger the post processor to output any special codes necessary forremoving a part from bar stock.

Entry MoveThe Entry Move can create additional movements that will be added to the tool path. When the firstoption is selected, a 90° arc of the specified radius value will be added to the toolpath. This arc will betangent to the start feature at the start point. If a value is entered in the Line text box, a line of thespecified length will be created tangent to the arc. When the second option is selected, a line of thespecified length will be added to the cut shape. This line will be perpendicular to the start feature atthe start point. Also, if this is selected and the radius value is zero, the line will not be perpendicularbut instead will be parallel.

Exit MoveThe Exit Move radio buttons instruct the system to create additional movements that will be added tothe toolpath of a particular process. When the first option is selected, a 90° arc of the specified radiusvalue will be added to the toolpath. This arc will be tangent to the end feature at the end point. If avalue is entered in the Line text box, a line of the specified length will be created tangent to the arc.When the second option is selected, a line of the specified length will be added to the cut shape. Thisline will be perpendicular to the end feature at the end point. Also, if this is selected and the radiusvalue is zero, the line will not be perpendicular but instead will be parallel.

Contour StyleThe Contour Style selection affects the toolpaths created for the current operation. If the Material Onlyoption is selected, the system takes into account the current stock conditions, including custom stockspecifications, when creating the toolpaths for an operation. When Material Only is on, the toolpathwill only feed over areas that have not yet been machined in previous operations. The system keepstrack of material removed in previous operations and generates the current toolpath based on thatinformation, providing for “no air cutting.”

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Because of this, the order of operations directly affects how the part will be cut. If the order ofoperations is changed or operations are added or removed, all operations should be reprocessed inorder to account for the change. The Redo All Ops item in the Edit menu makes reprocessing alloperations of a part very easy.

The Clearance value specifies an offset amount from the material that the system uses to calculatewhere the tool can safely rapid during an operation. If the tool is within the clearance amount, onlyfeed moves will be allowed.

The Full option gives the user more control over toolpath creation. When the Full option is selected,the toolpath generated will feed over the selected cut shape from the start point to the end point asdesignated by the machining markers.

Corner Break: The value entered in this text box specifies a radius that will be put on every outside sharpcorner of the selected cut shape. A value of zero will not break the corner, but will keep the tool incontact with the part as it moves to the next feature. Note that Corner Break is only available whenSquare Corners is not selected.

Fin. Stock ±: The Fin. Stock value specifies the minimum amount of material that will be left on the cutshape (equally on all faces) after a toolpath is completed.

Xr Stock: The Xr Stock value allows the user to specify any additional stock amount for the X axis. Thevalue entered here specifies the amount of material that will be left on the cut shape along the X axisonly.

Z Stock: The Z Stock value allows the user to specify a stock amount for the Z axis. The Z Stock valuespecifies the amount of material that will be left on the cut shape along the Z axis only.

Cutter Radius Compensation On: A checkbox that indicates whether Cutter Radius Compensation is turnedon or off. For most post processors, CRC will be turned on and off on the first and last feed moves ofan operation’s toolpath. CRC can not be used in conjunction with the No Drag option. Using the CRCoption requires that it is supported in the post processor. Processors can be updated to handle CRCfunctionality. See the Common Reference Guide for more information.

Coolant: A checkbox which indicates whether coolant is turned on in a process. Flood is the standardcoolant option. Additional coolant options are available with custom post processors.

CSS (Constant Surface Speed): Selecting the CSS item will activate Constant Surface Speed (CSS). CSS willcause the spindle RPM to constantly change based on the diameter the tool is at and the SFPM used.

Max RPM: The Max RPM setting is used to set an upper safe limit on the spindle RPM. If CSS is off, thespecified RPM value will be used for the spindle speed.

The SFPM and Feed values can be automatically calculated based on the material selected if theCutDATA Material database is installed. In order for these values to be calculated and entered in the

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appropriate boxes, the SFPM and Feed buttons must be clicked. If no material is selected or theCutDATA Material database is not installed, the user will need to manually enter values for the feedand speed. For more information on calculating feeds and speeds from the Material Database, refer to“Material Database” on page 57.

Cut Direction Axes: The Cut Direction Axes checkboxes allow the user to regulate the axes and directionsof the cut shape. Deselecting an axis will prevent cut shape moves in that axis direction. The defaultsettings should have all axes selected.

ROUGH PROCESSRough processesare used to takemultiple passeson a shape.When theRough functiontile is combinedwith a Tool tile,the followingProcess dialogwill appear.

Cut OptionsApproach Type:The ApproachType selectiondesignates theaxis (Z or X)along which thetool willapproach thepart. The ODand Front IDoptions specifythat the toolapproach and retract along the X axis, while the Front Face option requires that the tool approach andretract along the Z axis. Also, selecting one of these radio buttons changes the Clearance Diagram thatappears in the right-hand corner of the Process dialog.

Cut Direction: These checkboxes indicate the direction the tool will move along the designated cutshape. If the Forward option is checked, the tool will move from the start point to the end point of theselected cut shape as designated by the machining markers. Otherwise the tool will move from the

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end point to the start point of the selected cut shape. When the Back & Forth option is turned on, thetool will cut in both directions without rapiding to the beginning of the toolpath after each pass.

Start Side Extension: This option allows you to set an extra start distance for each roughing pass. Thishelps to ensure the tool will have a feed move starting off of the material.

Rough TypeThe Rough Type radio buttons indicate what type of roughing cycle will be used for the currentprocess. The three available rough types are Turn, Plunge, and Pattern Shift. Each rough type has acorresponding Clearance Diagram. The Plunge and Pattern Shift options will bring up dialogs askingfor additional information specific to the selected rough cycle. The information required for eachrough type is detailed below.

Turn: When the Turn option is selected, a Cut Depth amount must be entered that specifies the depth ofcut the tool will make on each roughing pass. Depending on the Approach Type selected, the cutdepth will either be an Xr or Z value.

Clearance Diagram: This diagram will change depending upon various options such as the RoughStyle settings and the Approach Type selected.

An Auto Clearance value in the Document dialog will disable the Entry and Exit Clearancepositions because they are handled universally.

If Material Only is selected as the Rough Style, the diagram will have options for Entry and ExitClearance Positions as shown in the picture. The Entry Clearance Position specifies the locationthe tool will make a rapid move to before feeding to the operation start point. The Exit ClearancePosition specifies the location the tool may rapid to after completing its toolpath for thatoperation. Both boxes are labeled with arrows going towards and away from the part, respectively.The use of the values entered for the Entry Clearance Position and Exit Clearance Positionchanges depending on the Approach Type selected. Refer to the Clearance Moves section in thischapter for more details.

The X Stock Start Position designates the position the first cut will be calculated from. Thisposition will only need to be specified if the Full option is selected for the Rough Style (instead ofMaterial Only). The move from this position to the first cut will be the amount of the cut depth. Itwill be a rapid move if the Rapid Step option is turned on under the Full option. Otherwise, it willbe a feed move.

Plunge: When a Plunge Rough Type is selected, the following changes are made to the standard Roughdialog.

Clearance Diagram: The diagram is dependent on the Approach Type selection and Auto Clearancesettings.

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The Entry Clearance Position specifies the position the tool will retract to between each pass. Theuse of this value changes depending on the Approach Type selected. The use of the value enteredfor the Exit Clearance Position changes depending on the Approach Type selected. Refer to theClearance Moves section in this chapter for more information.

The X Stock Start Position only needs to be specified when the Full option is selected for theRough Style. This position will only be used when either Peck Full Out or Peck Retract is chosen forthe First Plunge option. When that is the case, the value entered will be used as the point the firstpeck will be calculated from. The axis will change depending on the Approach Type selected.

Plunge dialog: This dialog allows the user to inputspecifications for Plunge roughing cycles. The PlungeAngle specifies the angle at which the groove tool willplunge into the part. The default value for the PlungeAngle is 270°, which causes the tool to plunge straightdown. There are two options available for the CutWidth. When the Constant option is selected, the userenters a distance in Z that the tool will step over oneach plunge. When the Details option is selected, theuser enters a maximum Z distance that the tool willmove over on each plunge. The Details option willvary the cut width as necessary so that the toolpathhits the endpoints of every feature in the selected cutshape. When the Center Out Cuts option is selected,the tool will make its first plunge in the center of thegroove, and then proceed to rough out each side. TheFirst Plunge options allow the user to select the type ofmove the tool will make when it first enters the part ina plunge roughing operation. The First Plunge optionsinclude Feed, Peck Full Out and Peck Retract and aredescribed in detail below.

Feed: This option designates that the first plunge will be a continuous feed move from theclearance position to the bottom of the groove. The value specifies the percentage of the feedrate setting for the Process.Peck Full Out: This option designates that the first plunge be a peck. The user specifies a PeckAmt and a Clearance amount. Because it is a Peck Full Out, after each peck the tool will retractall the way out of the groove to the clearance position. The tool will then reenter the part andbegin its peck move a clearance distance away from the remaining material.Peck Retract: This option also designates that the first plunge be a peck. A Peck Amt is againspecified. In addition, the user specifies a Retract amount which specifies how far the tool willcome out of the actual cut instead of coming all the way out of the part.

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Pattern Shift RoughWhen the Pattern Shift is selected, the following changes are made to the standard Rough dialog.

Pattern Shift: This dialog allows the user to input specifications forPattern Shift roughing cycles. The Xr Cut and Z Cut values specify theamount of material to be removed on each roughing pass. The cutamount in each axis does not need to be the same.

If the Full option is selected for the Rough Style, the user must enter aCycle Start Point and designate the number of passes to be made. TheCycle Start Point specifies the coordinate the tool uses as thebeginning point for the Pattern Shift roughing cycle. This pointshould be clear of the part. The Fixed option, when turned on,designates that the tool will return to the Cycle Start Point after eachpass. When this option is not on, the tool will return to the CycleStart Point minus the Xr Cut and Z Cut after each pass. The Passesvalue specifies the number of cuts necessary to remove the desiredamount of material in this process.

If the Square Corners option is selected, the system will not add a radius move at the corners of thecut shape. Instead, the tool will only make sharp moves when going around a corner and willleave contact with the finished shape, possibly creating a burr at the corner. If this option is notselected, the system will always stay in contact with the part when moving around corners.

Clearance Diagram: The picture will change depending on the Approach Type selected and theClearance option selected in the Document dialog. Auto Clearance will calculate the clearancepositions automatically if it is the selected option. If not, the user must enter Entry and ExitClearance Positions which are used differently depending on the Approach Type selected. Refer tothe Clearance Moves section for more information.

Rough Style: The Rough Style selection affects the toolpaths created for the current operation. If theMaterial Only option is selected, the system takes into account the current stock conditions, includingcustom stock specifications, when creating the toolpaths for an operation. When Material Only is on,the toolpath will only feed over areas that have not yet been machined in a previous operations. Thesystem keeps track of material removed in previous operations and generates the current toolpathbased on that information, providing for no “air cutting.”

Because of this, the order of operations directly affects how the part will be cut. If the order ofoperations is changed or operations are added or removed, all operations should be reprocessed inorder to calculate for the change. The Redo All Ops item in the Edit menu makes reprocessing alloperations of a part a very easy process.

The Clearance value specifies an offset amount from the part geometry that the system uses tocalculate where the tool can safely rapid during an operation. If the tool is within the clearance

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amount, only feed moves will be allowed. This Clearance amount will be looked at along with the AutoClearance amount when creating any necessary entry and exit moves.

The Full option gives the user more control over toolpath creation. When the Full option is selected,the toolpath generated will simply feed over the selected cut shape from the start point to the endpoint as designated by the machining markers. If the Rapid Step option is turned on, the tool will makerapid moves between each pass, otherwise all moves in the toolpath itself will be feed moves.

Corner Break: The value entered in this text box specifies a radius that will be put on every outside sharpcorner of the selected cut shape. A value of zero will not break the corner, but will keep the tool incontact with the part as it moves to the next feature. Corner breaks are only calculated with turn andpattern shift roughing cycles.

Fin. Stock ±: The Fin. Stock value specifies the minimum amount of material that will be left on the cutshape after a toolpath is completed. The Fin. Stock amount affects the cut shape which in turn affectsthe toolpath created in a canned cycle.

Xr Stock ±: The Xr Stock value allows the user to specify an additional stock amount for the X axis. Thevalue entered here specifies the amount of material that will be left on the cut shape along the X axisonly. This stock amount is used as a parameter in canned cycles.

Z Stock ±: The Z Stock value allows the user to specify a separate stock amount for the Z axis. The ZStock value specifies the amount of material that will be left on the cut shape along the Z axis only.This stock amount is used as a parameter in canned cycles.

Cutter Radius Comp. On : A checkbox that indicates whether Cutter Radius Compensation is turned on oroff. For most post processors, CRC will be turned on and off on the first and last feed moves of anoperation’s toolpath. Using the CRC option requires that it be supported by the post processor. PostProcessors can be updated to handle CRC functionality.

Coolant: Flood is the standard coolant option. Additional coolant options are available with custom postprocessors.

Prefer Canned: A checkbox that will output roughing cycles as canned cycles if the lathe beingprogrammed is capable of handling canned cycles. If the Auto Finish option is turned on, a cannedfinishing pass will automatically be added to the post processed code after the roughing canned cycle.The Prefer Canned option is only available when using Fixed Clearance positions (NOT Auto Clearance)and the Full Rough Style (NOT Material Only).

CSS (Constant Surface Speed): Selecting the CSS item will activate Constant Surface Speed (CSS). CSS willcause the spindle RPM to constantly change based on the diameter the tool is at and the SFPM used.The Max RPM setting is used to set an upper safe limit on the spindle RPM. If CSS is off, the specifiedRPM value will be used for the spindle speed.

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The SFPM and Feed values can be automatically calculated based on the material selected if theCutDATA Material database is installed. In order for these values to be calculated and entered in theappropriate boxes, the SFPM and Feed buttons must be clicked. If no material is selected or theCutDATA Material database is not installed, the user will need to manually enter values for the feedand speed. For more information on calculating feeds and speeds from the Material Database, refer to“Material Database” on page 57.

Cut Direction Axes: The Cut Direction Axes checkboxes allow the user to regulate the axes and directionsof the cut shape. Deselecting an axis will prevent cut shape moves in that axis direction. The defaultsettings should have all axes selected.

THREAD PROCESSThread processes are used to create ID and OD threads. When the Threading Function tile iscombined with a Tool tile, the Process dialog shown below will appear. For more information onthread creation, see “Threading” on page 40

Cut Direction: The selection made for this option determines the direction the tool will move whencreating the thread. If the Z- option is selected, the tool will move towards the spindle. If the Z+ optionis selected the tool will move away from the spindle. The Run In and Run Out distances and the actualthread start and end will change positions in the Clearance/Thread Diagram depending on the cutselection.

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Approach Type: With both selections in the threading process, the approach is along the X axis. Theseselections allow the user to determine whether the thread will be located on the OD or the Front ID ofthe part. The Clearance/Thread Diagram will change according to the choice made here.

Thread Clearance Diagram: If the Auto Clearance option is on, no Entry and Exit Clearance Positions needto be entered. If Auto Clearance is off, the Entry and Exit Clearance Positions must be entered tospecify where the tool will move to when approaching and retracting from the part.

Run In values are used if the threading tool needs to begin a certain distance away from the actualthread start in order to accelerate to the proper feed rate. The Z Run In distance allows the user todesignate a distance along the Z axis to begin the threading pass. The X Run In distance can be used inconjunction with the Z Run In distance to start the thread at an angle. The Run Out values allow theuser to designate a distance and angle for the threading tool to come off the thread and function thesame as the Run In values.

The Run In and Run Out labels and values will change positions in the diagram depending on whetherthe tool is cutting towards the spindle or away from the spindles which is determined by the selectionmade for cut direction (Z+ or Z-).

The Actual Thread Start and Actual Thread End values specify where along the Z axis the thread willbegin and end. Any Run In or Run Out values will be added on the actual length of the thread.

Style: The choices for Style are contained in a pop-up menu and allow the user to specify what type ofthread will be cut. The selection made here designates the appropriate thread form for control ofcalculations.

Nominal Xd: The value entered in this text box is the diameter location of the thread as specified on thepart blueprint.

TPI: The value entered in this text box specifies the number of threads per inch, or threads permillimeter for metric parts.

Taper: Taper is a “slope” value, not an angle. A slope is a ratio of vertical/horizontal distances. Theequivalent angle is:

angle = tan (vertical/horizontal) or tan (slope)

The NPT specification defines the taper as 1/16, or 1” vertical for 16” horizontal, with the horizontalmeasured on the diameter. This entry requires a radial slope, or 1/32. You may type in 1/32 or youmay type in .03125, the decimal equivalent. If your taper is defined as a radial angle, the slope =arctan (angle).

# of Starts: The value entered here is the number of starts for the thread. Most standard threads haveone start. If a value greater than one is entered here, the process will create a multiple thread start.

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Major Xd: The value in this text box automatically defaults to the value entered for the Nominal Xd;however, it can be changed. Cutting begins at this diameter on an OD thread.

Minor Xd: The value in this text box defaults to a calculated value based on the Nominal Xd and thedesired pitch. Cutting begins at this diameter on an ID thread.

Thrd Ht Xr: This value is calculated by taking the difference between the Major and Minor diametersand dividing it by two. It represents the Thread Height given as a radius value.

In Feed: This section allows the user to control how a threading insert will cut. The Balanced option willcut with both sides of the insert equally. For UN thread forms, a Balanced or 0° In Feed takes all cuts atthe same Z position. The Thrd Angle selection allows the user to specify the In Feed angle. The valueentered is measured in degrees and specifies the single edge In Feed angle for the thread form. Thevalue 29.5° is the default Thrd Angle for all thread types. Each cut starts at a different Z position,always cutting with one edge. The Alternate option is available when Thrd Angle is the In Feedselection. When turned “on,” each cut taken at the specified angle will alternate (e.g. 29.5°, -29.5°,29.5°) Only one edge is used at a time to cut, but it alternates to provide for maximum insert life. Thisis also known as “using the leading edge & trailing edge alternately”.

Depth of Cut: The selections made in this box allow the user to designate the cut depth for each pass ofthe threading operation. The One Finish Pass option specifies that the tool will make a single pass overthe thread. Its primary use is to remove burrs or small excesses of material on an existing thread. TheConst Cut selection allows the user to designate the Depth Of Cut that the threading tool will make oneach pass. The value is measured as a radius and is entered in the text box labeled 1st. The Const Loadselection allows the user to specify the depth of the cut made on the first pass. This value is alsomeasured as a radius and entered in the text box labeled 1st. The amount of material (the load)removed for that depth of cut will be calculated, and on each successive pass the depth of cut willdecrease while the tool pressure remains constant.

The Last Cut option is selected to prevent any cut from removing less than a given amount of materialon the last pass. The value entered is measured as a radius value and specifies the minimum cut for theconstant load to diminish to. The Spring Pass option can be used in conjunction with any of the depthof cut selections. It will create additional passes equal to the number entered after the thread has beencut.

Coolant: This checkbox indicates whether coolant is on. Flood is the standard coolant option. Additionalcoolant options are available with custom post processors.

Prefer Canned: A checkbox that will output threading passes as canned cycles if the lathe beingprogrammed is capable of handling canned cycles.

Material button: Clicking on this button will open the Materials dialog which will enable the system tocalculate the recommended speed for the material selected. Refer to the Material Database section inthis chapter for details.

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Speed: RPM: The value entered here is the rate of the spindle measured in revolutions per minute. Youmay manually enter the RPM or click the button to auto-calculate the RPM based on the Materialdatabase.

HOLES PROCESSHoles Processesare used to makeholes on center(X0). When theDrilling Functiontile is combinedwith a Tool tile,the followingProcess dialogwill appear.

Entry/Exit Cycle:The selectionsmade heredetermine thecycle the tool willuse to make its hole features. The choices include: Feed In-Rapid Out, Feed In-Feed Out, Tap, Rigid Tap,Peck Full Out, and Peck Chip Breaker. Additional Entry and Exit Cycles are available with custom postprocessors.

Clearance/Drill Diagram: Entry and Exit Clearance Positions will need to be entered only if the AutoClearance option is turned off, in which case these values specify the positions the tool may use whenapproaching and retracting from the part. The other four values described below are all interactive,automatically calculating the unknown values.

Sharp Tip Z: Specifies the absolute Z depth of the tool tip, and is the number that will be used in theposted output of the finished code.

Drill Surface Z: Specifies the absolute Z value of the surface of the part.

Spot Diameter: Specifies the diameter of the hole at the Surface Z. This is useful when counter-sinking,for instance.

Full Diameter Z: Specifies the absolute Z depth of the full diameter of the drill.

Clearance: This text box is only active if Peck Full Out is the selected Entry/Exit Cycle. The value enteredspecifies the incremental distance away from the material that the tool will start its next peck from.

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Peck: This text box is only active when either Peck Full Out or Peck Chip Breaker is the selected Entry/Exit Cycle. The value entered here specifies the depth increment the tool will drill on each peck.

Retract: This text box is only active if Peck Chip Breaker is the selected Entry/Exit Cycle. The valueentered here specifies the amount the tool will retract after each peck.

Dwell: The value entered in this text box allows the user to specify the length of time the drill willpause at the hole bottom with the spindle on. The value can either be measured in seconds (entered inthe text box labeled sec) or in revolutions per second (entered in the text box labeled revs). Because thetwo boxes are interactive, a value only needs to be entered in one and the system will calculate theother.

Material button: Clicking on this button will open the Materials dialog which will enable the system tocalculate the recommended speed for the material selected. Refer to the Material Database section inthis chapter for more information.

Speed: RPM: The value entered here is the rate of the spindle measured in revolutions per minute. Youmay manually enter the RPM or click the button to auto-calculate the value from the MaterialDatabase. For information see the Material Database section in this chapter for details.

Feed: Plunge: The value entered here is the inches per revolution. You may manually enter the feed rateor click the button to auto-calculate the value from the Material Database. For information see theMaterial Database section in this chapter for details.

Coolant: A checkbox which indicates whether coolant is turned on in the process. Flood is the standardcoolant option. Additional coolant selections are available with custom post processors.

Prefer Canned: A checkbox that will output the drilling moves as canned cycles if the lathe beingprogrammed is capable of handling canned cycles.

THREADINGThis section is intended to assist in calculating the correct parameters for cutting both straight threadsand standard NPT pipe threads using the system. First, an overview of general thread cutting usingthe system will be outlined. There are three things the user must define in order to properly cut athread using the system: what kind of thread to cut, how to cut the thread, and where to cut thethread.

THREAD DIMENSIONS - DEFINING THE KIND OF THREAD TO CUTStyle: This pop-up menu is used to select the thread style, such as UNF, NPT, etc.

Nominal Xd: This is the nominal thread diameter.

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TPI: This is the number of threads per inch, (per millimeter for metric parts). This value should only bein millimeters if the actual part file itself has been designated as a millimeter part. If a metric thread isbeing cut, and the part file itself is set to inches, then the thread pitch must be converted frommillimeters to inches and input as threads per inch.

Taper (Slope): This is the decimal slope of the thread taper, measured radially. For straight threads, thisvalue should be zero. For standard NPT pipe threads, this value should be 1/32 or 0.03125 (the slopeof NPT threads is 1/16 of an inch per inch on diameter, which is 1/32 of an inch per inch radially). Ifyou are creating a tapered thread with Run In, Canned Cycles should not be used. This is becausemost machines cannot handle this situation.

# of starts: This is the number of thread starts. For multiple start threads, enter the number of startshere. Otherwise, this value should be one.

Major Xd & Minor Xd: These values will default to the theoretical major and minor diameters based on aperfect sharp thread. The value as calculated is primarily for reference; this value can be changed asrequired for the particular thread class and fit desired. For OD threads, the minor diameter is criticalas this will be the diameter that the tool will cut on the finish pass. On ID threads, the opposite is true.The major diameter is critical as this will be the diameter that the tool will cut on the finish pass of anID thread.

Thrd Ht Xr (Thread Height Xr): This value is the actual thread height as a radius dimension. This value iscalculated as the radial difference between the Major Xd and the Minor Xd and can be changed asrequired.

CUT INFORMATION - DEFINING HOW TO CUT THE THREADCuts (Z-, Z+): This is used to specify the direction of the thread cut; Z- will cut toward the spindle andZ+ will cut away from the spindle. The Z- choice is the default as most threads will be cut toward thespindle; only in rare cases is the Z+ option used.

OD, Front ID (Approach Type): This is used to specify whether the user is cutting an external or internalthread; the type of thread will affect the approach moves to the thread cutting cycle. It is also correctto think of this as the Thread Type.

In Feed - Balanced: This choice will feed the thread tool straight in for each pass resulting in both edges ofthe thread tool cutting equally.

TIP

The Balanced In feed is often used when cutting tough stainless steels that are easily work hardened, as the equal metal removal method helps prevent work hardening during the cutting cycle. This method usually does not work well on softer materials that tend to load up on the insert; for these materials it is usually best to use the Thread Angle In feed.

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In Feed - Thrd Angle (Thread Angle): This choice will cause the positioning move at the start of each pass tofeed the thread tool in at the angle specified, resulting in the leading edge of the tool doing most or allof the cutting. It is common to set the in feed angle slightly steeper than the thread angle so that thetrailing edge of the tool takes a ‘light’ cut to ensure that the back side of the thread cleans up.

Alternate: This option is only available when the Thrd Angle is selected for the In feed. It willalternate the in feed, resulting in the tool first cutting with the leading edge, then alternating tothe trailing edge, and then back to the leading edge, etc. This provides even tool wear, in turnproviding maximum tool life.

Depth Of CutThe values and options in this section of the Thread dialog are used to control the number of cuts aswell as depths of cuts, minimum cut depth, and spring passes.

1st Xr: This value is the stock amount to remove on the first rough pass. This value also controls theentire roughing cycle as described below for Constant Cut and Constant Load.

One Finish Pass: This option specifies that the tool only take one cut at the finish thread depth. Thiswould normally be used to re-cut a thread as part of a de-burring process.

Const Cut (Constant Cut): The Const Cut option will cause the roughing cycle to step in the amountspecified in 1st Xr on each subsequent pass until the tool reaches the Last Cut amount. A larger 1st Xrwill result in fewer passes, while a smaller 1st Xr will result in more passes.

Const Load (Constant Load): The Const Load option is the most commonly used type of thread roughingcycle. This cycle will take a constant volume of material on each pass, resulting in a smaller depth ofcut on each subsequent pass until the tool reaches the Last Cut amount. The volume removed oneach pass is calculated based on the depth of cut specified in the 1st Xr field. This can also beconsidered a constant amount of tool pressure.

Last Cut: When selected, this option will prevent the roughing cycle from taking any rough passes atless than the value specified. In addition, the rough cycle will always leave exactly this amount for thelast pass.

Spring Pass: This value is used to specify whether to take one or more spring passes at the finish depth.

THREAD LOCATION - DEFINING WHERE TO CUT THE THREADThread Start Z: This value is used to specify where the actual thread begins in Z. If a thread begins at theface of the part, this value should be Z0; note that this is not the Z start of the thread cycle.

TIP

This option is often used to improve the chip flow on soft or gummy materials that tend to tear during the cutting cycle because of material load up on the tool

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Thread End Z: This value is used to specify where the thread ends in Z.

Z Run In: This is where the user specifies the acceleration distance, incrementally. For example, if thethread cycle is to start 3/10” before the actual thread start, simply enter 0.300 for the Z Run In.

X Run In: This value would be used to specify an X acceleration value if necessary. Note that this valueshould normally be zero.

Z Run Out: This value will extend the thread by the amount entered. If the threading tool needs to pullout from the thread on an angle, enter a value for the Z Run Out and the X Run Out. Typically, a zerowould be entered.

X Run Out: When used with Z Run Out, will cause the tool to pull out of the thread on an angle. Forexample, to specify a thread pull out of 3/20” at 45 degrees enter 0.150 X Run Out and 0.150 Z RunOut. A pull out move at 45 degrees for a distance of 0.150 will be added to the thread cycle.

CUTTING STANDARD NPT PIPE THREADSThe primary problem that most people encounter when trying to cut pipe threads is determining thecorrect Major or Minor diameter, which is necessary in order to program the tool path.Unfortunately, the Machinery’s Handbook does not supply these numbers. It provides the pitchdiameter, and the major or minor diameters must be calculated accordingly. This becomes tricky dueto the fact that all of these diameters are at an angle; therefore, these values will change dependingupon the horizontal Z value.

Step by step instructions will be provided for programming both a 2.5"-8 NPT external and a 2.5"-8NPT internal thread to show the actual process required to determine the minor and major diameters.

First, a given horizontal value must be established to act as a gauge point. Since the MachineryHandbook supplies the pitch diameter at the start of the thread, the horizontal value most commonlyused is Z0 (the face of the part). The system also assumes this value for the major and minordiameters, and will calculate the major and minor diameters at the start and end of the toolpath based

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An example of where this is used would be to machine a cable groove in the drum of a cargo winch; in this case a round groove needs to be cut at a given pitch (similar to a thread) where the groove must start in, and be timed with, a hole drilled through the diameter of the part. Using both the X & Z Run In would allow the plunging of the tool into the hole after starting the thread cycle, thereby not cutting the area between the face of the part and the hole.

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If the X Run Out value is less than the Z Run Out, a pull out move of less than 45 degrees will occur; and if the X Run Out is larger than the Z Run Out, a pull out move greater than 45 degrees will occur.

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on this assumption. The advantage of this is that only one value needs to be calculated; in the case ofexternal pipe threads, only the minor diameter at the face of the part is needed, and with internal pipethreads only the major diameter at the face of the part is needed.

2.5" - 8 NPT EXTERNAL PIPE THREAD1 Find the Pitch Diameter at Beginning of External Thread (E0) from Machinery Handbook:American Pipe Threads: Table 3 (Basic Dimensions, American National Standard Taper PipeThreads). For a 2.5" - 8 NPT external thread this value is 2.71953

2 Find the nominal truncated Height of Pipe Thread (h) from Machinery Handbook: AmericanPipe Threads: Table 1 (Limits on Crest and Root of American National Standard Taper PipeThreads). This value is given as a max/min dimension; add the minimum and maximum heightand divide by two to obtain the nominal thread height. For a 2.5" - 8 NPT external thread thiswould be (.1000+.09275)/2 or 0.096375

3 Find the Minor diameter at the start of the thread. To calculate this value, simply subtract thenominal thread height from the Pitch diameter (E0). For a 2.5" - 8 NPT external thread this wouldbe 2.71953 - 0.096375 or 2.623155

2.5" - 8 NPT INTERNAL PIPE THREAD1 Find the Pitch Diameter at Beginning of External Thread (E1) from Machinery Handbook:American Pipe Threads: Table 3 (Basic Dimensions, American National Standard Taper PipeThreads). For a 2.5" - 8 NPT internal thread this value is 2.76216

2 Find the nominal truncated Height of Pipe Thread. This value does not change for externaland internal threads and is the same as the 2.5" - 8 NPT external thread above (0.096375)

3 Find the Major diameter at the start of the thread. To calculate this value, simply add thenominal thread height to the Pitch diameter (E1). For a 2.5" - 8 NPT internal thread this would be2.76216 + 0.096375, or 2.858535

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AMERICAN NATIONAL STANDARD TAPER PIPE THREAD (NPT) CHARTThis is a simple chart containing the values for the Standard NPT Pipe Thread sizes. For an externalthread, enter the Minor diameter as given on the chart, and for an internal thread, enter the Majordiameter as given on the chart.

PIPE SIZE EXTERNAL THREADS INTERNAL THREADS

Nominal Pipe Size TPI Minor Major Minor Major

1/16” 27 0.2439 0.2985 0.2539 0.3085

1/8” 27 0.3362 0.3908 0.3463 0.4009

1/4” 18 0.4360 0.5188 0.4502 0.5330

3/8” 18 0.5706 0.6534 0.5856 0.6684

1/2” 14 0.7045 0.8124 0.7245 0.8324

3/4” 14 0.9138 1.0216 0.9349 1.0428

1" 11 1/2 1.1475 1.2797 1.1725 1.3047

1 1/4” 11 1/2 1.4910 1.6232 1.5173 1.6495

1 1/2” 11 1/2 1.7300 1.8622 1.7563 1.8884

2" 11 1/2 2.2029 2.3351 2.2302 2.3624

2 1/2” 8 2.6232 2.8159 2.6658 2.8585

3" 8 3.2442 3.4370 3.2921 3.4849

3 1/2” 8 3.7411 3.9339 3.7924 3.9852

4" 8 4.2380 4.4308 4.2908 4.4835

5" 8 5.2944 5.4871 5.3529 5.5457

6" 8 6.3497 6.5425 6.4096 6.6023

8" 8 8.3372 8.5300 8.4037 8.5964

10" 8 10.4489 10.6417 10.5246 10.7173

12" 8 12.4364 12.7286 12.6208 12.7142

14" OD 8 13.6786 13.8714 13.7763 13.9690

16" OD 8 15.6661 15.8589 15.7794 15.9721

18" OD 8 17.6536 17.8464 17.7786 17.9714

20" OD 8 19.6411 19.8339 19.7739 19.9667

24" OD 8 23.6161 23.8089 23.7646 23.9573

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PRE-DEFINED PROCESS GROUPSAll machining operations are created from the information contained in the Process List. Processesare created by combining a Function tile with a Tool tile and entering the necessary information inthe Process dialog. A Process Group is the collection of Process tiles contained in the Process List atany one time. A Process Group contains all of the tooling and machining information needed togenerate a specific set of operations.

A Process Group can be saved as an external file that can then be loaded into other part files. Thiscapability allows user to access and reuse common machining and tool data for multiple part filesquickly and easily without having to recreate tools and processes.

Process Groups can be saved by selecting Save from theProcesses menu when the Process List contains thecompleted Process tiles that will compose the group.The system will ask for a file name and a location to savethe file. Once a Process Group file is saved, it can beloaded into any part file by selecting the Load item fromthe Processes menu. Another way to quickly loadProcess Groups is by choosing a directory that containsProcess Group files. The directory is chosen by selectingthe Set Directory item from the Processes menu. When adirectory is set, all the Process Group files contained in that directory will appear in the Processesmenu. For a quick load, simply select the name of the Process Group file to be loaded from the list.

When a Process Group is loaded into a part file, any Process tiles currently highlighted in the ProcessList will be removed and replaced by the loaded Process Group (if this removes process tiles that wereneeded, simply select Undo from the Edit menu). If the Tool List contains Tool tiles, those tools willbecome deselected but not removed from the list. The system will search through the existing ToolList to find the necessary tools for the loaded Process Group. If the system finds an exact tool match,that tool will be used. If an exact match is not found, the necessary tools for the loaded Process Groupwill be created and added to the Tool List in the first available positions. Added tools will behighlighted.

Once the Process Group is loaded into the Process List, select the appropriate geometry to act as thecut shape and click on the Do It button to create the operation and toolpath.

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CLEARANCE MOVESThis section contains information and diagrams on rapiding and feeding around lathe parts. It is veryimportant when working with lathes to avoid tool interference with the part, the spindle, etc., whileat the same time quickly and efficiently maneuvering around the part. Clearance positioning is theterm used for various positions the tool will move to when not actually cutting the part.

The primary tool changeposition is specified in theDocument dialog. This positioncan be overridden on a tool bytool basis using the Turret Shiftfunction in the Tool Creationdialog. For more informationon Turret Shift, refer to theTool Creation chapter. If ToolChange is turned off, it isassumed that the finished codewill be manually edited tohandle the tool change.Otherwise, the tool will start atthe Tool Change position enteredin this dialog.

In addition to specifying theposition of the turret when tools are changed, the Document dialog provides the user with twooptions for handling part clearance, Auto Clearance or Fixed Clearance. The selection made willdetermine how the system will calculate positioning moves between operations.

AUTO CLEARANCEThe Auto Clearance option performs several functions when it is turned on. It will calculate the partclearances in both Z and X that are used to position the tool between each operation. Thesepositioning moves will be dynamically calculated for each operation. This means that as the stockconditions of the part change as material is removed, the clearance positions will adjust accordingly.When Auto Clearance is on, the system will also take into account where the tool needs to be to beginthe next operations’ toolpath when calculating the positioning moves. Additionally, the Auto Clearancefunction may add entry and/or exit moves to the toolpath in order to safely maneuver around thepart. The Auto Clearance function generates the most efficient positioning moves around a part.However, canned cycles cannot be used in conjunction with Auto Clearance. In order to use cannedcycles, which are turned on in Process dialogs by selecting the Prefer Canned option, Fixed Clearancepositions must be used.

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The Auto Clearance option requires the user to enter an offset amount from the part stock that thesystem uses to calculate the clearance positioning moves between operations. Because the stockconditions are constantly changing as material is removed from the part, in order to optimize thetoolpaths, an offset amount is used for positioning rather than absolute positions. Fixed clearance,which is used when Auto Clearance is turned off, uses absolute positions.

FIXED CLEARANCEWhen the Auto Clearance option is turned off, fixed clearance positions are used by the system tocalculate clearance moves. The user must enter an overall part clearance in the Document dialog, aswell as Entry and Exit Clearance Positions in the Process dialogs for each operation. When usingcanned cycles, fixed clearance positioning should be used.

The overall part clearance is entered in the Document dialog in the X and Z text boxes that becomeactive when Auto Clearance is turned off. They designate the position the tool will rapid to and fromduring a tool change. This position will also be used when moving from one approach type to anotherbetween operations that use the same tool. The absolute positions specified in the X and Z text boxesare locations the tool can rapid to when moving around the part. One or both of these fixed positionsare used whenever a tool is moving to the start point of the toolpath or exiting from the toolpath.Where the tool moves when approaching and retracting from the part depends on the Approach Typeselected and the positions specified in the Clearance Diagrams in the Process dialog.

The Approach Type selections are located in the upper left corner of the Process dialog. The tool canapproach the part along two different axes—either X or Z. The tool will approach the part along the Zaxis if Front Face is selected. The tool will approach the part in X if OD or Front ID is selected. When aDrilling Process is selected, the Approach Type is automatically set to Front Face. Only one selectioncan be made for each process.

Once the Approach Type is selected, the corresponding Clearance Diagram appears in the Processdialog. The boxes with the arrows next to them represent the Entry and Exit Clearance Positions thatthe tool may use when approaching and retracting from the part. The Entry and Exit ClearancePositions are only required when Auto Clearance is turned off.

When a Turn roughing cycle is selected, an additional move will be added between the EntryClearance Position and the X Stock Start Position. When a Pattern Shift roughing cycle is selected, anadditional move will be added between the Entry Clearance Position and the contour start point.

CLEARANCE DIAGRAMSThe tool will use some or all of the clearance positions depending on which Approach Type isselected. When Auto Clearance is selected, the tool will still move to the positions indicated in thediagrams shown below. However, the system will calculate these positions and they will change asthe material conditions of the part change. Also, when Auto Clearance is on, the system may addadditional entry and exit moves as necessary to prevent tool interference. The following conventionsare used in the clearance diagrams.

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Black Dot: Absolute coordinate the tool will move to; each Black Dot has an X and Z coordinate

Dashed Line: Rapid Move

Solid Line: Feed Move

SP - Start Point: The first move of the operation. Not necessarily the Start Point Machining Marker.

EP - End Point: The last move of the operation. Not necessarily the End Point Machining Marker.

OP1: Operation 1 (the first series of cuts made on the part)

OP2: Operation 2 (the second series of cuts made on the part)

APPROACHES FROM TOOL CHANGE POSITIONThe tool can approach the part in three different ways from the tool change position.

OD Approach From Tool Change

1- Tool Change2- SP Z, Part Clearance Xd

3- SP Z, Entry Clearance Xd4- SP Xd

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Face Approach From Tool Change

ID Approach From Tool Change

1- Tool Change2- SP Z, Part Clearance Xd

3- Entry Clearance Z, SP Xd4- SP Z

1- Tool Change2- Part Clearance Z, Part Clearance Xd3- Part Clearance Z, SP Xd

4- SP Z, Entry Clearance Xd5- SP Xd

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EXITS TO TOOL CHANGE POSITIONThe tool can exit from the cut shape to the tool position in three different ways.

OD Exit To Tool Change

Face Exit To Tool Change

1- EP Xd2- EP Z, Part Clearance Xd

3- Tool Change

1- EP Z2- Part Clearance Z, EP Xd

3- Part Clearance Z, Part Clearance Xd4- Tool Change

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SAME TOOL POSITIONSIf the next operation uses the same tool, there are seven different methods the tool could use to get tothe next start point.

ID Exit To Tool Change

OD To Face

1- EP Z2- EP Z, Part Clearance Xd3- Part Clearance Z, Exit Clearance Xd

4- Part Clearance Z, Part Clearance Xd5- Tool Change

Op #1

Op #2

1- EP Z2- EP Z, Part Clearance Xd3- Part Clearance Z, Part Clearance Xd

4- Part Clearance Z, SP Xd5- Entry Clearance Z, SP Xd6- SP Z

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OD To OD

Face To ID

Op #1Op #2

1- EP Xd2- EP Z, Exit Clearance Xd3- SP Z, Exit Clearance Xd

4- SP Z, Entry Clearance Xd5- SP Xd

Op #1

Op #2

1- EP Z2- Part Clearance Z, EP Xd3- Part Clearance Z, Entry Clearance Xd

4- SP Z, Entry Clearance Xd5- SP Xd

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Face To OD

Face To Face

Op #1

Op #2

1- EP Z2- EP Z, Part Clearance Xd3- Part Clearance Z, Part Clearance Xd

4- SP Z, Part Clearance Xd5- SP Z, Entry Clearance Xd6- SP Xd

Op #1

Op #2

1- EP Z2- EP Z, Part Clearance Xd3- Part Clearance Z, Part Clearance Xd

4- Entry Clearance Z, SP Xd5- SP Z

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CANNED CYCLESThe Auto Clearance and Material Only functions of the system calculate more efficient toolpaths thancanned cycles. Auto Clearance is activated in the Document dialog and designates that the systemdynamically calculate clearance positioning moves for the part. The Material Only option is located inProcess dialogs and designates that toolpath calculation for an individual process take intoconsideration the material conditions of the part to provide for no “air cutting.” If either of theseoptions are being used, the Prefer Canned option found in the Process dialogs will not be available.

ID To Face

ID To ID

Op #1

Op #2

1- EP Xd2- EP Z, Exit Clearance Xd3- Part Clearance Z, Exit Clearance Xd

4- Part Clearance Z, SP Xd5- Entry Clearance Z, SP Xd6- SP Z

Op #1

Op #2

1- EP Xd2- EP Z, Exit Clearance Xd3- SP Z, Exit Clearance Xd

4- SP Z, Entry Clearance Xd5- SP Xd

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Using canned cycles will output shorter processed code however, the Auto Clearance and Material Onlyfunctions will produce more efficient toolpaths in general. To generate canned cycles in the postedcode, turn Auto Clearance off and enter fixed X and Z clearance positions in the Document dialog, andselect the Full Rough Style in the Rough Process dialog.

MACHINING MARKERSMachining Markers allow the user to specify the start and end feature and start and end point of thecut shape, the cut direction, and the offset position of the tool. These markers appear on the screenwhen geometry is selected as the cut shape for Contouring and Roughing Processes.

Start Feature: The geometry feature (line or circle) on which the tool will start cutting.

Start Point: The point on the start feature where the tool will start cutting.

End Feature: The geometry feature on which the tool will stop cutting.

End Point: The point on the end feature where the tool will stop cutting.

Cutter Side and Direction: The circles represent the offset position of the tool with regardto the cut shape. The three possible options are the inside, centerline or the outside ofthe cut shape. The arrows indicate which direction the tool will travel. Simply click onthe desired circle and direction arrow.

HOW MACHINING MARKERS WORKMachining Markers appear on selected geometry for contouring and roughing processes only. Tomove a marker, the cursor is placed over the marker, and when the mouse button is depressed, thecursor changes to the marker. This is called “picking up a marker.” The marker is then moved to thedesired location and the mouse button released. Note: When positioning or placing a marker, place the“tip” of the “marker arrow head” onto the line, circle or point.

When the Start Feature marker is moved to a new feature on the geometry, the Start Point markerwill “follow” it and snap to the same point as the Start Feature. This is also true for the End Featuremarker. To make the Start Point and End Points the same: drag the Start Feature to the desiredfeature, and drag the Start Point to the desired location, drag the End Feature to the same feature- theEnd Point automatically snaps to the Start Point.

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For precise control over the Start and End Point marker locations,create a geometry point at the desired location. Dragging a Start orEnd Point marker close to the point will cause the marker to “snap” tothe point and use its exact XZ values.

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START AND END POINTSThe Start and End Points do not necessarily have to be on the part geometry. There may be timeswhen it is desirable to have the tool start or end its toolpath off the part. This can be done by movingthe markers. A geometry feature (e.g. line or circle) is trimmed between two connectors. When theStart Point marker is dragged off the part, it automatically snaps to the nearest extension of the StartFeature. The nearest section of the Start Feature may be a section that was trimmed away, so the StartPoint will snap to an extension of the Start Feature. This is also true for the End Feature. The endfeature markers may be quickly set using a Ctrl+Shift click. When performing a Ctrl+Shiftclick the end point markers will snap to the location you clicked.

SELECTED GEOMETRYThe machining markers allow the user to specify the portions of geometry to act as the outline for thecut shape. When markers are present on geometry, the cut shape is indicated by a dark blue color.When the cut shape is not the entire contour, the geometry not included as part of the cut shape isdrawn in light blue.

MATERIAL DATABASEThe Material Database is used forstoring and quickly retrievingfeeds and speeds for various typesof materials. All MaterialDatabase information must beentered by the user unless theCutDATA™ material library hasbeen purchased. The informationin the database can be changed byselecting Materials from the Filemenu. To use the information,click on the Material button in anyof the Process dialogs. Below is apicture of the Materials dialog. It isused for both creating and editingmaterials as well as placing feedsand speeds information intoProcess dialogs. These values can be directly overridden by typing in the speed or feed info in theProcess dialog at any time. The Material database is fully detailed in the Common Reference guide.

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OPERATION TILESThe operation list context menu contains several useful functions asdetailed in the following paragraphs.

Operation Data: It is possible to edit certain operation specifications in theOperation Data dialog. The values in the text boxes with raised bordersand the checkboxes that appear in the dialog with locks next to themcan be changed. Values are locked by clicking once on the lock next tothe text box. Unlocked values will return to their original values if theoperation is reprocessed. Locked items will retain the values entered inthis dialog even if the operation is reprocessed. Changes that affect thetoolpath can be seen in the toolpath drawing and the rendered image.The information in the Process Tile that created the operation will notbe modified to reflect the changes made in the Operation Data dialog.

Information entered in theOp Comment text box willappear in the posted outputbefore the selectedoperation it refers to. Utilitydata can also be entered inthis dialog. Custom postsallow the user to inputcustom commands in the AtOp Start and At Op End textboxes that will triggeractions inside the postprocessor. In addition, anytext that appears inquotations in the At Op Startand At Op End text boxes willappear in the posted output.Each set of quotes will be ona separate line in the postedoutput.

The Program Stop checkboxis only available in the Operation Data dialog. If it is turned on, a program stop command will beadded at the end of the operation in the posted output. The default position is off.

If operations contain locked values, a small lock symbol will appear on the Operation Tile. Ifutility data is entered in the At Op Start text box, a small recessed square will appear on the

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Operation tile in the upper left hand corner. If utility data is entered in the At Op End text box, a smallrecessed square will appear in the lower left hand corner of the Operation Tile.

Utility Markers: This selection allows the user to manually editthe feed rates of toolpaths. When chosen, the dialog shownbelow will come up as well as the current operation’stoolpath.

Preset on the toolpath are two markers, one is red the otherblack. The red marker indicates the active marker. When theUtility Markers dialog is opened the entry location will bethe active marker. The black marker indicates the location atwhich the toolpath changes it’s feed rate to the designatedContour Feed rate. When a marker on the toolpath isselected it changes from black to red.

Drag the Utility Marker Feedrate icon to the locations in thetoolpath where you want to change the feed rate. Thearrows below the marker cycle through all placed markers insequential order.

Once a marker has been placed a feed rate needs to be assigned. The user may designate a preferredrate as shown. The feed rate applied to this marker will apply to the entire remaining toolpath or untilanother marker is placed and speed is indicated. If you place a marker by a corner to slow down thetool be sure to place another further along the toolpath to speed up the feed rate.

This image shows Utility Markersplaced on toolpath. The markers areplaced by an arc, modifying the speedgoing into and coming out of the arc.

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Scale the Toolpath: This selection enables users to either shrink orenlarge the toolpath of the selected tile. When chosen, the TPShrinkage Dialog comes up allowing for a reduction or anenlargement of the toolpath by entering the percentage desired.Users may also modify the toolpath around one axis by selecting theXYZ option and inputting the desired percentage in the appropriatetext box. It should be noted that clearance planes are not scaled.

Operation To Geometry: This option converts the selected operations togeometry. This geometry can be edited and used as a centerlinecontour op if necessary.

Move To: This selection allows the user to move one or several of theoperation tiles to the end of the list or to another tile location byentering the tab number of the destination tile location and clickingMove To. It functions exactly the same as the Move To item on theTool and Process tiles.

Find: The Find option allows a user to locate a specific tile By Tile #, Tool #or to find the last tile. It functions exactly the same as the Find item fromthe Tile List Scroll Arrows.

Op To Geometry: When Op To Geometry is selected, the highlightedoperation’s toolpath will be converted to geometry. This geometry canthen be modified as needed and a center cut contour operation can be applied to it. This applies tocontour, roughing and surfacing operations. This may be useful for avoiding clamps and fixtures orediting a pocket or profile’s toolpath for individual preferences.

Sort Operations: This command will change the order of all operations. The operations will be sorted bytool number, from low to high. Operations created in the same Process List will maintain their orderto ensure that finishing passes cannot be moved in front of roughing passes, etc.

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OPERATION SUMMARYSelecting the Operation Summary item from the Part menu (the title of this menu is the name of thecurrent part) will bring up the Operation Summary dialog, shown on the following page, which providesinformation in spreadsheet form about each operation in the program, including estimated cut timeand the distance traveled by the tool. The information in the dialog can either be saved as a text file orprinted out. To save the summary as a text file, select Operation Summary from the Save Special sub-menu in the File menu. To print the summary, select Operation Summary from the Print sub-menu inthe File menu.

PRINTING THE TOOLPATHAfter the operation has beencreated and the toolpath drawn,it can be printed. Toolpaths caneither be printed in black andwhite or color. When the desiredtoolpath is on the screen, chooseDrawing from the Print sub-menuin the File menu. To adjust theway the image will print, choose Printing from the Preferences sub-menu in the File menu. The PrintingPreferences dialog allows the user to specify how the software will handle the background color. If theprinter being used is a black and white printer, choose the Black on White option to ensure that allportions of geometry, including those that are of a light color, can be seen in the print.

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TOUCH-OFF POINT INFORMATIONAll post data is output to the theoretical tool tip. If the tool is machining parallel to the Z-axis, the Xvalues are output to blueprint dimensions. If the tool is machining parallel to the X-axis, the Z valuesare output to blueprint dimensions. So, the theoretical tool tip only aligns with blueprint dimensionson faces and diameters.

When the tool is machining at an angle, the X andZ-axis values will not match the blueprintdimensions. This is because the theoretical tool tipis not always a blueprint dimension. So, in orderfor the system to get the surface of the tool inposition to cut the part, the theoretical tool tip iscalculated closer to the part, and in some casesinside the part.

CUT PARTRENDERING

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CHAPTER 5 : Cu t Pa r t R e n d e r i n gOVERVIEWCut Part Rendering displays a simulation of toolpath cuts.

The tool is cutting as fast as the computer can calculate the moves. Cut Part refers towatching the effect of the tools cutting, as opposed to seeing only the finished picture. In most cases,seeing the cutting process is more valuable than the finished picture. Rendering refers to the processof displaying the graphic image of the cut part model defined by the machining operations.

All operations will be rendered in their current order. The rendering process will start over wheneverthe view is changed or zoomed. Therefore, it is more efficient to select the desired view beforedepressing the Cut Part Rendering button. Selected operations will render in shades of yellow, whileall others will render in shades of grey. Shades of red will be drawn when non-cutting tool surfaces orrapid moves hit the material. Selected tools will be drawn in shades of yellow. All other tools will bedrawn in shades of grey. Smaller pictures will render faster and use less computer memory.

RENDERING PALETTEWhen the Cut Part Rendering button is clicked, the CutPart Rendering palette appears on the screen, and the stockshape will be displayed as a blue, solid image. The Cut PartRendering palette controls the cut part rendering process.The functions of the items in the palette are describedbelow.

Current Display: This box displays the number of the current operation being rendered or thecurrent runtime.

Rewind: This button sets the current operation to the first operation. If the Play button isdown when the Rewind button is depressed, the part will be redrawn.

Stop: This button stops any rendering in progress and raises the Play button.

Step Forward: This button renders the next feature of the current operation. If the Play buttonis depressed, it will be raised and rendering will be stopped at the end of the current feature.

Play: When the play button is depressed, the part will be rendered from the current feature ofthe current operation as listed in the Current Display box. Rendering will continue until oneof the other buttons is depressed or the last feature of the last operation is rendered. The Stop and StepForward buttons stop the rendering and raise the Play button. Pressing the Play button duringrendering will also stop the rendering. The Next Operation and Rewind buttons will change thecurrent operation being rendered, but will not stop the rendering process. When the last feature of thelast operation is complete, rendering will stop, but the Play button will remain depressed. Anytime the

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rendering process stops, hitting the Play button again will resume rendering from the currentlocation.

Next Operation: If the Play button is depressed, the current feature being rendered is finished andthe remaining features for that operation are skipped. The next feature to be rendered is thefirst feature of the next operation. If the Play button is not depressed, the current operation is set tothe next operation. The Operation Box will be updated, but nothing will be rendered until the Playbutton is depressed again.

Throttle Control: Shows the current location of the Throttle slider. The plus siderepresents maximum rendering speed, and the minus side the minimum. Thelocation of the slider can be changed by dragging it left or right. This can be doneduring the rendering process and the effects will be seen as the slider is moved.

Invisible Tool: If this button is selected, the tools will not be drawn during the rendering process,although the material as a result of the tools cutting is removed (see example below). Radii willrender more smoothly, and the part will render faster with this choice selected.

Transparent Tool: If this button is selected, transparent tools will be drawn during the renderingprocess (see example below).

Visible Tool: If this button is selected, solid tools will be drawn during the rendering process (seeexample below).

During the cut part rendering process, if the screen is redrawn due to a view change or redraw, therendering process will start over from the first operation. Therefore, it is good practice to set thedesired view before rendering the part.

When the rendering process is stopped by pressing either the Stop or Step Forward button, the nexttime the part is rendered the system will automatically stop the rendering process at the samelocation. User set stops are maintained by the system. Anytime the rendering process is stopped,simply click on the Play button to continue.

If the Play button is depressed when the Cut Part Rendering button in the Top Level palette is raised,it will resume playing when the Cut Part Rendering button is selected once again. It is essentially thesame as pausing the render. However, if the view was changed, it will restart as stated above.

CUT PART RENDERING CONTEXT MENURight-clicking on the title bar of the Cut part Rendering palette will bring up optional controls forsetting a stopping point during rendering and changing the status display.

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Optional Stop controlSet Op Stop #...: This option opens a dialog to specify a stop pointbefore a specific operation begins.

Stop Before Op: The rendering will automatically stop before thisoperation.

Use Op Stop: Placing a check mark on this option activates the Set Op Stop #... option. Removing thecheck mark will disable the stop point specified in the Set Op Stop # dialog.

Current Display OptionsShow Time: This will set the status to display the elapsed cut time.

Show Op: This will set the status to display the current operation number.

FAST UPDATEThe Fast Update quickly gets you back to the last rendered state of your part after changing the view.If you have begun rendering your part, press Stop then zoom or change the screen position of the partand press Play, the system will regenerate the rendering in the new viewing position and orientation asquickly as possible. It does this by automatically setting the CPR speed to the fastest speed and hidingthe tool when replaying the rendering. Once the render reaches the place it was last stopped thecontrols will revert back to your previous setting.

FLASH CUT PART RENDERINGFlash CPR is an OpenGL based rendering option that provides an alternative tothe standard rendering mode. Flash CPR is a non-view dependant optionmeaning that the part can be rotated, zoomed and panned during the cut partrendering. There are several other capabilities that go along with Flash CPRincluding the Rapid Cut option that displays only the end condition of eachoperation, resulting in a much faster rendering, but at a lower displayresolution. Flash CPR is activated and deactivated by right-clicking on theRender button in the Top Level palette and choosing the Flash CPR option. TheFlash CPR option uses the same Render palette as the traditional renderingengine.

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FLASH CPR CONTEXT MENURight clicking on the Render palette title bar provides access to theFlash CPR options. Set Op Stop#, Use Op Stop, Show Time and Show Op#are the same functions as the standard rendering mode.

Analyze Cut Part: The Analyze Cut Part dialog provides several options todetermine the results of the toolpath on a rendered part. This is an easyway to determine if there are areas on a body that are not beingmachined (Remaining Material) or if any cuts violate the part. A solidmust be selected prior to starting Flash CPR to use the Analyze Cut Partoption.

Transparent Stock: If Transparent Stock is selected, the stock will betransparent, showing both the part and the stock when rendering.

Transparent Fixture: If the Transparent Fixture item is selected any fixtures inthe part will be transparent, allowing you to more readily see the stockbody when rendering.

Acceleration & Checking: The next set of options provide methods foraccelerating or confining the rendered part.

Skip Pecks: The Skip Pecks option will not render any pecking movesused in drilling operations.

Skip Unselected Ops: Skip Unselected Ops will only render the currently selected operations.

Set CPR Stock=Target: This option causes Flash CPR to ignore the stock definition. Instead, theselected body is used as stock and rendering is run on this body. This is a quick and easy way tocheck for gouges.

Collision Checking: Selecting Collision Checking enables the collision checking based on the options setin the Preferences, See the section “Collision” on page 69 for more information.

Save To STL: Save To STL will save the current stock results of the Flash CPR rendered image to disk inSTL format.

Preferences: Preferences opens the Rendering Preferences dialog thatallows you to control the speed, quality and color of the Flash CPRdisplay. Alternatively, this dialog can be accessed by opening the GraphicsPreference dialog and clicking the Flash CPR Options button which opensthe Rendering Preferences dialog. When the Flash CPR option is disabled,standard Cut Part Rendering will be used.

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Flash CPR Rendering PreferencesCutting: The Cutting options section allow you to control the qualityand responsiveness of Flash CPR. These preferences are stored withthe part when the part is saved. This means that if you change thePreferences but open a part that has an older set of preferences, itwill override the changes you have made. To change the preferencesfor all new parts open the File > Preferences > Graphics and accessthe Flash CPR Options from there. Any changes you make with nofile open will set the preferences for all new parts. Any file that haspart settings will override the settings.

Time Slice: Time Slice specifies the amount of time the system willallocate for interruptions when rendering. Larger values willincrease rendering speed but decrease system responsiveness. Avalue of 250 milliseconds means the system will only respond toa mouse click every quarter of a second, while a value of 100will allow an interruption every tenth of a second. Thedifference in time may not seem like much but the renderingspeed is greatly affected by this. Experiment with values to finda setting that you find comfortable.

Steps Per Update: Steps per Update specifies the maximum number of CPR features to render beforeupdating the display. Large numbers will increase the rendering speed but will result in a rougherrendering animation. With large numbers the tool may appear to jump ahead of rendering, whichwill suddenly snap to the tool. This may be jerky, but can be rather fast. A low number provides asmooth animation, but may be slow.

Facet Resolution: Facet Resolution is the resolution for the part and tools displayed in Flash CPR.There are separate settings for inch and metric tools. The smaller the value, the higher quality ofthe display and the more resources needed by the system, resulting in a slower rendering.

Collision: The items found in the Collision section of the dialog provide control over how the systemreports machining errors while rendering. A collision in Flash CPR occurs when the tool rapids intothe stock or touches a fixture or if a holder touches anything. Any combination of the three availablealert methods may be used. Please note that the Collision Checking option (in the Render Control palette)must be activated for the system to check for collisions.

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Alert Types: The Beep option provides an audible alert, Log To Display will output an error in acollision log window and Stock Flash provides a visual alert to the error by flashing the renderedstock.

Tolerance: The Tolerance setting allows a different value for metric and inch parts. Any collisionwithin the specified tolerance will generate a collision alert.

Display: The Display… checkbox widens the RenderingPreferences dialog to display options for controlling thedisplay of the Flash CPR model. Statistics opens awindow that logs the current framerate for yourmachine as well as any logged errors for the CPRsession. Gradient Background switches the standard blackworkspace to a white-blue gradient (see below), makingit easier for you to distinguish between standardrendering and the OpenGL rendering modes, which maybe slower. The colors of the background may becustomzed in the Rendering Preferences dialog.

Lights: The model is lit by up to four lights. Eachlight’s position around the part can be controlledthrough XYZ vector values varying from –1 to 1.Alternatively, you can control the direction bydragging the light across the preview, Each light hasa color defined by RGB (Red Green Blue) valuesranging from 0 to 255. Alternatively, you may clickon the color button and select a light color from thecolor picker.

Material: You may control the display of the part’s material by controlling its Specular, Ambient lightand Shininess values. The Specular value is the color of the reflections. The Ambient value is thenon-directional illumination of the part. You can select a color or define the RGB values for the

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Specular and Ambient attributes. Shininess is the overall reflectivity of an object. It is a value from0-255.

Color: The items in the Colors tab allow you to definethe color of the various items displayed by FlashCPR. You may change the default color of renderedobjects by setting the RGB values or by clicking onthe appropriate color button and selecting a color.Separate colors may be applied to the Stock, selectedbodies (Target), Fixtures, toolpath (Op), interference(Clash), the primary color of the cutting tool (Tool),the Shank of the cutting tool, and the color ofwireframe drawing (Edge).

Background: The items in the Background tab allow youto define the colors of the cut part renderedbackground. Both the single color background andthe gradient background may be customized. Thegradient consists of up to four colors, one per cornerof the workspace.

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Color Selection: The Rendering Preferences allows theselection of a color from forty standard choices.Clicking the Default Color button is the same ashitting Escape in that the dialog will close and thecolor selection will not change. The color mixer atthe bottom of the dialog allows the approximatespecification of a color from the visual gamut. Theupper color button to the right of the color mixerselects the specified color and adds it to the currentcustom palette. The lower color button selects thecolor but doesn’t add it to the custom palette.

PRINTING THE CUT PART RENDERED IMAGEAfter the rendering is complete,the rendered image can beprinted in either black and whiteor color. When the renderedimage is on the screen, chooseDrawing from the Print sub-menuin the File menu. To adjust theway the image will print, choosePrinting from the Preferences sub-menu in the File menu. The Printing Preferences dialog, shown below,allows the user to specify how the software will handle the background color. If the printer being usedis a black and white printer, choose the Black on White option to ensure that all portions of the image,including those that are of a light color, can be seen in the print.

1 - Standard 2 - Custom 3 - Color

Mixer

POSTPROCESSING

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CHAPTER 6 : Po s t P r o c e s s i n gPOST PROCESSING OVERVIEWOnce the operations to machine the part have been created, the file needs to be postprocessed. Post processing converts a part file (VNC file) which contains the machiningoperations (toolpaths) into a text file (NC program) that can be transferred to the machinecontrol. Post Processors specific to individual machine controls are used to convert the VNC file intoa text file. Communicating the posted text file to the CNC machine is discussed in theCommunications chapter which follows this one.

POST PROCESSOR DIALOGThe Post Processor button in the TopLevel palette becomes active oncemachining operations have beencreated in a file. Clicking on the PostProcessor button will display the PostProcessor dialog shown below. Thisdialog allows the user to select a postprocessor, specify a program nameand format the output.

The Process button will generate theNC program for the file currentlyopen. The text file will be savedunder the file name displayed to theright of the Program Name button. Ifa file with that name already exists,clicking the Process button will erasethe old file and replace it with thenew one. To view the text file as it processes, click on the Text Window button. When this button isdepressed, a window will appear that displays the posted text file as it is created. The program willscroll by in the window as it is being generated. The Pause button allows the user to stop the scrollingof the output as it is being processed. The Print button will be available after the program file isfinished processing.

1- Post Processor Selection2- Program Name

3- Communications4- Text Window

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Before posted output can be generated, the post processorand program file name must be specified. When a file ispost processed, a text file is created with the extensionspecified in the Post text box in the File Extension dialog. Bydefault, this extension is set to .NCF. A file can be postprocessed multiple times and saved with different .NCFfile names. If changes are made to the part file, it must bepost processed again in order to incorporate the changesinto the posted output. As a default, the text file uses thepart file name with an .NCF extension (e.g.EXAMPLE1.NCF). This file name can be changed byclicking on the Program Name button and entering a newname.

To specify an output file name for the finished program,click on the Program Name button. The system willautomatically add the extension specified in the FileExtension dialog. Selecting File Extension from thePreferences submenu in the File menu will display the FileExtension dialog shown above.

To select the post processor, click the Post Selection button.An Open dialog will appear that allows the user to access the directory or folder where the postprocessors are stored in the system.

The actual file names of the post processors are different depending on the operating system.However, when selecting a post processor, the full name (including the Control and Machine) will bedisplayed in the Open dialog.

POSTED OUTPUT FORMATThe items in the top box of the Post Processor dialog change the format and contents of the finishedoutput. Each item can react differently with different post processors. Below is a description of theeffect they will have with most post processors.

Selected Ops: Checking this item will cause the output to only include operations that are currentlyselected in the Operations list. Items that are unselected will not be output.

Starting Program Number: This is the number of the program as it will appear in the control. It is also thestarting number for all sub-programs. If the Starting Program Number is one, the first sub-program willbe two, the second three, etc.

Sequence from: This is the starting number for the block numbers or “N” numbers. The by boxdetermines the increment.

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Minimize: If this option is turned on, the post processor will only output block numbers on tool changepositions.

Insert Comments: This option will output information about each operation and tool used as well as filelength. If any additional comments have been entered by the user about tools or operations, they willbe output as well.

Insert Optional Stops at Tool Change Positions: If this option is on, the software will output a machineoperator selectable program stop at every tool change.

POST OUTPUT PREFERENCESThe Post Processing preference allows the user to specify comment data that is output in the NCF filegenerated by the system. If an item is checked, that data will be output. This dialog can be found inthe File menu under Preferences

LATHE POST LABEL DEFINITIONS AND CODE ISSUESLathe post names use letters to signify their capabilities. The designation may be a single letter ormultiple letters to specify the post's capability. Following the letter designation is a unique number forthis post.

The general format of a post can be described as:

<control name><machine name>[client initials]<letter>###.##

Note that a metric post will end with an “m”.

Following is a description of how Lathe Posts are named and what they do. Also included are briefexplanations of code issues that might be encountered in Lathe Posts.

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2-AXIS LATHE

Label DefinitionsL This designates a regular 2-axis turning post. A Lathe post has 2 linear axes (X and Z) that canposition and cut simultaneously.

Example: Fanuc 16T [VG] L800.18.pst

Code Issues:• Tool Tip

1. The system draws the toolpath to the center of the tool tip radius. The X and Z-axis values areoutput to the theoretical tool tip if the system is able to calculate a touch-off point in bothaxes. X or Z-axis values are output to the center of the tool tip radius when the software is notable to calculate the touch-off point in that particular axis.

2. If the tool is machining parallel to the Z-axis, the X values are output to blueprint dimensions.If the tool is machining parallel to the X-axis, the Z values are output to blueprint dimensions.So, the theoretical tool tip only aligns with blueprint dimensions on faces and diameters.

3. When the tool is machining at an angle, the X and Z-axis values will not match the blueprintdimensions. This is because the theoretical tool tip is not always a blueprint dimension. So, inorder for the system to get the surface of the tool in position to cut the part, the theoreticaltool tip is calculated closer to the part, and in some cases inside the part.

4. Most Lathe Posts output X and Z values to the theoretical tool tip. Posts can be modified tooutput X and Z values to the center of the tool tip radius.

• Canned Cycles1. Lathe canned cycles are output when the Prefer Canned checkbox is checked. This checkbox

will only be available if Auto Clearance and Material only are not selected. If Auto Clearanceand/or Material Only are selected, the system will not output Canned Cycles.

3 & 4-AXIS MILL/TURN A Mill/Turn post supports both milling and turning operations in the same part. A 2-axis lathe post isno longer needed if a Mill/Turn post is available.

Label Definitions: ML This designates a Mill/Turn post.

S This designates a Mill/Turn post that segments rotary arcs into linear moves.

Example: Fanuc 16T [VG] SML800.19.pstI This designates a Mill/Turn post that supports Polar and Cylindrical Interpolation. A Polarand Cylindrical Interpolation Mill/Turn post will output a G2 or G3 with rotary moves.

Example: Fanuc 16T [VG] IML800.19.pstY This designation is for a 4-axis Mill/Turn machine that has a linear Y-axis.

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Example: Fanuc 16T [VG] YIML800.19.pstFanuc 16T [VG] YSML800.19.pst

P This designates a C-axis positioning post. A Mill/Turn positioning post will rotate the partand then move in X and Z. It will not rotate and cut simultaneously.

Example: Fanuc 16T [VG] PML800.19.pstN This designates a Mill/Turn post that does not use subprograms. This is known as a “LongHand post”. Subprograms are frequently used for multi-process drilling, C-repeat drilling, Z-repeat milling, C-repeat milling, Patterns (OD only), etcetera.

Example: Fanuc 16T [VG] NSML800.19.pstFanuc 16T [VG] NIML800.19.pst

B This designates a B-axis rotation post. This supports the creation of coordinate systems thathas the tool rotate about the B-axis.

Example: Super Hicell 250 HS [JMC] BSML1082.19.7.pst

Code Issues:• Tool Orientation

1. When using a mill tool on the Face or OD, it is important to define the orientation of thattool correctly. When Milling or Drilling on the face, make sure the orientation of the tool isperpendicular to the face. When Milling or Drilling on the OD, make sure the orientation ofthe tool is perpendicular the OD. If the tool is not oriented properly, the output will not becorrect.

• C-Axis And Y-Axis Output1. The radio buttons Position and Rotary Milling in the Rotate Tab determine whether C-axis

moves or Y-axis moves are output during Rotary Mill operations. If the Position radio buttonis selected, the system calculates Y-axis moves. If the Rotary Milling radio button is selected,the system calculates C-axis moves.

2. If your machine does not have a Y-axis, then you need to select the Rotary Milling radiobutton.

3. If your machine has a Y-axis, this capability can be added to any Mill/Turn post.

• Rotary Feedrates1. Most rotary feedrates are calculated in Degrees Per Minute per rotary segment based on its

length. Since the length of each segment is variable, the system outputs a different feedratefor each segment. The resulting rotary feedrate can be a large value based on the Degrees PerMinute calculation.

2: Certain CNCs, such as Haas and Mazak, calculate rotary feedrates using Inverse Time. AnyMill/Turn post can be modified to use Inverse Time for feedrates.

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3. Polar Interpolation posts use inches per minute for rotary feedrate calculations. Any Mill/Turn post can be modified to use Polar Interpolation with inches per minute feedrates.

COMMUNICATIONS

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CHAPTER 7 : Commun i c a t i o n sThe system contains integrated communications. Third party communications packages, includingGibbs ncCommunications, can also be used to communicate with CNC machines.

Before a file can be sent to the CNC machine, the parameters for a file transfer need to be set-up. Thisis done in the Com Set-Up dialog. It is accessed by selecting the Communication Set Up item in thePreferences sub-menu of the File menu. This dialog is used to set up communication protocols neededfor sending a program (text file) to a control or receiving a program from the control. Differentcontrols have different protocols (parameters). Refer to the machine control manual for the necessaryprotocol specifications.

PROTOCOLS

ADDING A PROTOCOLA new protocol is added bytyping in a new name andchanging all of the settings tomatch those of the CNCmachine. Clicking on the Addbutton will add the protocol tothe current database ofprotocols.

After a protocol has beenadded, the name will appear inthe upper left hand corner.Additional protocols can beentered and saved in the samemanner. Saved protocols canbe accessed in the Protocolpop-up menu in the upper left-hand corner of the dialog.

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CHANGING A PROTOCOLTo change information about a protocol, select the protocol from the list and change the information.The changes are automatically saved when the dialog is closed or when a different protocol in the listis selected.

REMOVING A PROTOCOLTo remove a protocol, simply select the desired protocol from the list and click on theRemove button.

COMMUNICATING WITH A CNC MACHINETo send a file to or receive a file from a CNC machine, click on the Communications button inthe Post Processor dialog.

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COMMUNICATIONS DIALOGThe Communication dialog can also be accessedfrom the File menu. Files can either be sent to themachine control or received from the control. TheFile type radio buttons indicate what type of filewill be sent. When a file is post processed, a textfile (NCF file) is created. NCF (text) is the necessaryselection when sending posted NCF files from thecomputer to the control or vice versa. The VNC(binary) selection allows users to send and receiveVNC files, which are the actual part files thatcontain the geometry and toolpaths. VNC files canbe communicated between computers that havethe system installed. This is especially useful whenthe system is built into the control of a machinetool. Part files (VNC files) can be communicated in their entirety from a computer to the machine’scontrol, and from the control back to the computer.

SENDING A FILE TO THE CONTROLTo send a file, the Send Mode button must be depressed. The protocol is chosen by using the Protocolpop-up menu. The program to be sent is specified by clicking on the Program Name button. Wheneverything is set correctly, click on the Send button to send the file. While the program is being sent,the Send button becomes the Stop button. Click on the Stop button to stop the communication. TheProgress Bar shows the status of the file being sent. If the Text Window is opened from the PostProcessor dialog, the program will scroll by as it is being sent to the control.

SENDING OTHER .NCF FILESAny text file that matches the extension set in the Post text box in the File Extensions Preference canbe sent to the control. Refer to the Post Processing chapter for more information on output fileextensions.

RECEIVING A FILE FROM THE CONTROLTo receive a file from the control, open the Communication dialog from the Post Processor dialog orfrom the File menu. The Receive Mode button should be depressed. Choose the correct protocol fromthe Protocol pop-up menu. The name of the received program is specified by clicking on the ProgramName button. When everything is set correctly, click on the Receive button, and then send theprogram from the control. If the Text Window is open from the Post Processor dialog, the programwill scroll by as it is received.

Note:It is recommended that edited NCF files received back from the machine control be saved under adifferent name than the original NCF file that was initially sent to the control. That way if the original

1- Send Mode2- Receive Mode

3- Program Name4- Protocol Menu

5- Progress Bar

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VNC file is reprocessed, it won't affect the edited NCF file. For example, a part file namedSAMPLE.VNC is post processed and a text file named SAMPLE.NCF is created. Changes are made tothe program at the machine control and the new file containing those changes is sent back andreceived at the offline computer, but under the name SAMPLE1.NCF. If SAMPLE.VNC is reprocessedagain at a later date, it won't destroy the SAMPLE1.NCF file that contains the changes that were madeat the machine.

LATHETUTORIAL

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CHAPTER 8 : L a t h e Tu t o r i a l

Exercise#1:LatheTutorial-PartSetup

The Lathe module is the most basic of the turning machines supported by the system. This chapterprovides instruction on how to create turning operations. Covered in this chapter are tool setup,process definition, operation creation, custom stock definition, cut part rendering and form tooluse.

Most of this information is covered in “Exercise #1: Lathe Tutorial” while “Exercise #2: FormTools” primarily covers creating and using a form tool.

EXERCISE #1: LATHE TUTORIAL

The following tutorial shows how a simple lathe part is set up, tooled and output. Each step isbulleted and additional information and tips are also provided. It is recommended that all theinformation contained in this tutorial is read to gain the most thorough understanding. This partwas created in the Geometry Creation manual and the dimensions for this part are also onpage 129. Refer to the Geometry Creation manual for details on constructing the Geometry for thispart. You may convert the measurement units with the Modify > Scale command if necessary.

THIS TUTORIAL EXPLAINS HOW TO:1 - Set up stock, clearance and tool change settings2 - Specify custom stock3 - Create a tool list with standard and custom tool settings4 - Generate different types of operations that rough, contour, drill and thread a part.5 - Render the machining operations.6 - Create posted code for the part.

PART SETUP

Open the Documents dialog.

The Document dialog contains information about the Machine Type, Material, measurementsystem, stock, Tool Change, clearance and a part Comment. It also has the file management toolsto open, save, close, etc.

Select Open in the Documents dialog.

Locate the Lathe tutorial part that was created using the Geometry Creation manual.

This part was created in both the Geometry Expert and Free-Form CAD Exercises in theGeometry Creation manual. Either of the part files can be used. If the part was not created, goback to the Geometry Creation manual and do so or use the dimensions at the end of the bookto create the geometry.

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Exercise#1:LatheTutorial–

PartSetup

Click the file then click Open or double-click Lathe Tut.vnc in the list.

Select the Auto Clearance option.

Auto Clearance defaults the clearance values of each process unless overridden by unchecking UseAuto Clearance in the Process dialogs.

Enter the stock, Auto Clearance and Tool Change positions shown.

Tool Change will send thetool to the specifiedlocation for the toolchange. If Tool Change isturned off, it is assumedthat fixture offsets arebeing used or theoperator will manuallyinput the tool changemoves.

Close the Document dialog (Ctrl+1, F1, Ctrl+W).

Open the View palette (Ctrl+5, F5).

Choose Help > Balloons from the menu.

Balloons provide a reference to the interface. A check mark will appear next to the Balloonsitem, indicating that it is on. Move the cursor over the object to see the information.

Select Unzoom (Ctrl+U).

The part may already be unzoomed if the part was saved.

TIP

The Auto Clearance option will calculate part clearances (in both Z and Xd/Xr) that are used to position the tool between operations. These values are dynamically calculated as the stock condition changes as material is removed. The clearance positions calculated will also take into account where the tool needs to move to begin the next operation’s toolpath. Additionally, the Auto Clearance option may add entry and exit moves as needed to safely maneuver around the part and complete each toolpath.

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Exercise#1:LatheTutorial–

Custom

Stock

Select the Isometric view (Ctrl+I).

The Isometric view is a 45˚ perspective of the part. Thisview gives the best overall perspective of the currentstatus of a part from the top, right and front view ofthe part.

The Top or Home view is recommended for creatinggeometry and toolpaths, while the Isometric view is an excellent choice for rendering andviewing the cut part.

Choose Help > Balloons to deactivate them.

Balloons are also activated by using the associated shortcut to the right of the menu command(Ctrl+B).

Switch back to the Top view.

Click the View button again to close the View palette.

CUSTOM STOCKThe stock specifications entered in the Document dialog simply creates acylindrical stock shape using the X and Z coordinates entered. It is possibleto define a custom stock shape by drawing the stock shape in a separate workgroup designatedfor part stock. This is very useful because the stock shape affects the machining of the part inthat the stock conditions are used to calculate the clearance positioning moves when using AutoClearance. The custom stock shape also appears when viewing the rendered image of the part.

Open the Geometry palette. (Ctrl+2, F2)

Click the Workgroup list button in the Geometry Creation palette.

In Level 2 this can be accessed from the main palette.

This button also accesses a workgroup selection menu if the mousebutton is held down. The menu will be discussed later in this tutorial.

Click New WG and rename it “Stock”.

A second workgroup is created and is now the current workgroup,indicated by the open eye. Also, notice that the screen now displaysan empty stock outline.

Click the Workgroup Info button.

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Exercise#1:LatheTutorial–

Custom

Stock

This button is located on the Geometry Creation palette in the Level 1 interface (File >Preferences > Interface).

The Workgroup #2 dialog defines whether the workgroupwill contain part geometry or a stock outline.

Select the Part Stock Revolve option.

Close the Workgroup #2 Info dialog.

In order to create the geometry for the stock outline, it willbe necessary to view the part geometry that we havealready created as a machining workgroup. The entryhighlighted in the Workgroup Selection dialog is the active workgroup.

Other workgroups can be viewed by opening the eye next to their name in the WorkgroupSelection dialog. Geometry in inactive workgroups are gray and can not be edited whileinactive.

Double-click the closed eye next to Workgroup #1.

Both eyes are now open. Workgroup 2: Stock is highlighted to indicatethat it is the active workgroup. Workgroup #1 is visible but inactive.

Close the Workgroup list.

We will use the Mouse-line tool in the Geometry Creation palette to draw a rough outline of thestock. Any geometry creation method can be used to create a stock outline.

Click the Line button.

Click the Mouse-Line button.

The Mouse-Line dialog contains Z andXd values determined by the locationof the cursor. The Grid value specifiesconstraint spacing the lines will snapto. For a review on using the Mouse-Line tool, refer to Exercise #5: Doodlein the Geometry Expert Section of the Geometry Creation manual.

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Exercise#1:LatheTutorial–

ToolList

The initial stock is a cylinder with two different diameters for our stock outline. The stock doesnot need to be perfect, but should not cross the finish geometry defined. The only condition isthat the bottom line must be drawn at X0 to have a correctly revolved part.

Draw a stock shape around the part as shown.

This will be thestock conditionbefore cutting ispreformed.

Hold the Workgroup Selection button down until the selection menu appears.

Select Workgroup 1.

Close the Geometry Creation palette.

TOOL LIST

Open the Tool list button in the Top Level palette.

Double-click tile position #1 in the empty tool list.

The Tool Creation dialog contains all tool specifications necessary for the system tocalculate accurate toolpath and rendering. Tool information can be edited at anytime by clicking on tool tiles and editing the information contained in the Tooldialog. For more information, refer to the “Tool Creation” on page 13.

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Exercise#1:LatheTutorial–

ToolList

Select the 80° C insert with the following specifications.

Values for insert specifications,such as Tip Radius, IC (InscribedCircle), Thickness, etc. can eitherbe selected from the list ofstandard inserts in the menus ormanually entered by selectingOther.

Holders can be chosen by usingthe scroll bar next to the insertdiagram. The text to the right ofthe scroll bar displays the holderspecifications which providedetailed information about theinsert angle and holder type.For our part, the first positionprovides the desired selection.The red circle at the end of theinsert indicates the touch-off point of the tool.

The selection of insert and tool holder also affects the toolpaths created using this tool. Thesystem uses the selections made here when constructing a toolpath to prevent tool interference.Therefore, selections made here directly affect the machining of the part.

Double-click the empty tool tile at position #2.

This closes the Turning Tool #1 dialog and brings up the Turning Tool #2 dialog. A tool tiledisplaying the insert type and tip radius appears in position #1 of the tool list.

This next tool is a drill, so it must be defined in a Milling Tool dialog.

Click the Milling Tool button.

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Exercise#1:LatheTutorial–

ToolList

Select the Drill tool with the following specifications.

Double-click tile position #3 in the Tool List.

Click the Turning Tool type button.

Select the 35° V diamond insert.

Enter the tool information shown.

The position on the insertorientation diagram remainsthe same as the previous insertselection, so no adjustment isnecessary.

The insert angle and holdertype selection is the last one inthe group.

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ToolList

Create this insert as tool #4.

Double-click the tool tile toopen the new tool dialog. Wewill skip this step from here on.

Create this custom insert as tool #5.

The tool holder diagram is setto None. Only the insert isdrawn in the diagramaccording to the valuesentered.

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ToolList

Create this insert as tool #6.

The Insert OrientationDiagram changes inappearance when the BoringBar option is selected.

Scroll down to reveal two empty tiles (if necessary).

The scroll arrows at the top andbottom of tile lists allow you toeasily move through the tiles inthe list. To scroll quicklythrough the list, hold down thebutton and drag the mousedownward. This will changethe arrow to red and scroll a“page” at a time. Refer to thethe Getting Started guide formore information on tile lists.

Create this insert as tool #7.

Once the Style and TPI (threadsper inch) values are selected,the Insert Width and Insert Typewill default to the desiredvalues.

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Create this custom insert as tool #8.

Close the Turning Tool #8 dialog.

The tools necessary to machinethis part have now beencreated. A good way to reviewthe tools contained in the list isby using the Window > Tool ListSummary.

Choose Window > Tool List Summary.

The Tool ListSummarycontains all ofthe current toolinformation.

The information may be printed by choosing File > Print > Tool List Summary. While the Tool ListSummary is the active window the print shortcut Ctrl+P will work. The list is set up to print inlandscape mode ONLY. When any of the summaries are displayed on the screen, they can beprinted or saved as a text file with the Save Special command.

Close the Tool List Summary.

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CREATING THE OPERATIONS - ODClick the CAM button in the Main palette.

The Machining palette, ProcessList and the Operation Listappear.

The Machining palette containsFunction tiles. The functionsavailable for use with lathe arecontouring, roughing,threading, and drilling.

Process tiles are created bydragging a Tool Tile and aFunction Tile to a Process Listlocation. Operation tiles arecreated from Process tiles when the Do It or Redo button is depressed.

In order to machine this part, operations must be created. Operations are created fromcompleted processes. To create a process, one tool and one process (roughing, contouring,drilling, threading) is needed. In this tutorial, we will first describe the necessary machiningoperation, then we will detail the steps necessary to create that operation.

First, we will create an operation that will face the front of the part.

Select the Contouring Function Tile and drag it to position #1 in the Process list.

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Drag tool #1 (80° C) and drag it to position #1 in the Process List. Place it on top of the Contouring tile in position #1.

When you place the Tool Tile in position #1, the tool number isdisplayed in the small box on the Contouring Process Tile. The ContourProcess dialog appears after the Tool tile is added.

Enter the information shown in the Contour dialog.

To position the tool to cutthe face of this part, we needthe tool to approach andretract along the Z axis.Therefore, the Front Faceoption is selected.

For this process, the MaterialOnly option is selected so notoolpath will be generatedunnecessarily to cut theface.

Close the Contour Process dialog.

When the Process dialog is complete, the cutshape must μbe defined. Machining Markers(shown below) are used to designate a cutshape for contouring processes.

1 - Start point2 - Offset cut3 - Start feature4 - End Point5 - End Feature6 - Centerline cut7 - Direction

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Select the vertical line at Z=0.

The Machining Markers will appear on the selected feature. The markersallow you specify the start and end feature and the start and end point of thecut shape. They can be “picked up” by clicking on them and dragging themto any location on the part geometry. The arrows allow you to choose thecut direction. The two circles allow you to choose the side from which thetool will be offset.

In this case, the start feature and end feature markers will stay in their initial positions becauseonly one feature, the face, will be cut. The start point and end point markers will be moved tocut the entire length of the face. The start and end point markers can rest anywhere on theselected line, even on the trimmed sections. Refer to the Machining Markers section in theMachining chapter for more information.

Select the outside circle.

This is the OD side of the geometry.

Click the arrow pointing down.

We will approach the line from the OD and bring the tool just past the centerto ensure a complete facing is done.

Drag the start point marker above the workspace as shown.

Because Material Only is used in this process, the start and end point markersdo not need to be placed in exact positions as long as they clear the stockoutline we defined.

Drag the end point marker down to the location shown.

If markers are notproperly placed aprocess may notgenerate the

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desired toolpath. The common mistake is to chose the wrong cut side.

Click the Do It button in the Machining palette.

An Operation tile will be created and added to the Operation list and the approachand retract moves and the toolpath drawn. The orange lines represent the toolpath,while the dashed gray lines represent positioning moves. The solid lines for both thetoolpath and positioning indicate feed moves. And the dashed lines of both colorsindicate rapid moves.

The picture above on the right shows the toolpath without the Machining Markers so you canget a better picture. To view the toolpath without the Machining Markers, simply clickanywhere off the part. The dashed gray line shows the tool rapiding from the tool changeposition (entered in the Document dialog, to the start point of the toolpath).

The angled lines at the beginning and end of the toolpath are entry and exit positioning movesthat have been added because Auto Clearance is turned on. They are angled along the centerlineof the insert angle. The position the tool can safely rapid to before beginning the toolpath isdetermined by the Auto Clearance value entered in the Document dialog.

Deselect the operation created by clicking on an empty Operation location, or by clicking an insertion point between Operation locations.

Tiles are considered selected when they are highlighted in yellow. Deselectedtiles are the standard gray color.

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CREATING OPERATIONS

Drag the Process in position #1 to the Trashcan.

When creating a new Process, you can either throw away the old tiles in the list or modify themin order to create the new operations. In this case we will throw away the old tile and start fromscratch. Every tile in the Process list will be used to create operations.

The next group of operations will rough and finish the outside contour of the part. This will beaccomplished using multiple process programming which allows multiple process tiles to beapplied to one cut shape.

Multiple Process Group Op 2-4Create this Rough process with tool #1.

To properly position thetool to rough the OD of thispart, we need the tool toapproach and retract alongthe X axis. Therefore, theOD option is selected for theapproach type.

Lathes use differentroughing (multiple cut)cycles. There are threegeneral types: Turn, Plunge,and Pattern Shift. Thesethree types of cycles willallow us to output thedifferent canned cyclesdefined in programmingmanuals for lathes. The software will output these roughing cycles as canned cycles if the PreferCanned option is selected and the lathe is capable of using canned cycles. If not, the postprocessor will output every move necessary to rough the part.

TIP

When operations have been satisfactorily completed, it is VERY IMPORTANT before proceeding that all operations are deselected. By deselecting the completed operations, they become fixed in the Operations List and will not be affected by changes made to the Process List. Operations can be edited, but to do so they must be reloaded into the Process List by double-clicking on them.

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Turn roughing cycles are the standard contour rough cycle. For turning cycles, the selectionmade for the approach type (OD, ID, Front Face) determines what type of contour rough stylewill be generated by the system.

Plunge roughing cycles are used to generate grooving operations. These cycles are used when itis desirable to rough the part with a groove tool. Pattern Shift roughing cycles are commonlyused when roughing a cast part. This type of cycle generates the part contour and shifts thetoolpath on each successive cut until the specified area is roughed.

In this process, we will use a turn roughing cycle. When a turning cycle is selected, a Cut Depthvalue is entered which designates how much material will be removed on each pass.

For this process, the Cut Depth value entered is 0.1. The Xr label indicates that it is a radius value.This means that 0.1" of material will be removed from each side on each pass.

The Shape Axes check boxes allow the user to regulate the axes and directions of the cut shape.Omitting an axis (such as X-) will prevent cut shape moves in the disallowed direction. Refer tothe Machining chapter for more information on cut shapes and the Shape Axes buttons.

For this process, the X axis in the negative direction is turned off. This will prevent the toolpathfrom making any moves in the X- direction so it doesn’t go into the grooves.

The value entered in the Fin. Stock ± text box designates the minimum amount of material thatwill be left outside of the part geometry after the roughing cycle is completed. The toolpathcreated by the system will be offset from the part geometry by 0.01" in Z and 0.02” in Xd. Wewill remove this excess with the finish pass.

Close the Rough Process dialog.

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Create another Roughing Process with tool #3 in position #2.

This process is included inthis group to rough theneck groove on the part.Again, an OD approach typeis selected so the tool willapproach and retract along the X axis. And a Turn rough cycle is selected with a Cut Depth of0.75".

The Cut Direction selection indicates the direction the tool will move along the designated cutshape.

In this process, Forward is selected and we have turned on the Back & Forth option. The tool willfeed from the start point to the end point of the toolpath on the first pass. Then, instead ofrapiding up and then back to the start point to begin the next pass, the tool will feed down andmake its next pass from the end point to the start point, going back and forth in this manneruntil each pass is complete and all the material is removed.

Material Only is again selected for the Rough Style so that the toolpath generated for this operationwill only cut the remaining material left on the part after the previous operations have beencompleted. The Material Only selection is particularly useful when utilizing the multiple processprogramming capabilities of the system. Feed moves will only be made where it is necessary toremove material. The tool will make rapid moves whenever possible while maintaining theclearance offset.

In addition to entering a finished stock amount which will leave the designated amount ofmaterial around the entire cut shape, it is also possible to enter separate stock amounts for eachaxis.

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In this process, we have entered a small stock amount to be left on the X axis. This is a radiusvalue, so this amount will be left on each side of the part, totalling two times the amount ofmaterial. A small stock amount will be left along the Z axis.

Close the Rough Process dialog.

In position #3 create this Contour process with tool #3.

To properly position thetool to finish the OD, weneed the tool to approachand retract along the X axis.Therefore, OD is selectedfor the approach type.

Entry and exit moves can be user defined and entered for each process. If entry and exit linesand/or radii are defined in the Process dialog, they will automatically be added to the toolpath.The Auto Clearance option may create additional entry and exit moves to maintain the necessaryclearances, but the entry and exit moves designated in the Process dialog will always be includedin the toolpath. It is useful to create entry and exit moves in the Process dialog when using theCutter Radius Compensation option because typically CRC is turned on in the posted output onthe first feed move and turned off on the last feed move of the toolpath.

In this process, an entry line and radius will be created at the beginning of the toolpath.Selecting the first option will allow us to create a 90° arc with a radius of 0.05" tangent to thefirst feature of the toolpath and create a 0.05" line that will be tangent to the arc andperpendicular to the feature.

Similarly, an exit radius and line will be created at the end of the toolpath. The 90° arc will betangent to the last feature of the toolpath, and the line will be tangent to the arc andperpendicular to the feature.

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Entering 0.02 in the Corner Break text box will create a toolpath that puts a 0.02" radius on everyexternal sharp corner. Unless the Square Corner option is turned on, the system will alwaysoutput a radius move for each corner. A Corner Break of 0 will not break the corner, but will keepthe tool in contact with the part as it moves to the next feature.

This process has CRC On option selected. Typically, CRC will be turned on in the posted outputon the first feed move of the toolpath and off on the last feed move. However, depending on thepost processor being used, the CRC functionality may vary.

Close the Contour Process dialog.

Now that the Process List is complete, we will define the cut shape.

Click the chamfer as shown.

The Machining Markers will appear on the selected feature.

Click the outside circle.

Click the arrow pointing up.

Drag the Start Point Marker to the position shown.

The Start and End Point Markers do not need to beplaced in exact locations as long as they clear thematerial.

Drag the End Feature Marker (black square) and drop it on the part geometry as shown.

The End Point marker will automatically move with the End Feature marker.

TIP

Alternately the End Feature Marker can be placed by pressing Ctrl+Shift and clicking on the end feature geometry.

When positioning any one of the four machining markers on a geometry feature, place the tip of it’s arrowhead on the geometry feature.

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Drag the end point marker to the position shown.

As you move theMachining markers,notice that the cutshape, represented bythe dark blue line, willadjust according to thepositioning of themarkers.

The dark blue cutshape is the part of thecontour that will bemachined using these processes. Notice that the middle V groove and the O-ring groove are notincluded in this cut shape. The Machining Markers, in this case the End Feature and End PointMarkers, allow us to specifically designate what portion of the geometry is to be machined bythe processes we have created.

Click the Do It button.

This will create the toolpath. Click the Redo button to make changes to a selected operation.

Three operations arecreated when youclick the Do Itbutton. Operationtiles are created andplaced in theOperation List onthe right side of thescreen.

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The Operation list should have four operations now.

The positioning moves and toolpaths for each of the operations are alsodrawn on the screen. In order to get a better picture of the toolpathsgenerated by the system, we will view the tool moves for the first roughingoperation separately.

Select Operation #2.

Clicking once on a tile will select and highlight the tile without opening anydialogs or selecting other tiles that were created with it.

Open the View Control palette.

Click the Redraw button (Ctrl+R).

Only the toolpathand positioningmoves for theselected operationare drawn. This ishelpful if you usemultiple processprogramming andwish to view individual toolpaths.

Notice that the custom stock outline was taken into account because Auto Clearance is on andthe Material Only option was selected. Also, the toolpath created does not slope at all into theneck groove because the X- Shape Axis was deselected in the Rough Process dialog that createdthis operation.

The dashed gray lines show the tool rapiding from the end point of the previous operation tothe start point of this operation, and to the tool change position at the end of the operation.

Now that operations have been created, we will render the part. There are several ways to verifythat the toolpaths generated by the system will safely and correctly cut the part. Looking at thetoolpaths, as we have done thus far, is one way. Another way is to render the part which allowsyou to actually view the tool removing material and cutting the part.

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Choose View > Isometric.

Open the Rendering palette.

This changes the working mode to CutPart Rendering. The initial stock wedefined at the beginning will display asa solid object. The Geometry is hiddenbut can be viewed by using View >Show Geometry ( Ctrl+[ ).

Click the Play button.

The Cut Part Rendering palette shown below also appears on the screen.

Click the Show Solid Tool button.

Click the Play button.

A part can be rendered at any time onceoperations have been created. The stockwill always be shown in shades of blue.Selected operations will render in shadesof yellow, while all other operations willrender in shades of gray. Red will bedisplayed when non-cutting tool surfacesor rapid moves hit the material. Refer tothe Cut Part Rendering chapter for moreinformation.

Close the Rendering palette.

Choose View Top from the menu or Ctrl+E.

This is also the same as the Home view in CS1.

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Deselect the operations by clicking on an empty operation location or by clicking on an insertion point between operation locations.

Shift select the three tiles in the Process List and drag them to the trash.

You may also use the Delete key.

Multiple Process Group Op 5-8For Process 1 create this Rough process with tool #4.

An OD approach type isselected so the tool willapproach and retract alongthe X axis. Material Only isagain selected for the RoughStyle. Also, a Finished Stockamount is left on thisgroove that will be removedin the following finish pass.

In this process, we will use aPlunge roughing cycle.

When the Plunge option isselected for the Rough Type,the Plunge dialog will comeup on the screen. To makethe Plunge dialog come up,click the Plunge option in the Rough Type selections.

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Enter the information shown below in the Plunge dialog.

The Plunge Angle specifies the angle at which thegroove tool will make its plunging moves. Thedefault is 270° which has the tool plunging straightdown.

For this process, we have selected the Details optionfor the Cut Width. This option will vary the Cut Widthdistance as necessary in order to hit the endpoints ofeach feature of the cut shape. The Z value enteredspecifies the maximum distance the tool will stepover on each pass. The Center Out Cuts option isselected so that the tool will make its first plungingmove in the center of the groove, and then proceedto rough each side.

For this groove, the Peck Full Out option is selectedbecause the groove is relatively deep, and in order toremove all of the chips (material), the tool will needto come all the way out of the part after the peck.The value entered in the Peck Amt text box specifies the distance the tool will plunge into thepart on each peck. The Clearance value specifies the distance away from the remaining materialthe next peck will begin.

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For Process 2 create this Contour process with tool #4.

The No Drag option isturned on in this process sothat the toolpath is createdin such a way that only thepositive insert angle of thetool cuts material. Thedesignated cut shape issegmented into pieces toaccomplish this.

For Process 3 create this Rough process with tool #5.

An OD approach type isselected so the tool willapproach and retract alongthe X axis. Material Only isagain selected for the RoughStyle. Also, a Finished Stockamount is left on thisgroove that will be removedin the following finish pass.Plunge is selected for theRough Type.

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Enter the information shown below in the Plunge dialog.

The Constant option is selected for the Cut Width.The tool will step over a distance of 0.2" on eachpass regardless of the endpoints of the cut shape.The Peck Retract option is selected for the FirstPlunge. The Peck Amt specifies the depth of eachplunge and the Retract amount specifies the distancethe tool will come out of the groove after each peck.

For Process #4 create this Contour Process with tool #5.

Now we will define the cutshape for this process list.

Click the part geometry as shown.

The Machining Markerswill appear on the selectedfeature.

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Right-click the last feature shown and choose Move End Feature here so the Machining Markers appear as shown.

Make sure you select theoutside circle and thearrow pointing left. Theblue cut shape drawnshould include the Vgroove and O-ring.

Create the toolpath.

The toolpaths that arecreated will properlyrough and finish both theV groove and the O-ring.Notice that the toolpathcontains no unnecessarymoves. Material Only takesfull advantage of multipleprocess programmingwithout makingunnecessary tool moves.

Switch to the Isometric view. (Ctrl+I)

Render the Operations.

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During the rendering process, you will beable to better see the No Drag contouroption at work. Notice the tool will finishone side of the groove, rapid up and over,and then go down and finish the other sideof the groove, always cutting along thepositive direction of the insert angle.

Exit Rendering mode.

Switch to the Top view (Ctrl+E).

Deselect any operations.

With the Process list selected choose Edit > Select All (Ctrl+A) and delete the tiles or drag them to the Trashcan.

Except for the thread, the OD of our part is complete.

CREATING THE OPERATIONS - IDNow, we will create the operations to drill a hole through the center of the part and rough andfinish the ID.

Multiple Process Group Op 9-11Create this Holes process with tool #2.

The depth the drillwill feed to isspecified by thevalue entered inthe Sharp Tip Ztext box. Valuesmay be entered inthe text boxesspecifying the FullDiameter Z depthand the SpotDiameter. Thesevalues will cause the Sharp Tip Z to be recalculated. The Sharp Tip Z is the value used in theposted output.

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The drill cannot feed through the part in one pass. Therefore, the Peck, Full Out option isselected. Because it is a Peck, Full Out, the drill will rapid all the way out of the part after eachpeck.

The value entered in the Peck text box specifies the amount the tool will peck into the materialon each pass. The next peck will start a Clearance amount away from the material remainingafter the previous peck.

Drilling operations do not require the selection of geometry. In a standard lathe a drill can onlyfeeds in at X=0. Therefore, the placement of the Machining Markers will only affect the toolpathcreated for the Roughing and Contouring operations.

For Process #2 create this Rough Process with tool #6.

A Front ID approach type isselected so the tool willapproach and retract fromthe part along the X axis. ATurn Rough Type is selectedand separate stock amountsare entered for each axis.

?Remember to use the Balloons in the Help menu if you don’t understandthe fields.

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For Process #3 create this Contour process with tool #6.

The Front ID approach typeis selected and Material Onlyis turned on in the process.

Position the Machining Markers as shown.

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Create the toolpath.

The dashed orange line atX = 0 shows the toolrapiding out of the partafter it has pecked in tothe Sharp Tip Z depth inthe Drilling operation.

Switch to the Isometric view.

Render the Operations.

Deselect the operations.

Clear the Process list.

We will skip stating these last two steps inthe future.

Switch back to the Top view.

THREADINGOp 12Next, we will create the operation that willcut the required thread.

Create this Thread process with tool #7.

Thesevalues canbe found intheMachinery’sHandbook,and arecalculatedfrom thevalues

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entered for an “ideal thread.”

The Minor Xd will default to a calculated value according to the Nominal Xd and the desired pitch.The Thrd Ht Xr is calculated [(Major - Minor)/2]. Changing the Nominal Xd will change the values inthe Major Xd, Minor Xd, and Thrd Ht Xr.

Const Load is selected to maintain the same amount of tool pressure on each pass. The Last Cutoption is selected to prevent any cut from removing less than the value entered from each side.This is also the cut depth that the threading tool will remove on the last pass.

Threadingoperations do notrequire theselection ofgeometry. Theinformationentered in theThread dialogdetermines wherethe thread will belocated on thepart.

Create the toolpath.

CUT OFFOp 13Finally, we will create an operation to cut off the machined part from the bar stock.

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Create this Contour Process with tool #8.

An OD approach type isselected so the tool willapproach and retract alongthe X axis. Material Only isselected for the Rough Typewith a Clearance of 0.25. TheClearance value is relativelylarge to ensure that no toolinterference occurs withour finished part.

The Cut Off option is turnedon so the post processedoutput will contain thenecessary codes forremoving the part from barstock. Not all postprocessors support thisoption.

Close the Contour Process dialog.

Select the cut off line of the part and position the Machining Markers as shown.

Ensure the endpoint extends pastX0 and the startpoint begins abovethe stock.

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Create the toolpath.

As the last stepwe will sort theoperations tohave less toolchanges.

Click the Sort Ops button in the Machining palette.

The only changethat occurs is theDrillingoperation that uses Tool #2 will be moved up in the Operation List to location #3.

Select the Isometric view. (Ctrl+I)

Render the Operations (F6).

For this case, changing the order of theoperations does not cause any toolinterference and does not appear to affectthe efficiency of the toolpath andpositioning moves generated by thesystem. Had there been any problems, wewould have needed to reprocess theexisting operations so that the systemwould have recalculated the tool moves foreach operation based on the newconditions. Reprocessing the operations isvery easy using the Redo All Ops item in theEdit menu or the Operation list contextmenu.

!

Whenever the order of operations is changed, it is good practice to verify that the positioning moves and toolpaths are still valid. When using the Auto Clearance option and/or Material Only option, the material condition is taken into account when it creates the tool moves for each operation. Changing the order of operations has the potential to change the initial material conditions for existing operations. Rendering the part is a good way to check the validity of the toolpaths.

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POST PROCESSINGNow that all of the operations to machine the part have been satisfactorily created and verified,we need to post process the file. Post processing will create a text file that the CNC machine willuse to cut the part.

Open Post Processor dialog.

From the Post Processor dialog a postprocessor may be selected as well asgenerating a post file and communicatingwith a machine control. Refer to the PostProcessing and Communications chaptersfor more information.

Click the Post Processor Selection button.

Select a Lathe post processor.

Click the Open button.

The name of the selected postprocessor will appear in the dialognext to the button.

Click the Program Name button.

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The Program Name defaults to thename of the part file. You can changethe name or leave it as it is.

Click the Save button.

Once you have selected a postprocessor and named and saved theprogram, the Process button at thebottom of the dialog becomes active.

Click the Text Window button.

This allows you to view the posted code as it isprocessing.

Click the Process button.

This will create a post file that can then be sent tothe machine.

The program will scroll by as it is being processed.You can click the Pause button to momentarily stopthe processing so that you can read the program.Once the program has finished processing, the Printbutton becomes active and the posted code can beprinted.

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EXERCISE #2: FORM TOOLS

This exercise introduces you to creating and using Form Tools in GibbsCAM. We will start with anexisting, very simple part file, create a Form Tool and apply a machining operation using the FormTool.

Open the part file Form Tool.vnc located in the Tutorial Parts folder that was installed with the software.

The file contains geometry for the part, a tool and two roughing operations. The existingoperations face and rough the part. First we need to create geometry for the Form Tool.

Create a new workgroup for the Form Tool.

Use the data in “Part #2: Form Tool Blueprint” on page 130 to create the geometry for the form tool.

Remember that thesystem uses the origin asthe tool’s touch-off point.The tool should look likethis image.

Open the tool dialog.

Select Form tool as the tool

type.

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You are prompted to select ashape to use for the tool’sprofile.

Double click the Form Tool geometry and click Apply.

The shape of the tool isdisplayed in the Tool dialog.Note the touch-off point isshown in the tool diagram.

Form Tool ContourWe will now make acontour process using theform tool.

Create this Contour Process with the form tool.

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Position the machining markers as shown.

We have placed the start point markerabove the roughed surface. The end pointmarker should be on the connecting pointto drive the tip of the tool to that point.

Since we are contouring ona single line some optionsbecome disabled whenusing a Form tool.

Create the toolpath.

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The result should be a single feed line intothe part.

Switch to the Isometric view and render the results.

Save this part, it is complete.

129

Part

#1:

Tut

oria

l Par

t Bl

uepr

int

130

Part

#2:

For

m T

ool B

luep

rint

6 m

m

8.6

mm

R 0.

25 m

m

R 1.

25 m

m

2 m

m

60°

120°

25 m

m

13 m

m

2 m

m

1.6

mm

INDEX

Index ◆

133

NUMERICS

7006: 38

7007: 38

7008: 38

A

Advanced Mill Module: 9

Air Cutting: 26, 29, 34, 55

Approach Type: 10, 48Changing: 48

Contour: 28

Front Face: 48

Front ID: 48

OD: 48

Roughing: 31

Thread: 37

Auto Clearance: 10, 27–28, 32, 35, 39, 47–48, 55–56, 90, 106

B

Back & Forth Roughing: 32

Balloons: 90

Balloons and Prompting: 3

Bar Stock: 29

ButtonClose: 9

Do It: 26

Document Control: 7Machining: 25

Material: 38, 40

New: 9

Open: 9

Post Processor: 75

Receive: 85

Redo: 26

Save: 9

Save As: 9

Save Copy: 9

Send: 85

Tool List: 15

C

C.A.T.: 3

Canned Cycles: 35, 38, 40, 47–48, 56

ClearanceAuto, see Auto ClearanceContour operations: 28

Data: 8

Diagrams: 48

Fixed: 10

Fixed, see Fixed ClearanceMaster: 28

Moves: 47

Clearance Moves: 10, 32, 47Approach From Tool Change: 49

Exit To Tool Change: 51

Same Tool Moves: 52

Clearance Positioning: 47

Clearance Positions, Entry and Exit: 48

Close File: 9

CNC, Communication with: 84

Com Set-Up dialog: 83

Comment: 11

CommunicationSet Up: 83

Stop: 85

Communication dialog: 85

◆ Index

134

Communication ProtocolChange: 84

New: 83

Remove: 84

Constant Cut: 38

Constant Load: 38

Constant Surface Speed, see CSS

Contour Cutter Compensation: 20

Contour process: 28

Contour Style: 29Full: 30

Material Only: 29

Contouring function: 27–28

ControlReceiving files from: 85

Sending files to: 83

Coolant: 30, 35, 38, 40

Corner Break: 30, 35

CPR: 65Controls: 65–66

CPR palette: 65

CRC: 20–21, 30, 35

CSS: 30, 35

Current Display (CPR): 65

Cut Depth: 32Thread: 38

Cut Direction: 31

Cut Direction Axes: 31, 36

Cut Off: 29

Cut Shape: 26

CutDATA: 9

Cutter Radius Compensation, see CRC

Cycle Start Point: 34

D

Decimal Slope: 41

Depth Of Cut: 38

Diameter Relief: 18

Diameters, part size: 10

Do It: 25, 46

Document Control dialog: 7, 28, 32, 47, 89, 91

Drill Entry/Exit Cycle: 39

Drilling: 117Diagram: 39

Dwell: 40

Feed In-Feed Out: 39

Feed In-Rapid Out: 39

Full Diameter Z: 39

Peck Chip Breaker: 39

Peck Full Out: 39

Rigid Tap: 39

Sharp Tip Z: 39

Spot Diameter: 39

Surface Z: 39

Tap: 39

Drilling Function: 27, 39

Drilling Process: 39

Dwell: 40

E

Entry ClearanceContouring: 28

Position: 48

Roughing: 32

Entry Move90° arc: 29

Contour operation: 29

Line: 29

Index ◆

135

Exit ClearanceContouring: 28

Roughing: 32

Exit Move: 2990° arc: 29

Line: 29

F

Face Relief: 18

FeedMove: 49

Plunge rate: 40

FileSend to Control: 85

File Extension: 76

File Management: 7

Find Operation: 60

Finish Stock ±: 30, 35

Fixed Clearance: 35, 47–48

Form Tool: 17

Forward: 29

From Tool Center (CRC): 21

From Tool Edge (CRC): 21

Front Face ApproachContour: 28

Roughing: 31

Front ID ApproachContour: 28

Roughing: 31

Full Radius: 17

Function Tile: 27

G

G50 Offset: 10

G50 offset: 19

G-code: 26

Gouge Avoidance, see Cut Shape

H

Help: 3

HolderDiagram: 18

Specs: 19

HoldersBoring Bars: 17

None: 17

Tool Holder: 17

Holders, number of: 9

Hole Diameter: 39

I

ID (Inner Diameter) Thread: 36, 38

In Feed: 38Balanced thread: 42

InsertFace Angle: 18

IC (inscribed circle): 18

Insert Type: 18

Material: 19

Orientation diagram: 18

Positive Angle Direction: 29

Size: 18

Specifications: 17

Specifications of: 16

◆ Index

136

Thickness: 18

Thread Style: 18

Tip Width: 18

TPI: 18

Width: 18

Insert Comments (Post): 77

Insert Type: 16

Inserts, number of: 9

Invisible Tool (CPR): 66

Isometric view: 91

L

Last Cut: 38

Lathe Inserts: 16

ListOperation: 25

Process: 25

Scroll Arrows: 97

Tool: 15

M

Machine Type: 9

Machinery’s Handbook: 43, 119

Machining Markers: 25–26, 56, 100How To Use: 56

On Geometry: 57

Machining palette: 25, 27

Making OperationsGeometry: 25

Material Database: 9, 19, 31, 36, 38, 57

Material Only: 10, 26–27, 29, 34, 55–56Clearance: 34

Material Only, Clearance: 30

Max RPM: 30

Measurement Units: 9

Mill Class, back end holder: 11

Mill Module: 9

Mill Tools: 16

Mill/Turn Module: 16

Minimize (Post): 77

Mouse-Line: 92

Move Operation: 60

Multiple Process Creation: 26

Multi-Task Machining Module: 9, 16

N

NC program: 27

NCF file: 85

New File: 9

Next Operation (CPR): 66

No Air Cutting, see Air Cutting

No Drag: 29–30

Nominal Thread diameter, see Thread, Nominal Xd

NPT: 40Chart: 45

Cutting: 43

O

OD (Outer Diameter) Thread: 36

OD ApproachContour: 28

Roughing: 31

Offset # (Tool): 19

One Finish Pass: 38

Index ◆

137

Open File: 9

Operation Data: 58

Operation List: 25–27

Operation Summary: 61

Operation Tile: 27

Operation To Geometry: 60

Operations: 103Deselecting: 26

Order of: 27

Reprocessing: 15, 27

Optional Stops (Post): 77

P

PartComment: 11

Material: 9Set Up: 7, 9

Stock: 10

Part ClearanceMaster: 48

Part Surface in Z: 39

Part X Dimension: 10

Pattern Shift: 34Cycle Start Point: 34

Fixed: 34

Passes: 34

Square Corners: 34

Xr Cut: 34

Z Cut: 34

Pause Posting: 75

PeckAmount: 40

Chip Breaker: 40

Clearance: 39

Full Out: 39

Retract: 40

Play (CPR): 65–66

PlungeAngle: 33

Center Out Cuts: 33

Clearance: 33

Cut Width: 33

Details: 33

Feed: 33

First Plunge: 33

Peck Amount: 33

Peck Full Out: 33

Peck Retract: 33

Retract: 33

Plunge dialog: 33

PostFrom Part File: 75

Name: 76

Output: 75–76

Requirements: 76

Selection: 76

Unit Conversion: 9

Post Output Preferences: 77

Post Processing: 75

Post Processor: 30Coolant: 40

Custom: 29–30, 35, 38–40

Drilling Cycles: 39

Prefer Canned: 35, 38, 40, 47, 55Auto Finish: 35

Preset Point: 19see also Touch-off Point

Print Post: 75

Printing: 21, 61, 72

ProcessLoading Saved: 46

Post: 75

◆ Index

138

Stock Amount: 20

Process dialogs: 27Contour: 28

Rough: 31

Thread: 36

Process Group: 46Pre-defined: 46

Process List: 25–27, 60

Program Name button: 85

Program Name, post: 75

Prompting: 3

Protocols: 83

R

Radii, part size: 10

Radius Move, contouring: 29

RapidMove: 49

Step: 32, 35

Redo: 15

Redo All Ops: 27, 30, 34, 122

Render, checking the part: 27

Rendering, see CPR

Rewind (CPR): 65

Rough process: 31

Rough Style: 32, 34Full: 32–35, 56

Material Only: 32, 34–35

Rough Type: 32Cut Depth: 104

Pattern Shift: 32, 34–35, 48

Plunge: 32

Plunge Rough: 32

Turn: 32, 35, 48

Roughing function: 27, 31

RPM: 39–40

Run In: 36–37

Run Out: 36–37

S

SaveDuplicate Copy: 9

File: 9

File As: 9

Special: 21, 61

Saving Processes: 46

Saving Tool Data: 46

Scale Toolpath: 60

Selected Ops (Post): 76

Send Mode: 85

Sending a File: 85

Sequence from (Post): 76

Set Op Stop #: 67

Shank Size: 9, 11

Slope, see Thread, Taper

Sort Operations: 60

Sort Ops: 27

Speed: 39

Spindle Speed: 30, 35

Spring Pass: 38

Square Corners: 29, 34

Start Side Extension: 32

Starting Program Number (Post): 76

Step Forward (CPR): 65–66

StockFinish: 30

Xr: 30

Index ◆

139

Z: 30

Stock Size: 8, 10

Stop (CPR): 65–66

Stop Before Op: 67

Surface Z: 39

T

Text Window, post: 75

Theoretical Tool Tip, see Touch-off Point

Thread# of Starts: 37, 41

1st Xr: 42

Actual End: 37

Actual Start: 37

Alternate In Feed: 38, 42

Approach Type: 41

Balanced In Feed: 38, 41

Constant Cut: 42

Constant Load: 42

Cut Direction: 36, 41

Depth of Cut: 38, 42

End Z: 43

Front ID: 37

Height Xr: 38, 41

ID: 41

Last Cut: 42

Major & Minor Xd: 38, 41

Nominal Xd: 37–38, 40

OD: 37, 41

One Finish Pass: 42

Run In: 43

Run Out: 43

Spring Pass: 42

Start Z: 42

Style: 37, 40

Taper: 37, 41

Thread Angle In Feed: 38, 42

TPI: 37, 41

Thread Angle: 38

Thread Clearance: 37

Thread Load: 38

Thread Process: 36

Threading: 36, 40

Threading function: 27

Threads Per Inch, see Thread, TPI

Throttle Control (CPR): 66

ToolComment: 19

Custom, see Form ToolHolder Size: 9

Offset: 20

Other: 17

Radius Offset: 20

Tool Change: 10, 47, 90

Tool Change Position: 8, 19Offset: 19

Primary: 47

Tool Creation dialog: 15–16

Tool ListSummary: 21, 98

Tool Movement: 47

Tool Specifications, modifying: 15

Tool Tile: 25, 27

Tool Type Toggle: 16

Toolpath: 26Cutter Side and Direction: 56

End Feature: 56

End Point: 56

Recalculate: 27

Start and End Points: 57

Start Feature: 56

◆ Index

140

Start Point: 56

Touch-off Point: 17–18

Transparent Tool (CPR): 66

Trashcan: 103

Turret Shift: 19–20, 47

U

Undo: 46

Units of Measurement: 9

Utility data: 58

Utility Markers: 60

V

Visible Tool (CPR): 66

VNC file: 85

W

Work Fixture Offset: 10

X

X Dimension Style: 10

X Stock Start, roughing: 32

Xr Stock: 30, 35

Z

Z DepthFull Drill Diameter: 39

Tool Tip: 39

Z Stock: 30, 35