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INTRODUCTION

The following examples show how each of the 2D machining strategies are used and
gives an explanation of how they work. All 2D machining is performed on profiles,

INTRODUCING you should be familiar with profile creation from day 1 of the basic modelling course.
A brief explanation of profile creation will be given at the start of the machining
course.

Included within the 2D machining we will cover basic drilling and point sets.

BASIC 2D MACHINING

V12.x

Revision 1

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Profile Creation Select WIREFRAME/PROFILES/CLOSE and pick one of the elements that make up
the outer profile (See Fig 3.0). Select the A from the icons presented on the left to
automatically close the profile.
Select the FILE/OPEN command and open the file 2D Milling Example.wkf from the
training folder.

You should see the following part. (See Fig 1.0)

Select ‘A’ for Automatic


Figure 3.0

This will join all elements, travelling in the direction of the arrow, to become one profile.

Select ‘Yes’ to confirm the profile creation

Figure 1.0 : 2D Milling Example

Select the WIREFRAME/ PROFILE/QUICK command

Make sure the intersection icon is selected and pick anywhere inside the centre slot.
This will create a profile for the middle slot (See Fig 2.0).

We now have created profiles for all of the provided geometry. Now we must define
the required thickness for each profile.

“NOTE’’
All profiles must have a thickness and material side before any 2D machining can be
performed on them.

Pick inside centre Select MACHINING/PROFILE CAM ATTRIBUTES and pick the outer profile (See Fig
profile 4.0).
Pick inside profile Outer Profile
Arrow
pointing
outwards
Figure 2.0 : 2D Milling Example
Select again outside the two slots (as indicated above), this will automatically create
all profiles apart from the outer rectangle (See Fig 2.0).

Figure 4.0

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The direction in which the arrow is pointing on the highlighted profile is an indication Profiles - PF1, PF2, PF3, and PF4 (CIRCULAR SLOTS) all material sides to be
of the material side. When the arrow is pointing out then it is indicating that the outside (arrows pointing outwards) and the thickness to be as follows (See Fig 5.0).
material is on the outside and all machining will be calculated on the inside (a
pocket). For this example, the outer most profile will have the material side pointing
outwards.

‘The material side can be changed by pressing the space bar’

When the arrow is pointing inside then it is indicating that the material is on the inside
and all machining will be calculated on the outside (a boss).

Once the required material side has been selected hit the right hand mouse button
and you will be presented with the following dialogue box.
Profiles - PF5, PF6, PF7, PF8 and PF9 (CIRCLES & LARGE LINEAR SLOT) all
material sides to be outside (arrows pointing outwards) and the thickness to be as
follows (See Fig 5.0).

Enter the values as in the box above and select ‘OK’

We have now assigned a material side and thickness to one of the profiles. Profile - PF10 (SMALL LINEAR SLOT) material side to be outside (arrow pointing
outwards) and the thickness to be as follows (See Fig 5.0).
Repeat the procedure for the remaining profiles with the values shown on the next
page.

PF1 PF2

Profile - PF11 material side to be inside (arrow pointing inwards) and the thickness
PF5 PF6
to be as follows (See Fig 5.0).

PF10

PF9

PF8 PF7

PF4 PF3

PF11 ‘The material side can be changed by pressing the space bar’

Figure 5.0 NOTE : The colour of a pocket and a boss are different

We now have all the profiles set ready for machining

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10. Expand/Collapse all Tree items – This will expand all the tree items of all the Select – NEW OPERATION
operations and active projects.
11. Copy – Copies the selected toolpath.
New Operation
12. Operations Ordering – Here you can re-order the toolpath into the sequence
that you require. Operations can be ordered using different methods, at any time
the original order can be re-instated.
13. Edit Toolpath – This allows the user to edit the toolpath completely. Points on
the toolpath can be edited or even deleted if necessary.
14. Toolpath Trimming – With this option a toolpath can be trimmed to a profile or a
set of profiles. The internal or external part of the trimmed toolpath can be
retained. A copy of the original toolpath can also be kept.
15. Tool Length Check – This allows the user to calculate the minimum presetting
length of the current tool.
16. Geometrical Tools – Provides a set of tools that allow the creation of boundaries
(profiles) using 5 methods and tessellated fillet surfaces. Both of these can aid in
the creation of new programs.
17. Sub-Path Trimming – This is similar to toolpath trimming but differs in that you
can remove individual levels or areas of a toolpath.
18. Edit Approach/Retract – The approach or retract distance of the toolpath can be
altered here. An absolute or relative position can be used.
19. Pick Operation – If there are many toolpaths visible on the screen then this icon
will let you pick an operation and automatically highlight which toolpath you
selected within the operations manager.
20. Paste – Will paste the copied toolpath.
21. Jobs Manager – This is where all the information is gathered and set-up for the
batch processing of multiple operations outside the system using the Visi-Batch
Scheduler. First select ‘2D Operations’
22. Show/Hide log window – When activated this will show/hide the log window of
the last calculated toolpath in the current working session. The log window gives
information such as: - start and finish calculation time, total calculation time and
whether or not the calculation was performed successfully.
23. Edit parameters – Allows the parameter editing of the selected item in the
operations manager.
24. Delete operation – A selected operation can be deleted using this icon (as
opposed to the whole project).
25. Change attribute – This allows the user to change the attributes of the selected
toolpath.
26. Verify Toolpath – Using this icon, the toolpath is simulated more graphically.
Individual or sets of toolpath can be simulated at once from a 3D solid block. Will
not handle multiple origins, inclined tools etc. Runs quicker than icon 27.
27. Simulate Toolpath – This is where the toolpath is simulated with more features.
Multiple origins, inclined tools etc. are all handled. Runs slower than icon 26.
28. Change NC – Different post processors are selected here and the selection will
post the programs using the selected post for the current session only. Pocketing Spiral
29. New Project – New projects are created via this icon. Projects allow the grouping
together of machining operations.
30. Batch Build – This is where the toolpath is calculated. Once all the values have
been set within the machining parameters then the toolpath must be calculated..
Multiple toolpaths can be selected and calculated sequentially. Select ‘OK’

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You will now be presented with the tool library. Now we are presented with the following dialogue box.

Operation Parameters

Select tool number 2 - the ‘10mm End mill’.

The islands have automatically been recognised so all we need to do now is to set up
Select ‘OK’ the operation parameters.

Double-click on operation parameters. You will then be presented with the following form.
We are now prompted to select the profile to machine.

Select the outer rectangular profile and any islands will be automatically selected.
These can be shown from within the operations manager

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Machining Form

Distance between passes - This is the distance between each pass needed to
machine the pocket. The default is half of the cutter diameter.

Bottom/Lateral Oversize - This is the amount of material left on for finishing. The
bottom and side values can be different.
NOTE – This is not the amount of material left on the islands, this is set using a
different switch.

Safety Distance - This is the distance from the profile (incremental value) at which
the tool will start its approach at feed rate, after the initial rapid move.

Starting Z - This is the value at which machining movements begin at feedrate. The
default value is the top of the profile.

Max Depth of Cut - This is the value set for each Z level pass. This value is
calculated automatically, be default it is displayed as the same value as the diameter
of tool.

Last Pass Z - This value will be automatically calculated to identify the depth for the
final cut or last pass. It may be used to generate a later smaller depth finishing cut to
clear the bottom of the profile.

Use Clearance Plane - This switch allows you to avoid unnecessary rapid Islands/Approach/Retract Form
movements to the Clearance Plane. If switched off, a movement to the clearance
plane will be forced between each machining level. Approach Mode

Clearance Plane - This is the default Z plane defining the final Z level relative to the Feed - If selected, it defines that the descent to the start point is
top of the profile at which all rapid moves are made. made in feedrate mode.

Final Z Plane - This is the plane defining the Z level where the tool will return after Rapid - If selected, it defines that the descent to the start point is
each operation. It is normally the same as the clearance plane but may also be set to made in rapid mode.
a different value where an obstacle is to be avoided or where the tool should return to
a specific height between consecutive toolpaths. Descending - If selected, it defines the approach will be an angular move.
When used, the starting point will be automatically selected.
Use Bottom Radius/Bottom Radius - This will allow a radius to be roughed out at the
bottom of a pocket when the flag is active, the size of the radius is set by the value Zig Zag - If selected, it defines a ZigZag approach. When used, the
entered in ‘Bottom Radius’ dialogue box starting point will be automatically selected.

Use Draft Angle - This switch allows you to set a Draft Angle to be applied on the
profile during the machining. This does not apply to the draft angle of islands, this Descending Angle - This parameter is available only if the Descending Approach
can be set with another switch. Mode has been selected. It represents the tool-descending angle.

Residual Profiles - Lets you automatically generate any residual profiles showing Descending Step - This parameter is activated only if a ZigZag Approach Mode has
where the current tool has not removed any material. This material may normally be been selected. It represents the maximum Z step to reach the right depth.
removed by a subsequent operation using a smaller tool.
Islands Face Mill - When active this will allow the user to specify a top oversize on
Auto Rebuild - If this flag is active, the system to automatically re-calculate the the islands. The islands will be automatically cleaned during the pocketing operation.
machining once you select OK.
Top/Lateral Oversize - This is the value that represents the amount of stock that you
want to leave on the top and sides of each island.

Use Draft Angle - This is the value of the draft angle to be machined on the islands.

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Fill the values into the Machining form the same as the values below

Cutting Condition

Spindle Speed - This is the spindle speed of the tool displayed in RPM
The Approach should be ‘Descending’
Plane Feedrate - This is the Feedrate of the tool or the cutting feed displayed in
mm/min Select ‘OK’

Feedrate into Material - This is the plunge feed of the tool when feeding down to The Machining will calculate automatically and the result should be similar to the
each cut and is displayed in mm/min. picture below but you will only see one view. Press ‘F2’ to see the other views…

*Length Compensation Number - This is the number that is read by the post
processor for any Length Compensation Number that might be needed for the
program.

*Cutting Side - This is where you specify where the tool should be climb or
conventional milling.

*Coolant - This is where the type of coolant can be specified.

*User Remark and PP info - are specific for the post processor. Ask your instructor
for a more detailed explanation.

NOTE :
All of the flags marked * will not effect the calculation in any way and the
values will only become visible when the program has been post processed.

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We have now calculated our first 2D machining strategy. Simulate the toolpath to see After we have simulated the toolpath, clear the toolpath and then select ‘New
the results. Operation’ to create our second toolpath.

Select the ‘Toolpath Simulated display’ icon


Select ‘Quick Pocketing’

Select ‘Quick Pocketing’


The system will now show the first level of the toolpath onscreen and a new set of
icons will appear on the left: -

Select tool number 2 - the ‘10mm End mill’.

These icons control the display and animation of the toolpath. You can: -
See individual levels.
See all levels.
Move to the first or last level.
Simulate the tool in shaded or wireframe mode (VISI must be in ‘shaded
display mode’ for a shaded tool to be available).
Set the tool transparency.
Exit back to the Operation Manager

10mm End Mill

If you click the ‘show tool’ icon, the animation icons will also appear as shown below:

These icons control the animation of the toolpath. You can: -


Play, pause and stop the animation. Select ‘OK’
Jump the animation to the next point in the toolpath.
Speed up or slow down the animation. (Note: the animation speed can
also be set with the keyboard + and - )

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We now have to select the profiles we want to machine. The results will be as follows: -
Select the 4 circular profiles and the large linear slot profile in the centre of the model.
(PF5, PF6, PF7, PF8 and PF9) Use Block control to pick more than one at any time.

Simulate the toolpath to see the results.

We have now completed our second 2D machining strategy. Most of the 2D


Double click the ‘Operation Parameters’ and fill in the values as the picture below. strategies are very similar to those shown and are easy to follow.

Quick Pocketing will apply the same values set in the operation parameters to all of
the profiles selected, regardless of depth, shape or material side.
The rest of the operation parameters are almost identical to the previous operation.
Refer to the previous operation for an explanation of the commands.

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Clear the toolpath and then select ‘New Operation’ to create our next toolpath. We are now presented with a selection of tools from the Visi-tools database of milling
tools. It is from here where we can select the desired tool.

Select ‘Quick Milling’

Quick Milling

We are now going to select a tool that is not in the current library.

Select to create a tool from the Global Library

Create tool from


Global Library Select the second 4mm-end mill

Select this end mill

Select ‘Mill’ and


‘OK’ Select ‘OK’ to the
speed and feed
defaults

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We now have to select the profiles we want to machine. The option differences between pocketing and milling operations in 2D are as follows: -
Select the 4 circular slot profiles PF1, PF2, PF3 and PF4. Use Block control to pick more
than one at any time. Machining Form

PF1 PF2

PF4 PF3

Double click the ‘Operation Parameters’ and fill in the values as the picture below.
Diameter Compensation – This section allows you to apply the DIAMETER
COMPENSATION NUMBER that is used on the CNC control as a corrector for any
adjustments needed on the size of the piece. The LENGTH COMPENSATION
NUMBER which works in a similar way to the diameter corrector and calls values
from the CNC control.

Toolpath Offset
These parameters apply different offset strategies according to your requirements.

None – This means that the system will leave the centre of the tool on the selected
profile with no offset applied.

Profile Offset – When this flag is activated the toolpath is offset by half of the cutter
diameter and also allows the use of the diameter compensation switch.

Profile Corrected – This allows the centre of the tool to be left on the profile although
the toolpath is adjusted and extra circular moves are added where necessary.

Quick Milling will apply the same values set in the operation parameters to all of the
profiles selected, regardless of depth, shape or material side.

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Approach/Retract Form Select ‘OK’ and display the toolpath. The result will be as follows

Profile Approach
Direct – The tool moves directly away from the last tool position to the start point in a
straight line.
Perpendicular – This allows a perpendicular approach to the start point of the Simulate the toolpath to see the results.
selected profile. The approach point is projected perpendicular from the start point.
Circular – This will create a circular approach from the selected starting point on the We have now completed our third 2D strategy. Most of the 2D strategies are very
profile. similar to those shown and are easy to follow.
Helicoidal - This will create a tangential approach to the selected start point but uses
a 3 axes helical move to perform the approach. You should now be at a stage where you can start to understand the principle of how
2D machining works.
Approach Radius – This will let the user enter the required radius for the approach
and is only active with the circular and helicoidal approach mode selected.

Profile Retract
Direct – The tool moves directly away from the last tool position to the retract point in
a straight line.
Perpendicular – The tool moves away perpendicularly form the end machining point
to the retract point.
Circular – This will move the tool circularly away from the machining end point to the
retract point.

Retract Radius – This will let the user enter the required radius for the retract method
and is only active with the circular retract mode selected.

Material Approach
Feed or Rapid determines whether or not the descent to the start point is a Feed or
Rapid move.

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Clear the toolpath and then select ‘New Operation’ to calculate our next toolpath. We will now machine the final slot profile.

Select ‘Milling’

PF10

Select ‘Milling’

For the last operation we will select a tool from the current library.

Select the small centre profile ‘PF10’

We are now asked to select the start and finish machining points for the final profile.
Select the mid-point of the long bottom edge of the profile as both the start and end
machining point.

Start and end


point

Select ‘6mm End Mill’

We could now change the machining direction from climb to conventional milling if we
needed*. For this profile we will accept the default so select the right hand mouse
Select ‘OK’ to confirm the tool selection button to confirm the machining direction.

*NOTE
By pressing the space bar we can change the machining direction from climb
to conventional.

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Double click the ‘Operation Parameters’ and fill in the values as the picture below We have now machined our first 2D job and the same principles applies to all 2D
machining strategies on any job.

Go through the following examples using the strategies you have already learned
and apply your own parameters to the strategies.

You will be given the depths of the profiles and the rest is up to you.

Example 1

Select the workfile ‘Example 1.wkf’

Select ‘OK’ and display the toolpath. The result will be as follows

The profiles should have the following values.

Outer profile = Material pointing inwards

4 off large circular profiles = Material pointing outside (pocket) 50mm thickness

This operation is almost the same as quick milling and all the parameters in the forms
are identical. Refer back to the quick milling operation for an explanation of all the
parameters on each form.

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4 off circular slots = Material pointing inwards (bosses) 30mm thickness Example 2

Select the workfile ‘Example 2.wkf’

Larger inner circular profile on datum = Material pointing outside (pocket) 20mm
thickness
PF1 PF3

PF4

PF2

Small inner circular profile on datum = Material pointing outside (pocket) 50mm
thickness

The profiles will have the following values.

Using the information given create the machining for the above file. PF 1 = material pointing outside (pocket)

PF 2 = material pointing inside (boss) PF 3 = material pointing inside (boss)

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Open the file ‘Profile and section1.wkf’
PF 4 = material pointing outside (pockets)

4 off circular profile = material pointing outside (pockets)

The model consists of one ‘closed’ shape profile and one ‘open’ section
profile.

NOTE
Only one section profile can be used at any one time.

Open ‘Operation manager – New operation – 2D operations – Profile


Section’

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Select ‘T3 – 6mm Ball Nose tool’ Change the settings to match the following : -

Select the bottom planer shape profile and pick a point on that profile to
indicate the start and end machining point.

Confirm the machining direction using the ‘RHM’ button

Now select the ‘section profile’ and use the ‘RHM’ button to confirm the
machining direction.

Open the ‘Operation Parameters’


Select ‘OK’

The result will be the same as shown above.

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Open the file ‘Revolution Example.wkf’
Open ‘Operation manager – New operation – 2D operations –
Revolution’

There is only one ‘open’ profile present.

The first thing that must be done is the profile must have a machining side
attached to it. This is necessary to determine whether or not the cutter will
class the machining as inside or outside.

NOTE
There is no need to assign any thickness to the profile as no thickness
is need for this particular strategy, but giving the profile thickness will
not affect the machining.
Select ‘T3 – 6mm Ball Nose tool’
Select ‘Machining – Profile CAM attributes’ and pick the profile. Make
the material side ‘Inside’ as shown below: -

NOTE
Only Ball Nose tools can be used on this strategy

Select the profile and confirm the default machining direction using the
‘RHM’ button. Use the ‘RHM’ button to confirm that there are no
No thickness is needed on the profile machining boundaries.

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We now have to inform the system where the machining centre will be and Open the ‘Operation Parameters’
what will be the machining axis.

Enter ‘X0, Y0 and Z0’ for the machining centre

And ‘X’ as the revolution axis. Confirm using the ‘RHM’ button

Change the ‘Constant Step’ to 1mm and calculate the machining.

The result will be as shown above.

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The toolpath in our case has machined above the profile when the ‘Start and Open the file ‘Extra 2D operations.wkf’
End angle’ were 0° and 180° respectively and the profile was above the
revolution axis. If the profile was below the revolution axis but the ‘Start and
End angle’ was the same the result would be different. This is shown below.

Profile above
Revolution axis

Switch on the layers ‘Layer 1 and Open Pocket Profiles’

Profile below Revolution


axis, same settings used

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Open ‘Operation manager – New operation – 2D operations – Open Select the top one of the 2 profiles and select the straight end segment as the
pocket open part

Select this edge as


the open segment

Confirm the profile and edges using the ‘RHM’ and ‘confirm selection’
Select ‘T2 – 10mm End Mill’

We now must select the profile to be used for this strategy and also select the
open edges from the profile we have just selected. The open edges are where
the tool will cut outside and are confirmed using the ‘RHM’ button and
‘confirm selection’.
Open the operation parameters and set up the parameters as laid out on the
next page. You will notice that all the parameters are very similar in this
strategy to the existing pocketing strategy. An explanation of these settings
and parameters has already been given earlier in these notes. Please refer to
those for an explanation of the parameters.

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Please setup the parameters as follows for this strategy: -

The result will be as shown above and the machining goes outside the
selected open edge.

Select ‘OK’ Repeat the process for the lower profile

Next, the system will ask you to ‘Indicate the approach point’ Clear the toolpath from the display.

Press ‘F2’ until you have a top view. Switch on the layers ‘Layer 1 and Helical Milling Profiles’

Note: the outer toolpath pass is shown to aid selecting the approach point
(you would normally approach from outside the pocket)

Select a point (intersection free point) similar to the one shown below: -

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Open ‘Operation manager – New operation – 2D operations – Helicoidal Milling Use the ‘RHM’ button to confirm the cutting direction.

Open the operation parameters and you will be presented with the following
form. Once again you will notice that all the parameters are very similar in this
strategy to the existing pocketing strategy. An explanation of these settings
and parameters has already been given earlier in these notes. Please refer to
those for an explanation of the parameters. An explanation of the different
parameters is given below.

Pitch
This is in effect the depth of cut. It is the distance the tool will travel in Z from
one complete circular tool movement to another.

Final Contour
This option ensures that there is an extra circular pass added to the bottom of
the toolpath. This makes sure that when you are machining into a blind hole,
the bottom of the hole will be flat.

Change the parameters to the ones show below and select ‘OK’
Select a 20mm tool from the global library

Select ‘OK’
Now select one of the 2 circular profiles.
The system will now ask for the start\end machining point and the direction.

Select the ‘Centre point’ icon and pick the centre of the profile.

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Open ‘Operation manager – New operation – 2D operations – Mill Thread

There are no thread mill tools in the default library, so we will have to create
one manually: -

The result will be as shown above. Notice the extra pass at the bottom of the
hole.

Repeat the process for the other profile

Clear the toolpath.


Enter the tool parameters as shown below: -
Switch on the layers ‘Layer 1 and Thread Milling Profiles’

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Open the operation parameters and fill in the following parameter as laid out
below.

Select ‘OK’to create the tool

Thread Milling can be done either from profiles or points. We will mill the
thread using profiles

Select the 2 profiles and confirm the selection using the ‘RHM’ button

Once the operation parameters dialogue box is open you will be presented
with the previous form. Once again you will notice that all the parameters are
very similar in this strategy to the existing pocketing strategy. An explanation
of these settings and parameters has already been given earlier in these
notes. Please refer to those for an explanation of the parameters. An
explanation of the different parameters is given on the next page.

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Nominal Diameter
This value relates to the actual thread diameter and the value is taken from
the size of the profile selected, or a default value is entered if a point is
selected.

Internal Diameter
The internal diameter is the internal size of the thread and this value will
change depending upon whether an internal or external thread is selected.

Thread Length
The depth of the thread is determined here and this value indicates the depth
to machine. The value is taken from the attributes assigned to the profile
selected, or a default value is entered if a point is selected.

Start Machining Angle


This value is the angle about the Z-axis where the machining will start around
the thread

Number of Pitches
This is the complete number of threads taken from the tool parameters that
will be machined on the component. For example if the value is set to 5 and
the pitch is 2 then the system will machine the full depth of the thread in a The result will be as shown above.
series of 10mm cuts.
Try to changing the values and options within the operation parameters to see
Threading type – Internal and External the different results that can be achieved.
Internal or External thread type determines where the tool will produce an
internal or external thread form on the component.
Clear the toolpath
Pitch type – Left or Right
This flag defines either a left or right hand thread. When these switches are
activated the machining will be from either the top to the bottom of the thread Switch on the layers ‘Layer 1 and Blending Profile’
or vice versa depending on whether conventional or climb milling is used.

Change the parameters to the ones show on the previous page and select
‘OK’

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Open ‘Operation manager – New operation – 2D operations – Blending Now select the open profile near the radius on the top of the open pocket and
the start and end machining point on the profile as opposite ends of the
profile.

Select the profile

Select the start


and end point for
the machining

Select ‘T3 – 6mm Ball Nose’

Open the operation parameters and you will be presented with the form
shown on the following page. Once again you will notice that all the
parameters are very similar in this strategy to the previous strategies. An
explanation of these settings and parameters has already been given earlier
in these notes. Please refer to those for an explanation of the parameters. An
explanation of the different parameters is given below

This strategy is very similar to the profile and section strategy that was
explained earlier on in the notes. The difference is the following parameter.

*NOTE: - Only Ball Nose/Bull Nose and Corner rounding tools can be Fillet Radius
used for this type of strategy. This is the size of the radius to be machined

Select ‘OK’

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Change the parameters to the ones show below and select ‘OK’ Now select the open profile near the radius on the top of the open pocket and
the start and end machining point on the profile as opposite ends of the
profile.

Open the operation parameters and you will notice that the machining form is
different because of the different tool that we selected. Once again you will
notice that all the parameters are very similar in this strategy to the existing
strategies. An explanation of these settings and parameters has already been
given earlier in these notes. Please refer to those for an explanation of the
parameters. An explanation of the different parameters is given below

Guide point – High and Low


This flag determines where the application point for the machining will be
calculated from with regard to the tip of the tool and the profile. The High flag
assume the machining to be calculated from the top of the profile and the Low
flag the machining to be calculated from the bottom of the radius defined on
the tool. If the profile top and bottom were set to 0 and –20 respectively, and
the radius on the tool was 5mm, then if the flag was set to be low the
machining would not go lower than –5mm.

Change the parameters to the ones show below and select ‘OK’
On this particular strategy the operation parameters form will change
depending on the tool that is selected.

Repeat the procedure but create and use a corner-rounding tool with the
following parameters.

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Open ‘Operation manager – New operation – 2D operations –
The result of each toolpath will be as below: - Chamfering

Select ‘OK’
Clear the toolpath
We now need to create a tool manually with the following parameters
Switch on the layers ‘Layer 1 and Chamfering Profiles’

Select ‘Create tool manually’

Create a chamfering tool with the following parameters

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Now select the open profile and also the start and end machining point on the Radial and Axial
profile These 2 options define what type of multiple passes will be created on the
Select the profile toolpath. The Radial option defines a number of vertical steps to clear material
to the chamfer and the Axial option defines a number of horizontal passes to
the chamfer.

Approach/Retract
Disengagement type – Radial and Axial
This defines the disengagement type of the tool from the chamfer. The Radial
option represents a retraction towards the tool centre by the distance entered
in the Input value and the movement type is radial from the cut on the profile.
The Axial option represents a retraction towards the tool axis by the distance
entered in the Input value and the movement type is axial from the cut on the
profile. The Preset diameter allows the user to enter a diameter in the Input
value and this is the diameter that the toolpath will offset to when disengaging
the toolpath.

Select the start


and end point for Change the parameters to the ones show below and select ‘OK’
the machining

Open the operation parameters and you will be presented with the form
displayed on the next page. Once again you will notice that all the parameters
are very similar in this strategy to the previous strategies. An explanation of
these settings and parameters has already been given earlier in these notes.
Please refer to those for an explanation of the parameters. An explanation of
the different parameters is given below

Chamfer Depth and Chamfer width


The values entered here are the vertical and horizontal sizes of the chamfer to
be machined

Angle
Is the angle of the chamfer with respect to the vertical axis

Depth Mode
This determines whether the chamfer will be machined by entering a value for
the depth and width or the width and angle

Multiple Passes
This option defines the approach type to the first pass on the profile and is
used in conjunction with the number of passes and the Radial or Axial option.

Number of passes
This defines the number of passes used to use with the Radial or Axial option
when the toolpath is generated.

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The result of the toolpath will be as set out below: - Open ‘Operation manager – New operation – 2D operations – Extrusion

Clear the toolpath

Switch on the layers ‘Layer 1 and Extrusion Profiles’ Select ‘OK’

Select ‘T3 – 6mm Ball Nose’

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Perpendicular Mode
Now select the curved profile on the model. When this flag is activated it will create the machining toolpath perpendicular
to the vertical profile that was originally selected.

Change the parameters to the ones show below and select ‘OK’

Use the space bar to select the machining direction and confirm the selection
with the ‘RHM’ button (In this case, we will machine in the downwards
direction)

Open the operation parameters and you will be presented with the form
displayed on the next page. Once again you will notice that all the parameters
are very similar in this strategy to the previous strategies and in particular the
Profile and Section strategy. An explanation of these settings and parameters
has already been given earlier in these notes. Please refer to those for an
explanation of the parameters. An explanation of the different parameters is
given below: -

Left\Right Extrusion Distance


This is the machining extrusion distance to the Left/Right of profile (looking
along the direction of the profile)

Left\Right Cut Depth


The values entered here refer to the depth of cut that is applied to the
extruded machining to the left and right of the profile.

Although these parameters actually seem to be the same and give the same
results they are in fact different and can be used to in different ways to
machine only a section along the profile. An example of this is given below.

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The results should be as below: - Try some different settings yourself on all the strategies explained in these
notes.

You may have noticed that in the ‘Operation Manager’ the colour of text of the
strategy name changes based on its status. The colours are as follows: -

x A GREEN strategy means that the toolpath is new and has yet to be
calculated.

x A PURPLE strategy means that the toopath has been calculated but some
parameters have been modified and the toolpath needs to be re-
calculated.

x A BLACK strategy means that the toolpath has been calculated


successfully

x A RED strategy means that the toolpath cannot be calculated with the
parameters you have supplied. Look in the ‘CAM log window’ for an
indication as to the problem.

Congratulations!
Open the operation parameter again and change the values to the following
and select ‘OK’ This completes the basic 2D milling
tutorial
Right Extrusion Distance = -70
Right Cut Depth = 20

The result will be the same as below and only a 20mm section of the profile
has been machined but away from where the original profile is positioned.

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Drilling

Select the file ‘Drilling Example1.wkf’

Open the ‘Operation Manager’

Open up the type of cycle you require, for this example we will choose ‘Drilled Hole’

Select here to open


drilling cycles

Select ‘New Drill Cycle’

You will now be presented with the following form.

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We now have to choose what type of hole we are going to drill, whether the hole is to Geometry selection means we can pick up the required information about the
be a through hole or a blind hole. diameter and depth of the hole from a 3D model if available.

Select ‘Through Hole’ from the drop-down


Cylinder selection allows the diameter and depth to be
defined by selecting a cylinder from the 3D model. The
information from that cylinder is then transferred from the
model to the correct D and DP values.

Through Circle selection allow the diameter to be defined by selecting


Hole a circle from the geometry and the information from that circle
is then transferred from the data to the values of D. The depth
must be entered manually

Select ‘Circle info’

Click “Apply”

We now have to pick a circle from the drawing provided.


We now have to give a size and depth for the holes we are going to drill.
Select one on the 12 circles from the drawing.

Select a circle

This is the main form where we enter the sizes and depths for the holes.
You will now see the diameter of the hole is entered in the dialogue box
Value D = Diameter of the hole in question

Value DP = Depth of the hole*

*NOTE
The depth of the hole is taken from the land of the drill and not the tip.

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We now have to select the holes that we want to drill.

Holes can be picked from points on model e.g. Midpoint, Endpoint, Intersection, or
centre point. It is also possible to select pre-defined points already created.

We will select the points already created.

Select the point’s environment selection method.

Enter a value of 40 in the DP dialogue box (this will then drill the hole 40mm deep)

Select ‘OK’

Now select one of the points at the centre of one of the diameter 12 holes.

You will automatically be taken back to the form above and probably think that noting
has happened.

Now select ‘OK’

The cycles will be created and placed in the ‘Operations Manager’ and will disappear
from the ‘Fixed Cycle’ panel.

NOTE :
The system automatically picks up the correct drill, in this case a centre drill is also
selected. The ‘Fixed Cycle’ panel is still active and is waiting to carry on with more drilling
routines as required. Select ‘Cancel’ to exit.
Each cycle is different and trying different cycles will select different tools assigned to
each cycle.

The ‘TOOL PARAMETERS and CYCLE PARAMETERS’ can be edited here or at a


later stage.

We will accept the defaults for this example.

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The result will be as follows. Machining Form

Drill Type:
Normal – This is the standard drilling type, this will force the tool to drill straight to
depth and then rapid back out of the hole.
Chipping – This is where the drill stops at a set depth and rapids back off by a few
mm and then starts to feed again to the drill depth and does this all the way to the full
depth of the hole.
Pecking – This is similar to chipping but will rapid all the way out of the hole and rapid
back to a safe distance from the last Z value and continues to work in this way until
the full depth of hole is reached.
Param1, 2 & 3 – These parameters are only used for ‘chipping’ and ‘pecking’ cycles.
Param1 allows you to set the ‘Z’ increment. Param2 allows for the dwell time to be
set and Param3 is post-processor dependant.

Depth Management
Set Depth/Set Diameter - Only applies when using a CNC type combined centre drill
and chamfer style tool. You can select to go to a specific depth or diameter.
Depth - This is the calculated drill depth to the point of the drill. (You set the depth to
the shoulder and the system automatically calculates the depth to the point).
Mark Diameter - This value is only applicable for the centre drill and works from
If we now enter the ‘Operations Manager’ you will now see there is 2 drilling cycles, either the depth or the distance across the diameter of the centre drill. See below.
one for centre drilling and one for drilling. Starting Z – This is where the drill starts to drill to the depth you set (relative to the ‘Z’
position of the point(s). A positive value will start drilling the holes that distance
All the operation parameters are now just like any other cycle and are fully editable. BELOW the point(s) you select. A negative value will start drilling above the point(s)
An explanation of the operation parameters are as follows.

You must first activate the ‘Set Diameter’


switch and then when a value is entered in
the ‘Mark Diameter’ you can then compute
the correct depth from the value entered.

Compute Depth value

Optimise Toolpath* – This will allow the user to view different ways in which the tool
will travel between holes. Different variations can be tried here, which include No
optimization, Min X or Y distance, shortest toolpath and minimum distance.

*NOTE
This is not applicable on sets of points.

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NOTE: It is also possible to set the machining attributes for groups of profiles rather Select - MACHINING/OPERATIONS MANAGER
than just individually as detailed on the previous page.

On the Machining menu you will see the command ‘Quick Profile attributes’

Using this command, you are able to pick multiple profiles and apply machining
attributes to them

NOTE: The same attributes will apply to all profiles picked at the same time using
this method….. i.e. The material side and heights will be the same for all profiles You will now be presented with the dialogue box shown above. The icons within the
picked at the same time. Operation Manager dialogue box are explained below: -

If you use this command, the panel shown below will appear: -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16

Notice that the second box has the legend ‘Negative thickness’. This means that a 1. New Operation – This selects the type of operation or template file to use.
negative value is implied in this box and therefore a minus sign is not required…. i.e. 2. New Drill Cycle – This selects the drilling options.
If the bottom of a pocket is at Z-50.0mm then you would enter a value of 50 3. Post Process – Select this to post process the calculated toolpath.
4. Toolpath Simulated Display – This is where the toolpath is simulated within the model
view environment.
5. Display Toolpath – This displays the completed toolpath on the screen.
We will now create the required toolpaths for this part. 6. Clear Toolpath – This icon hides the toolpath.
7. Delete – This deletes the selected item. (Including the whole project if selected).
8. Save template file – This is where the operations are saved into a template file
and can be used on any other job.
9. Print – Allows an HTML (or .xls) machining report to be produced of the
calculated operations.

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Rapid Management
Clearance plane – The tool retracts to the clearance plane after every hole. The Select ‘Drilling Example 2.wkf’
value of the clearance plane is set on the ‘Cutting conditions’ tab
Safety distance – The tool retracts the safety distance after every hole. The value of
the safety distance is set on the ‘Cutting conditions’ tab
Absolute Z obstacle – Allows you to enter an absolute ‘Z’ value that the tool will
retract to after every hole. However, the first and last moves will be at the clearance
plane.
Set Relative Z Obstacle – Allows you to dynamically ‘drag’ the ‘Z’ height of the
toolpath between holes. i.e. To edit the toolpath to make it ‘jump over’ an obstacle.
Obstacle Manager (icon) – This icon brings up the Obstacle Manager. With this icon
you can select solids and nominate them as obstacles (clamps etc.) The system will
automatically make the toolpath jump over the obstacles.
Check collisions – Activates the checking of the solids (clamps) as selected in
Obstacle Manager.

Obstacle
Manager

Refer to previous 2D operations for an explanation of the cutting conditions form.

Complete the examples on the following pages using the information given and
choose you own cycles and depths for the holes.

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Select ‘Drilling Example 3.wkf’

Try different cycles on the files given to see the results. Use Tapping and Counter-
bore cycles to see how they work.

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INTRODUCTION

This training document is intended to give an explanation of how to create, edit and
manage both the Machine Tool definition and Cutting Tool Libraries.

We will learn how to use both of these and how they can aid in the manipulation of
machining components.

A Machine Tool definition is needed for the creation of NC programs for fixed 3, 4
and 5 axis-machining centres. (The default is set as a standard fixed 3-axis milling
machine.)
Tool libraries are used to create a list of specific tools available for either all or
specific machine tools.

ToolLibraries
Select the menu item > Machining > NC-machines manager. You will be presented with the following form

The standard installation comes with a few machines already configured. The one’s
apart from the ‘Standard 3 Axis Milling’ are configurations for continuous 5-axis
milling machines. We will step through the procedure of creating a new 3-axis
machine in this tutorial: -

Select ‘New NC Machine configuration’


New NC Machine
On this form, general information about the machine can be set.
Edit NC Machine
Machine Description – We give a description of the machine here and you can enter
anything you like. The type of machine is usually entered here e.g. Bridgeport,
Delete NC Machine HAAS, Huron etc.

Comment – Here you may enter some comment of you own, maybe the workshop
Copy NC Machine where the machine is situated.

NOTE: - If you check ‘Set as default machine configuration’ then this machine will be
Show NC Machine Details used as the default machine when the system starts up. The post processor and
library assigned to this machine will also be used.

Default Local Library – Here you assign the tool library to be used with this machine.
This box will allow a specific library to be assigned to a specific machine.

Post Processor Configuration File – This is where you select the post processor to be
used with this machine. You can always change the post later if required, but this will
be the default post processor assigned to this machine.
For our training purposes, enter ‘Bridgeport’ in the Description and ‘Toolroom’ Single Horizontal - In this case we have a horizontal 4-axis machine tool. The post
in the comment dialogue boxes. processor considers it as an XYZ, plus an extra rotation around a primary axis.
Specific Configuration - To identify a machine tool with more axes you can select
Leave the ‘Set as default machine configuration’ un-checked the number of axis (1 or 2) after setting the specific configuration flag. If you select 2-
axis (i.e. 3-axis + 2-axis = fixed 5-axis) then the secondary axis portion of the panel
Leave the ‘Default local library’ set at none (we will create a new tool library next, will become available.
then come back and attach it to our new Bridgeport machine)
Primary and Secondary Axis.
Next, we will set the default post processor for our new Bridgeport. Click the
browse button, and then select the ‘Fanuc0m.cfg’ file. A large range of post- Table, Divisor or Head – These options are for future implementation. With this
processors is available. For this training example, we will stick with the Fanuc. version, selection of any of these three will not affect the NC output.

Select the ‘Axes Parameters’ form. Rotation Axis - When the post processor calculates new axis orientations, there is
NOT PRESENT usually more than one way to achieve the desired result. Generally, there will be
more than one potential combination of a primary and secondary axes rotation. The
post-processor will always select the combination that can be effected with the
minimum rotation. The initial axis angles may be defined as part of the configuration.
When the configuration file is loaded, the contents are checked, and you will receive
a warning message if the parameters are invalid.

Rotation Axis
On both the primary and secondary axis, you need to specify the tool axis and the
letter for the rotation axes. The axis can be rotated A around X, B around Y or C
around Z.

Rotation Direction
Bi-Directional – This flag means that the rotation of the fourth or fifth axis can be in
either direction.

Clockwise – This means that the rotation of the fourth or fifth axis can rotate only
clockwise.

Counter-Clockwise – This means that the rotation of the fourth or fifth axis can rotate
only counter-clockwise.

The user can specify the minimum and maximum angles of rotation around each
axis.

It is of course possible that you may create a machining operation that takes place in
This form is where we specify the way in which 4 and 5 axis positional machining will an orientation that is unachievable in your particular machining environment. In this
be handled when we post process a file that has machining on multiple faces. The case, the system will output an error message during post-processing.
default is ‘None’. If we change to Single Vertical, Single Horizontal and Specific
Configuration we can then specify the type of 4th and 5th axis.

Rotation axis type


None - In this case a classic 3-axis milling machine is set up and the post processor
considers the machine as a simple XYZ axis machine. Is not important in this case if
the machine is vertical or horizontal, the post processor will take care of the format
output and the corresponding axis system will be used.

Single Vertical - In this case we have a vertical 4-axis machine tool. The post
processor considers it as an XYZ, plus an extra rotation around a primary axis.
Select the ‘Extra Parameters’ form Now we will create a new tool library, and then assign it to our new machine.
NOT PRESENT
Select > Machining > Local libraries manager.

The parameters here are used to


configure a continuous 5-axis
machine and are not described in
this document
The system supplies one default local library with a few tools already added. A
sample tool-holder library is also provided. We will step through the procedure of
creating a new tool library.

Select ‘New Local Library’


New Local Library

Edit Local Library


Tool Change
This option allows you to select the tool change type (Automatic or Manual). This
parameter will be used by the post processor, which will then output the correct
information to the NC file. Delete Local Library

Change Position
If the machine needs a special tool change reference point it is possible to define the Copy Local Library
correct tool change co-ordinates here (normally left at X0, Y0, Z0).

Tool Axes
Copy Tools from Local
This parameter is connected only to the rotary axes setting. If you have a machine
Library
tool with more than 3 axes, the tool axes identify the default tool direction in respect
to the absolute co-ordinate system.

In our case we are just defining another 3-axis machine. We will leave all the default Display Library Details
settings set, apart from the ones we have already altered within the ‘General
Parameters’ form.

Select ‘OK’ and ‘OK’

We have now created a new machine.


We now presented with local library editing panel: - Select ‘Create Tool from Global Library’

Select the type of tool to create.

Select ‘Mill’ and ‘OK’

Next, we will start to fill out our new library.

Enter the Name of your new library in ‘Local Library Description’ (Use
Bridgeport) We now have a list of tools available in the global database of milling tools and we
can choose the tool we want to add to our new local library.

Now we need to start adding tools to our library.

Tools can be created in 3 ways; they can be selected from a global library of tools,
created manually or copied from one local library to another. New tools can also be
made during the creation of a cutting operation. So even if we need a new tool on a
job that is not in any library, we can always create them on the fly.

The first tool we create will be copied from the global library.

The global library is a list of tools that come as standard with the system.
For our first tool we will select a 12mm End mill. Click on the ‘Tool Holder parameters’ tab

This panel (shown on the next page) allows us to define a tool holder (or holder
assembly) that will be associated with this tool. If a tool holder is added to a tool,
collision avoidance and gouge detection are possible during 3D cutter path creation.

The tool holder must be defined as an assembly and can be made up of: -

1. A tool holder
2. An extension
3. An adaptor

Any combination of the above components can be included in the assembly.

Select the 12 mm End mill with the 111 mm overall length and click ‘OK’
There are very few restrictions on how the tool assemblies can be added together,
however,

1. Different Assemblies cannot be saved using the same name


2. You cannot save an empty assembly

The picture below shows the normal relationship of holder+extension+adaptor

Now we are presented with the cutting parameters form where we can set up the
speed and feed for the selected tool. The parameters here will be explained when we A few example assemblies can be found in the ‘Default Tool Assembly Library’
create a manual tool.
Allows you to save the selected component(s) into the
database. You have a choice to save the component(s) into
either the tool holder, holder extensions or holder adaptors
database .

Allows you to remove the selected component(s) from the


assembly.

Removes all components from the assembly.

The values here control the relationship of the


holder assembly to the machine spindle nose. They
are only used during 5-axis (continuous) simulation

A description of the Tool Holder parameters follows: -

The ‘Assembly Description’ box is used to name the assembly you are creating. You
must provide a name before you click the save icon or the OK button. Displays the presetting length. By
default it equals: - If enabled, this button
“Flute length + (Overall length- will run the automatic
Allows access to the holder’s database. From here you can Flute length)/2)” tool length checking
create, modify and delete holders. If a tool holder assembly has computation.
been added to the tool, the user
can input a value that is different
to the default. However, if a tool
holder assembly has not been
Allows access to the holder extensions database. From here added, the default-preset length
you can create, modify and delete holder extensions. will remain in effect.

Allows access to the holder adaptors database. From here


you can create, modify and delete holder adaptors.
The system is able to automatically compute the minimum tool preset length
based on a particular tool+holder assembly+tool-path combination. At this point
in time, the auto calculate will be greyed out as we have no tool-paths computed.
Allows you to bring in a pre-defined assembly.
Below is the Holder Definition panel: -

Remove the selected slice

Delete all displayed slice data.

Note. The user must supply a name for the holder before clicking on the OK button.

The other panels for Holder Extensions and Holder Adaptors work in the same way.

We will not add any tool holder data for this tool.

Select ‘OK’

We have added one tool to our library.

Holder definition
This user interface allows the user to define a slice of tool holder by inserting the top,
bottom diameter and height.

Slice Z height

Slice bottom diameter

Slices editing
These buttons allow
Notice that there is no tool position assigned to this tool. We can set this at any time.
the user to move
These buttons allow We can set the tool position when we create the tool, after the tool has been created
and reorder the
the user to add a or even when we post process the program.
slices to define the
required shape of slice, remove a slice
the tool holder. or remove all the
NOTE: The “undo” slices.
button allows only
one level of undo.

Add a slice under the selected position


Other options on the local library form are: - A red tick
This means that this tool has already been used
Filters
Tool Source, Type, Subtype and Diameter – These filters can be used to filter the A red bounded tick
display of tools. Each filter is activated by the check box to the right of that filter box. This means that this tool is the currently used tool

A tool holder overlaid in the top right hand corner of the icon
This indicates that this tool has a tool holder attached to it
Create a tool from a Global Library
We will now create a tool manually.
Create a tool Manually Select ‘Create Tool Manually’

Edit a Selected Tool

Delete the Selected Tool

Change the Tool Position Manually


Select ‘Mill’ and ‘OK’
Automatically Assign Tool Number

Display Selected Tool Details

The icons in the ‘Pos.’ column indicate how the tool was created and it’s usage
status. See the description below: -
Open up the ‘Subtype’ and select ‘Ball nose’

The different icons here


indicate a tools current usage
and how it was created. You
can also see if a tool holder
has been attached to the tool.

A green cylinder
This means that this tool comes from the global library.

A white cylinder
This means that this tool comes from the local library

A green hand
This means that this tool has been defined manually in the local library

A white hand
This means that this tool has been added and it was not selected from any library
Enter ‘7’ in the Diameter (D) box and then select the Tool Parameters, Diameter (D) - This is the main diameter of the tool.
‘Enhanced Editing’ flag. 2nd diameter (d) – This is a second diameter setting, and is only active on certain tool
types. It relates to the diameter (d) on the tool image.
Tip Angle – This is the angle of the cutter on milling tools (where applicable) and the
angle of the tip on drilling tool.

Corner Radius – This is the corner radius of the tool. It is dependent on the type of
tool selected and is only active on bull nose, ball Conic and corner rounding tools.

Tool Length – This value applies to the overall length of the tool
The various flags and options are explained below.
Usable Length – This value applies to the overall cutting length of the tool.
General Parameters Form
Num. of Teeth – This is the number of teeth, inserts or number of flutes for the tool.

Tool Rotation – This is the direction the tool is rotating for normal cutting.

Coolant – This is the type of coolant that will automatically be turned on when this
tool is used.

Tool Position – This is the tool number or carousel position. It can be set manually,
left un-set by entering a question mark or set automatically.

Cutting Parameters Form

Lock database tool settings


This flag is for unlocking the link to an external database. If the tool has been
selected from an external database then we can unlock the link to the database by
de-selecting this flag and then all the parameters of that tool then become editable.
Database type – This is the name of the database from where the tool has been
selected. If the box says ‘NONE’ then there is no link to any database and the tool
has been created manually.
Database reference code 1 and 2 – These are internal codes of the tool and do not
affect the machining in any way. During the creation of a tool, text can be entered
here to help identify the tool e.g. Tool supplier or meaningful reference code.

Subtype – This is where you select the specific sub-type of tool. For example, an end
mill and a ball nose are both sub-types of a milling tool whilst a centre drill and a flat-
bottomed drill are both sub-types of a drill.
Materials
Tool Parameters Tool/Insert Material and Piece Materiel – Here the type of material can be defined
Enhanced Editing – When this flag is active, more options are available for the user and must be used in conjunction with the correct type of piece material. When
to define the tool. selected the correct speeds and feeds for the selected tool and material will be
selected and input into the Cutting Conditions form and the Feed Speeds dialogue
boxes *.
Cut Mode – This is the type of cutting the selected tool is actually doing and the
relevant cutting conditions will be entered into the Cutting Conditions form and the
Feed Speeds dialogue boxes *.

Cutting Conditions – This is where we can directly enter the cutting conditions for this
tool. The Vc[m/min] is the cutting speed of the tool in Metres per minute and Fz[mm]
is the feed of the tool in mm per tooth. If we have access to this information (from a
cutting tool catalogue for example), then we can compute the correct feed and speed
by entering the ‘metres per minute’ and ‘feed per tooth’ then clicking on the Compute
feed speeds icon (shown below): -

Feed Speeds – This is the actual spindle speed in revolutions per minute S[rpm] and
the cutting feed in mm per minute F[mm/min].

Cutting Parameters
Step Over – This is the default step over of the tool.
Step Down – This is the default step down of the tool.
Safety Distance – This the safe distance of the tool above the top of the workpiece.
Length and Diameter Corr – These values represent and length and diameter
compensation numbers that are applied to the tool and will only be seen in the post
processed output. Normally these are left blank, as the post-processor will use the
tool station number for these values instead. Select ‘OK’ and ‘OK’

*NOTE
To cover all combinations of speeds, feeds, cutting material and piece material,
Visitools will need to be used to input the correct information into the relevant
databases. This is further than the scope of this document and, suffices to say, most
customers ‘bracket’ the speeds and feeds entered here for other materials.

Enter the following information into the ‘General Parameters’ form and the ‘Cutting
Parameters’ form.

We have now created two tools within our new library and this demonstrates the
process needed to create a complete new local library. We have illustrated how to
create a tool from the global library and manually creating a tool.
Using the information you have been given, continue to enter a few more new tools
into our Bridgeport library.

Make sure you try different types. Try to create tools that are relevant to your
workplace.

Finally, once you have finished adding tools to your new tool library, we need to link
the new library to the Bridgeport machine we created earlier.

If any of the local library manager panels are on screen, click ‘OK’ to close
them.

Select Machining > NC-machines manager

Highlight ‘Bridgeport’ then click ‘Edit NC machine configuration’

Edit machine
configuration
icon

Highlight ‘Bridgeport’ from the ‘Default local library’ drop down selector box then
click ‘OK’ on both panels

Default local
library selector box

This has linked the Bridgeport tool library to the Bridgeport machine configuration.
Now, if the Bridgeport machine is selected when creating tool paths, the new tool
library and post-processor will be used automatically.

This concludes the tutorial on Tool Libraries and Machine configuration


Welcome to VISI-Machining

In this training documentation, the first type of toolpath (Roughing Spiral- Cavity) will
be explained in detail, while all subsequent toolpaths will be explained in more
general context.

Once you have created the first toolpath, you will notice that the dialog boxes
remain consistent for all toolpaths, which considerably reduces the learning process.

Agenda:
3DCAMRoughing
Roughing
Roughing Spiral
Rest Roughing Spiral
Roughing Against a Stock Model
Roughing Spiral – Cavity Pre Drilled Point
Roughing Spiral - Core
Roughing Zig-Zag
Roughing – Checking Collisions
Let’s create our first Roughing Spiral strategy.

Roughing Click the New


Roughing Spiral - Cavity Operation icon to
create a new strategy.
Open the file “Cavity-123.wkf”

From the following dialogue window select the Roughing Spiral strategy and then
pick ‘OK’ to confirm this.

Once the model is loaded into the software


we can begin to define the various cutting
strategies required to manufacture the part. The first strategy we will apply will be a
Roughing Spiral cut which will clear the bulk of the material away. To do this we need
to begin by opening the Operation Manager, this is the place where the entire
project can be managed and organized.

Go to the menu Machining > Operation Manager to start up the operation manager.

You should now see the operations manager appear on the right hand side of the Now create a tool appropriate for roughing out this job.
screen containing an empty project. Click the Create Tool
Manually icon to create a
new tool. Choose the tool
type Mill from the next
dialogue box.
From the “General Parameters” page create a “Bull Nose” tool subtype using the Assign the feeds and speeds using the parameters shown on the dialogue box below.
parameters shown on the dialogue box below. The parameters you will need to The parameters you will need to adjust are ringed.
adjust are ringed.

Info: - The Enhanced editing


switch allows access to the
extra tooling parameters that
are otherwise frozen if this box
is not checked.
Automatic numbering allows
the system to allocate a tool Info: - Clicking the Cut Mode button to “Rough”
position in the library normally allows the entry of Roughing Speeds and Feeds.
in the first available position. It Here we use the “Feeds speeds” input to manually
is possible to have 2 tools with assign our values.
the same position no. if one
has been created manually and
Click the “Set tool defaults” icon to assign
one has come from Global tool
defaults for the Cutting parameters such as Step
library.
Over, Step Down and Safety Distance.

Finally let’s assign a “Tool Holder” for this tool. We will select one of the default holders
Now switch to the “Cutting Parameters” page to assign some default Speeds and from the library that comes as standard with the software. Click on the “Tool Holder
Feeds for this tool. Click on the tab as shown Parameters” tab as shown below.
Select a holder from the standard library. From the list of Available holders select the Selecting the Machining Geometry
ISO50 type and then select ‘OK’ to confirm the choice.
Immediately after confirming the Toolholder parameters it is now required to select
the model for machining. Using the standard VISI controls pick the model from the
Click the Holders
screen area.
Database icon to pick a
holder from the default
library. The Edit Model geometry dialogue will appear.

A fuller description of the Piece


Manager, detailing its features
and function can be found in the
document “Piece Definition”.
Please ask your tutor if you do
not have a copy of this document.

All we need to do here is click on


the green tick

Info: -We are in fact creating a


Triangulated mesh representation
of the model for machining
purposes. These values represent
the accuracy of the mesh. The
The resulting dialogue box will now display the tool and holder together. Give the values here (0.1 and 10) are
Assembly Description a name and select ‘OK’ to continue. perfect for a Roughing Model.

Now we have decided the cutting strategy and tool, we have to set the relevant
machining operation parameters for this tool path. Your Operation manager should
now look like this and contains a default machine tool, the origin for the toolpath, the
tool and a cutting strategy (Roughing Spiral).

Double Click with the Left


Mouse button on the Roughing
Spiral strategy to access the
cutting parameters.
Setting Up the Machining Strategy
Step Over Adjust
The dialog box will appear, and will have 7 different tabs, each containing different This flag will only become active when bull nose tools are used for roughing. When the flag is active
parameters which control the toolpath. the step over is adjusted to always compensate for any extra material left on planar areas because of the
The first tab “Machining”, represents all the fundamental parameters for the cutting step over used and the size of the radius used.
strategy. Use the values shown below in the Dialogue Box.
Corners management
Smooth corners:
This option optimises the toolpath for high speed machining (H.S.M). For this type of machining it is
necessary to remove any sharp corners in the toolpath allowing the tool to run at a higher feedrate and
reduce cutter wear. Activating this option will add radii to all sharp corners within the toolpath.

Max radius:
This value represents the maximum radii value that can be added to the corner of the toolpath.

Profile tolerance:
Each Z level consists of a contour profile (where the piece is cut) and a set of concentric offset
profiles. The profile tolerance controls the amount of smoothing to add to the corners when machining
a profile. The value is the maximum distance that the smoothed profile will diverge from the actual
contour profile.

Offset tolerance:
The value is the maximum distance that the smoothed profile
offset will diverge from the inner (offset) profiles. In essence, this
parameter is identical to the Profile Tolerance, except that it
refers only to the inner (offset) profiles and not to the outer
profile.

Smooth stepover:
This option optimises the toolpath for high speed machining
(H.S.M). For this type of machining it is necessary to remove any
sharp corners in the toolpath allowing the tool to run at a higher
feedrate and reduce cutter wear. Activating this option will add an
S-shaped transitional movement between each step across.

What’s happening here? An explanation of the Parameters in use on this page. Now we can move on to the Approach / Retract page. Click the tab to open this
dialogue panel.
Stock Oversize 0.5 mm
This means that we are leaving 0.5mm of material on sidewalls of the component for finishing.

Step Down 2mm


This is the size of step between each Z level of the toolpath.

Step Over
This is the distance between the passes on each level of the toolpath and can be set to a percentage of
the tool diameter or entered directly. Here we are using 40 percent of the tool diameter to define the
step over distance.
Approach / Retract Settings Ramp/helix angle:
The angle that the tool will move down into the material, in our case we are ramping using a 2 degree
The approach and retract settings will dictate how the cutter will move onto and off angle.
the machined piece. There are many parameters that have subtle effects on the
approach and retract type, most of which are set to sensible values based on the Ramp min. diameter:
cutter geometry. Please reproduce the settings shown below. A toolpath which would produce ramps smaller than this size (diameter span) will not be processed in
our case we will eliminate any toolpaths that are below 66mm span.

Vertical movements
Approach:
This is the size of a (vertical) radial movement added to the top of the approach ramp.
Retract:
This is the size of the (vertical) radial movement in the retract move.

Horizontal movements
Approach:
This is the size of the horizontal component in the approach ramp.
Retract:
This is the size of the horizontal component in the retract move.
Retract angle:
This is the angle of the retract move.

Plunge Area:
The plunge area allows the user to input a physical X, Y value to force an area at where the toolpath
should approach the part. If for example, the roughing strategy was being applied to a multi cavity
block. Selecting an area close to one cavity would force the toolpath to start inside that cavity.
It is also possible to select a point using the pick starting area icon.

Fitting options
Choose how the lead in and lead out arcs of the retract movements fit to the machining pass.

Machine all of pass:


The path of the cutter will match the surface, including vertical surfaces and the corners. An arc will
only be inserted at the end of the pass, and then only if it can be done so safely without hitting the job.
This dialog contains the following information: Minimise trimming: In use here.
The path of the retract will be as close to the surface as possible, maintaining a minimum distance from
the surface to fit the arc of the set radius.
What’s happening here? An explanation of the Parameters in use on this page.
Fully trim pass:
In cases where it is crucial to prevent over-machining, this is a good and cautious strategy modification.
Plunge mode = Ramp: The pass is trimmed back so the entire arc fits into it, but no nearer than a full machine pass link would
If selected, the approach will follow the contour of the part as it ramps down to the next Z level. When be.
this option is selected a ramp angle is required for computation.
Maximum trimming distance:
Ramp/helix height/offset: 3mm The size of the pass trimming can be no greater than this distance.
The ramp height offset is an extra height used in the ramping motion. It ensures the tool has fully
slowed down from rapid speed before touching the material so that it enters the material smoothly at All of the values on the Approach/Retract tab are set to sensible default values based on the tool,
the ramping angle and ramping federate, here we are using a value of 3mm. strategy, depth of cut etc. Normally, it is not necessary to alter these values.
Transitions In our example we are using the method By Depth, although due to the shape of the part either
method would probably yield similar results.
Here we can set various parameters that control specific aspects of the tool Step
Down and lift off.

Click the “Transitions” tab to open this dialogue panel and reproduce the parameters
as shown.

Min. Step over without Lift Off:


This value allows the user to specify the maximum distance between two different passes where the
system is allowed to create a connecting feed movement.
If this value is set to zero, all the connecting movements will be executed in rapid mode at the rapid
height.

Small pockets management:


This is a very important option when trying to avoid small pockets not to be machined. This function
can be used to avoid the tool machining down into pockets that are only a little larger than the tool
diameter. This can be used to preserve the tool life as it prevents the tool making small ramping moves
and ‘bottoming out’. It is also linked to the ‘Ramp min. diameter’ function.

Boundary
What’s happening here? An explanation of the Parameters in use on this page.
The Boundary page allows us to fine tune how the toolpath is constrained to any
Step Down Management selected boundaries and also controls the Z start / end depth limits within the
The step down management allows the user to control the Z step down for the roughing strategy. In our toolpath.
example we are using :-
Now we can move on to the Boundary page. Click the tab to open this dialogue
Constant: panel.
The system will remove the stock material using the fixed Z step down value of 2mm in our case.
Using this method, any planar areas that fall between two levels will not be machined.

Transition method:
Using this option the user can decide if cutting multiple pockets, whether each pocket should be cut
sequentially, or if thin walls are present, cut them level-by-level.
On the “Boundary” page reproduce the parameters as shown below. Most of the Batch Build the Roughing Spiral toolpath
values will be fine as default, the only one to change is highlighted. Toolpaths can be calculated in 2 ways. They can be processed automatically when
exiting from the machining parameters tabbed dialogue box, or alternatively they
can be calculated using the “Batch Build” technique. This in theory allows a user to
stack several un processed toolpaths in the operations manager and batch
calculate them in one hit.
In our case we only have one toolpath so far but can still calculate it with the batch
build technique.

Highlight the Roughing Spiral strategy inside the operation manager and click the
batch process icon as detailed in the image below.

Click with the Left Mouse button


on the batch process icon to begin
processing the toolpath..

Make sure the Roughing Spiral is


selected in the Operation Manager.

Now that the toolpath has been calculated lets display it on the screen, this can be
done from the operation manager.
Click next to the Roughing Spiral
strategy to display the toolpath. A
red tick will appear.
Next we will calculate the toolpath P.T.O

The resulting toolpath.


Now we have a toolpath displayed on the screen the cutter can be animated to
show the tool movement at each Z level.
Roughing
Rest Roughing Spiral
From the Operation Manager click the Toolpath Simulated Display toolpath.
In this example we will continue with the previous
model which should now have 1 roughing cut
applied to it.
Click the Toolpath
Simulated Dislpay
icon to animate the Rest roughing is done after at least 1 toolpath has
toolpath. already been created, the option for Rest Roughing
will not appear in the New Operation list until this
condition has been met. Rest Roughing removes
Use the controls on the left side of the screen to control the various display properties the material left by the previous cutter, and can be repeated several times with
of the toolpath. different size cutters. Although similar to finish rest machining, Rest Roughing
recognizes large amounts of material that still remain and adjusts the passes
Click the Show Tool icon to show the tool moving on the screen. accordingly in order to plunge safely into material, and approach safely from outside
the material. You will get different results, depending on what values you enter.

Enable the Shaded Tool icon to show the tool in shaded representation. Now create a new Rest Roughing Spiral strategy.

This icon will display all the Z level steps. Click the New
Operation icon to
create a new strategy.
These 2 icons show only the top or bottom levels respectively.

These 2 icons allow the stepping up and down through each Z level.
From the following dialogue window select the Roughing Spiral strategy and then
pick ‘OK’ to confirm this.
The image to the right
shows the tool displayed
using the icon to step
down the Z levels.
Let’s edit the parameters for this toolpath by double clicking on the Rest Roughing
In this example, use a 20mm diameter cutter with a 5mm corner radius. Enter the Spiral strategy in the operation manager.
cutter parameters as shown in the dialogue below. Note: - If you are unsure how to
access the cutter parameters please refer to the Roughing tutorial or the Tool Libraries
guide.

Double click here to access


the parameters for this
strategy.

Enter the parameters shown on the Machining tab in particular adjust the Stock
oversize and the Step Down.

Add some default feeds and speeds from the “Cutting parameters page” and set
the tool defaults. An example is shown below.
Now click onto the Remachining tab, this is one of the most important pages for this The system will now create a stock model (not seen by the user) based on the
strategy as this is the place where the user can reference previously calculated reference toolpath(s). The Rest Area passes will be based on a comparison between
roughing toolpaths. the actual model and the stock model.
From the remachining tab there are several parameters that will effect the quality of
the stock model and toolpath behaviour.

Tolerance: The amount the cutter can move


above or below the surface. The smaller the
value the more accurate the calculation.

Resolution: This is the granularity of the


Click the Reference Operations icon to begin to calculation - the smaller the value, the finer the
add the roughing cut to reference against. detail, but the calculation is slower. Using a larger
resolution will decrease detection time, but may
Select the previous roughing cut as the reference operation, this should be the only lead to very small features being missed.
one available.
Stock offset: This is an extra thickness that can be
temporarily applied to the cutter and can be set
when editing passes using a stock model. Use of
the Stock Offset parameter can help to create better-trimmed passes. A negative
value will cause the system only to select passes that are below the surfaces of a
stock model by the specified amount, while a positive value will select all passes that
are within the specified distance from the surfaces of a stock model.
Click the transfer button to pass the
Roughing Spiral cut to the right hand Before confirming the machining parameters go
column so it can be referenced. to the Boundary tab and make sure ‘Use defined
boundary’ is checked.

Select OK to confirm the choice of the Roughing Spiral strategy. The reference
operations box should now be displaying 1 to indicate only 1 item is being
referenced.

The resulting toolpath will now only


attempt to machine areas left over from
the previous referenced operation.
In this example, Select ‘T5 – 26mm R5 Bull Nose’ from the available cutters list as
Roughing shown below.
Against a 3D Stock Model

The process of roughing against a stock model is very necessary when machining
castings. More than often the casting model needs to be machined down to a
finished component size. To avoid excessive cuts and moves when roughing away
the casting it is important to be able to reference the actual rough casting model as
a stock model rather than roughing to a generic bounding profile.

Open the file pump.wkf

Now create a new Roughing Spiral strategy.

Click the New


Operation icon to
create a new strategy.

From the following dialogue window select the Roughing Spiral strategy and then
pick ‘OK’ to confirm this.

Make sure that you have filtered the Mesh selection so that the stock mesh(casting)
cannot be picked from the screen. Now pick the purple solid model as the machining
piece. Disable the mesh filter and
then pick the purple solid
for the machining piece.
Check that you are using similar Now add the geometry using the same dialogue window.
values to those shown below for
the triangulation of the model for Click on the Add Geometry
machining purposes, the chordal icon to begin the selection of
tolerance is set at 0.1 for a the geometry from the screen.
Roughing type of cutting
Strategy. Note: - It is possible to select Meshes,
Solids and Surfaces when using the By
Solid stock definition.

The Stock offset determines the


material to be removed or retained
from the surfaces of the stock. The
same value is also used for the
Adding the Stock Model machining of semi-finished
components (typical of die casting),
Now we need to select the Roughing Stock model to limit our roughing cuts against. when the "stock offset" value is set.
Look at the operation manager and double click on the Stock Geometry item nested
under the Roughing Spiral strategy. Select the mesh model from the screen as the stock model item. Make sure that you
filter only the Mesh when picking the geometry from the screen to avoid picking the
solid model.
Enable the mesh filter and
then pick the grey mesh for
Double click the Stock the stock model.
Geometry item to begin
adding the casting model.

From the next dialogue window make sure you use the drop down window to select
the correct geometry stock type.

Click on the drop down arrow


to select stock type and select
the option By Solid The strategy should now contain 1 Model and 1 Stock model as shown below.
Let’s edit the parameters for this toolpath by double clicking on the Roughing Spiral Now click on the Approach / Retract tab and use a plunging type of approach.
strategy in the operation manager.

Now calculate the toolpath by clicking OK from the dialogue box. The calculation
Double click here to access takes a little longer when trimming back to a stock model.
the parameters for this
strategy. As you can see the toolpath is now trimmed back to the stock model the down side
of this kind of process is that there are more rapid moves introduced into the
toolpath.

Enter the parameters on the machining as shown below, the values that need to be
changed have been highlighted.

Trimmed toolpath with rapid


moves shown.

Trimmed toolpath with rapid


moves hidden for clarity.
Enter the parameters of the Roughing Spiral toolpath and go to the Approach /
Roughing Retract tab. Click on the Use Drill Points checkbox to enable the selection of drill
Roughing Spiral - Predrilled point points, and then press the selection icon as indicated below.

To prevent a cutter from plunging into hard


material at a given point sometimes it is
preferable to have the cutter enter into a hole
that has previously been created by a drill. The
roughing strategies in VISI-Machining allow us
to do this by specifying pre-drilled points.

Open the file Rcavity-predrilled.wkf

The file already contains a Roughing Spiral


toolpath where the system has calculated the
current plunge point. Also note that the Helix
Click here to begin the ramping parameters are
selection of drill points from disabled once we use the drill
Switch on the toolpath display using the operations manager to see the current
the screen graphics area. points option.
toolpath.

Select the drill point as indicated in the image below.

Click here beside the Select this point as the pre


Roughing Spiral strategy to drill entry point.
enable the red ‘tick’. This will
display the toolpath in the
graphics area.

Click OK from the Add /


remove points dialogue box
Also from the Approach / Retract tab make sure the plunge co-ordinates are closer to Open the file multiple drill points.wkf
the drilled entry point to avoid making the cutter have to travel a long way across
from the drill point to the plunge co-ordinate area. This move is performed as a
cutting feed move and would mean the cutter traveling across the job whilst cutting Using what you have learned from the
at full width. previous example open the machining
parameters for the toolpath that
already exists and add the 6 points for
each cavity.

This co-ordinate represents the centre of the machined piece adjust your values to
suit.

Now recalculate the toolpath using either Auto Rebuild from the machining tab form
or Batch Build from the operation manager.

The image below shows the cutter now vertically approaching the preset drilling
point.

This diagonal move represents


the cutter travelling from the
pre drill position to the plunge
co-ordinate influenced start
point.

Note: - It is not possible to use a Plunge Point that is outside of the model geometry.
Remember, the Plunge area coordinates dictate which pocket the tool will start in first
USING MULTIPLE DRILL POINTS and ultimately the machining order.

In the previous example only one drill point was used as a pre drilled entry point.
However if your file contains multiple cavities, each requiring the tool to enter at a
specified drill point then more than one point can be picked.
Now create a tool appropriate for roughing out this job.
Roughing
Roughing Spiral - Core In this example, use a 30mm End Mill cutter. Enter the cutter parameters as shown in
the dialogue below. Note: - If you are unsure how to access the cutter parameters
Core roughing is almost identical please refer to the Roughing tutorial or the Tool Libraries guide.
to Cavity roughing, except for a
couple of toggle switches that
need to be checked, in order to
get the result we are looking for.
As the name suggests this type of
roughing strategy is suited to
Core types of model geometry
where the tool will machine the
part from the outside to the
inside.

Open the file core-roughing.wkf

Now create a new Roughing Spiral strategy.

Click the New


Operation icon to
create a new strategy.

From the following dialogue window select the Roughing Spiral strategy and then
pick ‘OK’ to confirm this.

Add some default feeds and speeds from the “Cutting parameters page” and set
the tool defaults. An example is shown below, you can enter feeds ands speeds that
you feel appropriate.
Now select the model from the screen area. Check that you are using similar values
to those shown below for the triangulation of the model for machining purposes, the Enter the parameters on the Machining tab as shown below. The important area to
chordal tolerance is set at 0.1 for a Roughing type of cutting Strategy. note on this form is the Core Management area. Make sure that the Detect core
areas is flagged.

Let’s edit the parameters for this toolpath by double clicking on the Roughing Spiral
strategy in the operation manager.

Horizontal link clearance

For core roughing, the cutter enters the materially horizontally from outside the part.
This parameter defines the distance outside the part from which the cutter will start.
Double click here to access Note that this parameter is only active if detect core areas is switched on.
the parameters for this
strategy. Now switch to the Boundary tab and make sure the box is checked for the parameter
Use defined boundary. This will ensure that the toolpaths will be constrained to the X
and Y bounding box for the part.
Select OK to calculate the toolpath and then run the toolpath simulated display from Points to NOTE about Core Roughing
the operation manager.
The very first Z level is the only level at which the user can influence the entry point for
the cutter. The parameter that effects this position is shown below. Go to the
Approach / Retract tab and look at the Plunge area coordinates.

Use this icon to pick an area


for plunging.

Here is the full Core


Roughing Toolpath result.

It must be stated that this coordinate is not an EXACT coordinate point but is used to
Now use the simulated display to check the result. define the general area of the plunge, the software will then dictate the exact
Click the Toolpath position of the plunge.
Simulated Display to
animate the cutter at each
level. Select the icons shown Here is the plunge point
below. on the 1st level of our
example, influenced by
the plunge area
coordinates 0, 106.

On subsequent Z levels of the toolpath the system will pick the entry points and these
points should always be from outside of the part.

Try experimenting with the Plunge Area Coordinate to see how it influences the
position of the tool.
Tool approaches from
outside of the part and
works inwards to wards the
core form.
In this example, Select ‘T5 – 26mm R5 Bull Nose’ from the available cutters list as
Roughing shown below.

Roughing Zig-Zag
Zig-Zag roughing is an effective
strategy for cutting softer materials
such as aluminium, graphite, copper
and various types of modeling
board. It is also a very good strategy
to employ if the machine tool being
used cannot process too many
circular movements as this strategy
has a lot of liner point to point
movements and fewer arcs.

Open the file Zig-Zag-Rough.wkf

Start the Operation Manager and begin by adding a Constant Z toolpath.


Machining > Operation Manager

Select the “New Operation”


menu to create the new
operation.

Now select the model from the screen area. Check that you are using similar values
to those shown below for the triangulation of the model for machining purposes, the
Pick the New Operation “Roughing Zig-Zag” chordal tolerance is set at 0.1 for a roughing type of cutting Strategy.
The Offset value represents the distance between the ZigZag path and the
Let’s edit the parameters for this toolpath by double clicking on the Roughing Zig-Zag contouring passes within each level of the toolpath. This parameter is necessary to
machining strategy in the operation manager. clean up the cusps left on the part after the Zig-Zag passes have removed the bulk of
the material.
The default value is [flat radius tool] * 0.45 for flat and bull nose cutters, while it is
forced to equal zero on Ball tools.
In our example(26 R5 tool) this equates to 8 x 0.45 = 3.6

Now switch to the Boundary tab and make sure the box is checked for the parameter
Use defined boundary. This will ensure that the toolpaths will be constrained to the X
Double click here to access and Y bounding box for the part.
the parameters for this
strategy.

Enter the parameters on the Machining tab as shown.

Click OK to calculate the passes. The image below shows one Z level pass of Zig-Zag
roughing. You can see in the images here, the effect of the offset parameter.

Contour pass added around


In this example we are using a Stock oversize of 0.5mm and a Step Down value of the model to clean up the
5mm with a Step Over percentage of 45 percent. cusps left from the Zig-Zag
passes.
Step Down Management - Auto The Resulting Toolpath – The extra levels have been added where required.

So far all the roughing strategies have used a Constant Step down in the Z axis. The
last thing we will change on this example is the type of step down used.

Go back to the machining parameters and click on the Transitions tab. Change the
values to represent those in the image below.

Click the Auto button.

Auto: - Using this option, the system will


automatically add extra Z slicing levels in
between the main roughing levels. These
extra steps are part of the roughing
operation and cannot be closer
together than the value specified in the
minimum step over.
This method is very useful when the part
being machined contains many shallow
faces at different Z levels.
Extra Z levels have been
added into the toolpath
Precision where the conditions are
This value controls how accurately the system finds the appropriate Z height at where met.
to insert a new Z level slice.

Extra Pass
This value relates to the maximum horizontal distance between two adjacent Z level
slices. If the horizontal distance between the two Z level slices is greater than the
specified value, an extra Z slice is added. Using this parameter you will be able to
control how many extra slices are required on the ‘flatter’ areas to ensure a constant
stock volume is left for secondary machining operations. The smaller the value for
extra pass the more Z slices will be calculated by the system.

Now rebuild the toolpath and check the results. If you zoom into the toolpath you
can see that there have been extra levels introduced. P.T.O
Double click on the Roughing Spiral strategy to access the machining parameters for
Roughing this strategy. Go to the General tab and look at the ‘Consider Tool Holder’ parameter
this needs to be checked to enable holder collision detection.
Checking Collisions
When creating a set of machining toolpaths it is critical to check that the selected
tooling and holder assembly can machine the passes without collision. If you choose
to make use of this functionality any collisions that are detected are automatically
trimmed out from the areas the tool and holder cannot access.

Open the file roughing with toolholder.wkf

Open the Operation Manager and you will see a pre calculated toolpath.

Display the toolpath by


enabling the Red Tick.

If you animate the toolpath using the ‘Toolpath Simulated Display’ and step down to
the lower levels of the toolpath you can see a tool holder collision.

Important Info About Holder Clearance

Holder clearance
Defines the safety distance between the holder and the model geometry.

The Roughing operation fully gouge checks the Tool holder against both the part
Tool holder shown gouging model and the un-machined stock model.
with workpiece.
For Finishing paths please note that this value represents ONLY the distance between
the holder and the model geometry. Any stock oversize is not considered. Therefore
this value must always be larger than any stock oversize value.
Now rebuild the toolpath to see the effect of Toolholder collision checking. Tool Presetting Length

With tool holder collision detection applied. A second method of preventing a collision
with the workpiece is to calculate the ideal
length of tool required for currently applied
toolpath.

Again open the file Open the file roughing


with toolholder.wkf

From the previous example we already


know that there will be a collision with the
holder and workpiece, but we do not know
how long the tool should be if we wanted to
adjust the tool to a length that will cut the
part without problems.

Open the Operation Manager and you will see a pre calculated toolpath.

Toolpath has been trimmed


away where there would be
a collision between holder
and the workpiece.

No Tool holder collision detection applied. Select the Roughing Spiral


strategy from the operation
manager.

Now click the Tool Length Check icon from the Operation manager Toolbar.

Toolpath has machined to


the very bottom of the cavity Click the Tool Length check
which will introduce a icon.
collision.
The tool length dialogue box will now appear. If you now perform a tool path simulation you will see that the tool is now detached
from the holder, this is because the presetting length has been adjusted (the amount
the tool is out of the holder) but not the overall length of the tool.
Details of the current tool.

This is the current length Notice that the Tool appears


that the tool is protruding detached from the holder.
out the holder.

Represents a specified tolerance


around the tool holder and tool
shank which is taken into
account when checking for
collisions. No collision will be
considered if the interference
will be in this tolerance.

Leave the settings as shown in the image and now calculate a new presetting length. Now edit the Tool and make the total length suitable as shown below.

Click the Compute Presetting


to begin the tool length
optimisation.

Take a look at the prompt bar in the bottom


left corner as it displays the amount of
collisions detected during the calculation.

Notice that the Tool


Presetting length has now
been adjusted.
Take a look at the Tool holder parameters to check the tool and holder assembly,
now everything seems to be in order.

After editing the tool select OK to confirm and select YES to update the operation
parameters and cutting conditions.

Tool Holder now misses the


part with the preset length of
100mm.
Welcome to VISI Machining 3D

In this training documentation it is assumed that the user is familiar with the basic
navigation of VISI Machining and the Operation Manager, so only parameters
relative to the machining strategy will be explained in detail.

Once you have created the first toolpath, you will notice that the dialog boxes
remain consistent for the majority of the toolpaths, which considerably reduces the
learning process.

What is Covered in this Chapter?


Semi&Finish Semi & Finishing

Constant Z
Parallel Plane
Parallel Plane Cross Machining
Planar Face Machining
3D Stepover
Radial
True Spiral
Contour Projection
Tracing 3D
ISO Machining
Semi & Finishing In this example, use a 12mm diameter cutter with a 3.5mm corner radius. Enter the
cutter parameters as shown in the dialogue below. Note: - If you are unsure how to
Constant Z access the cutter parameters please refer to the Roughing tutorial or the Tool Libraries
guide.
Open the file Waterline.wkf

Start the Operation Manager and begin by adding a Constant Z toolpath.


Machining > Operation Manager

Select the “New Operation”


menu to create the new
operation.

Pick the New Operation “Constant Z”

Add some default feeds and speeds from the “Cutting parameters page” and set
the tool defaults. An example is shown below.
Now select the model from the screen area. Check that you are using similar values Enter the parameters on the Machining tab as shown below.
to those shown below for the triangulation of the model for machining purposes, the
chordal tolerance is set at 0.05 for a finishing type of cutting Strategy.

Let’s edit the parameters for this toolpath by double clicking on the Constant Z
strategy in the operation manager.

Significant Parameters Used Here

Stock Oversize: - We have set a value of zero here so the piece is finished to
Double click here to access component size.
the parameters for this Step Down: -Each Z level pass will be calculated at constant 0.5mm depth increments
strategy. Machining Strategy Unidirectional: - The cutting strategy will be moving in one
direction only as opposed to changing direction at the end of each pass.
Notice that the dialog box is very similar to the ones used during roughing. This Step Over Mode Constant: - The passes will be calculated at a constant Z pitch of
strategy is most effective on steeper surfaces. This is because the spaces between the 0.5mm with no intermediate passes calculated.
passes are calculated from the stepdown value, and on surfaces where there is little Auto Rebuild: - With this switched checked and when the ‘OK’ button is clicked the
z-level change, the spaces between the passes are greater and you may get toolpaths will be calculated straight away.
unsatisfactory results. You can therefore limit the work area to surface angles
between, for example, 40 and 90 degrees. Limit your passes to work within an angle Now switch to the Boundary tab to change some of the machining limits.
range, to get the best results for the tool.
Look at the parameters shown below and change those that are marked in the red As you can see from your toolpath the Z steps stay a constant pitch all the way down
box. the job and the motion is in one direction only.

Parameters To Change.
Let’s make some subtle changes to the toolpath by adjusting the parameters of the
strategy.

Ramping Between Levels

Open the machining parameters again and go to the Transitions tab. In this instance
we will make the tool ramp between each Z level to try and eliminate a constant
witness line down the part. Adjust the parameters as shown below and select ‘OK’ to
calculate the toolpath.

You can visibly see the


ramping between each level
around the part.

Tangential Link
Min Z Level: - Here we have set the Z level for the passes to fall between 0 and 29, this
ensures that the passes are calculated around the main form and do no machine Try checking this option to see the difference between this and a standard ramping
around the outside of the part base and do not drop below a Z depth of 29. option.
Without changing any other parameters click the ‘OK’ button to calculate The ramp will blend in and
the first set of passes. out of each Z level with a
smooth tangential motion.

Trim to ramp

Finally try checking this option and again


compare the difference. You should see in areas
where it is achievable , that Z level passes are
trimmed back to meet the start and the end of
the ramp transition.
Ramp trimming occurs in this area
and helps eliminate witness marks.
Constant Z with Adaptive Stepdown that meets all requirements is found. The smaller the number here, the more likely
extra passes will be found.
When using a Constant Z strategy with a constant step down on a part that is not
completely steep or completely shallow, it is very likely that in the shallow areas there Let’s look at the results in our
will be large gaps between passes. To combat this problem and create some example.
intermediate passes we can use As you can see extra passes
the “Stepover Mode” Adaptive. have been inserted into the
areas where there were
Open the file AdaptiveZ.wkf previously large horizontal
voids between each Z level.
Looking at the passes already You can experiment with
applied to the part it is clear to the 3 parameter values to
see that using the “Constant” obtain different results.
step down method does create
areas where the passes are
widely spaced horizontally and Constant Z with Drive Curve
would result in a poorer surface
finish. Another good solution for
creating “intermediate”
Open the cutting parameters for passes on parts that have a
this strategy and go to the combination of steep and
Machining tab. shallow areas is to use the
Step Over Mode Drive Curve.
Here is an example of how this option works.

The information on the file for the boundaries and the drive curves has already been
generated and the information needs to be present before the options can be used.
Go to the “Step Over Mode” drop down and switch it to Adaptive, this will open up 3
new parameter boxes, enter the values as shown below. Click OK to calculate. Open the file “Multiple Curves no machining.wkf”

Minimum Step Over: - This specifies the minimum stepdown value to be used for the in
between passes, meaning passes will be no less than this distance from each other.
Precision: - This controls how accurately the system finds the appropriate height to
insert a new slice.
Extra Pass: - This parameter relates to the maximum change in the surface profiles for
two adjacent z-levels. Having calculated the surface profile at a given z-height the
profile at the next z-value is provisionally calculated. The maximum value of the
shortest horizontal distance between adjacent points on the two profiles is then
calculated. If the change in profiles from one z-level to the next is greater than the
Profile Step-in, then the provisional profile is discarded. An adjustment is then made to
the z-level so that an extra profile is inserted. This process is repeated until a profile
If you need assistance in generating these curves or profiles then please ask for Pick the model and confirm
assistance.
Generate a new machining operation using the “Constant Z” strategy using a “6mm
Ball Nosed Tool”

Select the 3 yellow profiles as machining boundaries. If you are unsure how to do this
please ask your tutor for more help.

SELECT THESE 3
PROFILES
Open the operation Parameters and change the “Step-Over Mode” to “Drive Curve” The step on the curve is calculated as shown in the diagrams below: -

Constant Z step Z levels using drive curve

The next step is to choose the drive curve/s


Select the “Pick Drive Curves” icon.

NOTE
Single or Multiple drive curves can be used for this option.
Select the 3 blue curves highlighted below: -

Once the drive curve option is selected then the “Step on curve” becomes active
and the “Step down” is now unavailable.

The “Step on curve” now relates to the step along the curve and not the step in Z, as SELECT THESE 3
is the default option. CURVES

The option of having the step along the curve allows greater control of the slices
along the model and this is particularly useful for components that have a shallow
angle.
Select “OK” to accept the curves Constant Z Helical

The last option to investigate within


the parameters of the Constant Z
strategy is another Transition based
parameter, Helical. Let’s see its
effect with an example.

Open the file Helical Machining.wkf

Activate the “Auto Rebuild” flag (Machining Tab) and switch on the option for the
rapid management from the Boundary tab to “Safety Distance” and generate the
toolpath.
Start the Operation Manager and begin by adding a Constant Z toolpath.
HINT!!!! Machining > Operation Manager

Select the “New Operation”


menu to create the new
operation.

The result will be as below with the Z levels adjusted to the drive curves, shown here Pick the New Operation “Constant Z”
with the Rapids hidden from the display.
In this example, Select ‘T3 – 6mm Ball Nose’ from the available cutters list as shown
below. Let’s edit the parameters for this toolpath by double clicking on the 2 Leading Curve
Machining strategy in the operation manager.

Double click here to access


the parameters for this
strategy.

Enter the parameters on the Machining tab as shown. Add a Step-down value of
1mm in the Stepdown box.

Now select the model from the screen area. Check that you are using similar values
to those shown below for the triangulation of the model for machining purposes, the
chordal tolerance is set at 0.05 for a finishing type of cutting Strategy.
Now switch to the Transitions tab and focus on the Transition method parameters. Constant Z Helical – Removing the toolpath “lifts”.
Switch the Transition method option to Helicoidal as shown in the image.
As you can see from the image and the toolpath
From the Boundary tab make sure that the Min Z Level values are set as shown below itself, where the part has a totally vertical wall the
so that the toolpath will not fall over the edges of the main rectangular base area of Helical transition can produce some anomalies. This
the part, i.e we are restricting the Z limits to which the toolpath can be applied. can be solved by reducing the machining tolerance
slightly.

Go to the General tab and slacken off the machining


tolerance to a value of 0.03 as shown below.

This should solve the problem and produce a better quality toolpath with out the
small spikes.

Now click the OK button to calculate the toolpath. The result is shown below.
The toopath motion should be totally Helical, in this case there is one approach and
one retract move. This option ensures that there are no marks left on the part and if
necessary will
automatically switch to
a normal Constant Z
transition if a Helical
transition cannot be
achieved. There will also
be a clean up pass
applied on any flat
areas of the part. Check
out the very bottom
pass on this part, this is a
horizontal clean up
pass.

Note: - You will instantly


notice some strange
toolpath “lifts” at the
near vertical area of the
part. P.T.O for advice.
Semi & Finishing In this example, use a 12mm Ball Nose diameter cutter. Enter the cutter parameters
as shown in the dialogue below. Note: - If you are unsure how to access the cutter
Parallel Plane parameters please refer to the Roughing tutorial or the Tool Libraries guide.

Open the file raster.wkf

Start the Operation Manager and begin by adding a Parallel Plane toolpath.
Machining > Operation Manager

Select the “New Operation”


menu to create the new
operation.

Pick the New Operation “Parallel Plane”

Add some default feeds and speeds from the “Cutting parameters page” and set
the tool defaults. An example is shown below.
Now select the model from the screen area. Check that you are using similar values Enter the parameters on the Machining tab as shown below and select ‘OK’ to
to those shown below for the triangulation of the model for machining purposes, the calculate a basic toolpath. Later other options will be changed to see the
chordal tolerance is set at 0.05 for a finishing type of cutting Strategy. differences.

Let’s edit the parameters for this toolpath by double clicking on the Parallel Plane
strategy in the operation manager.

Significant Parameters Used

Double click here to access Stock Oversize: - We have set a value of zero here so the piece is finished to
the parameters for this component size.
strategy. Step over: -Each pass will be calculated at a constant horizontal pitch of 0.5mm
between each pass.
Machining Strategy Zig-Zag: - The cutting strategy will be move the cutter in two
directions changing direction at the end of each pass, moving back and forth across
the piece.
Raster Passes are spaced perpendicularly to the tool axis. Consequently, this
Stroke Angle: - The passes will be calculated at 45 degrees across the job, this is
machining strategy is most effective on shallow (nearing horizontal) surfaces. The z-
sometimes good way of ensuring a better overall finish where surfaces may be
height of each point along a raster pass is the same as the z-height of the
otherwise parallel to the machining direction e.g zero degrees.
triangulated surfaces, with adjustments made for applied thickness and cutter
Auto Rebuild: - With this switched checked and when the ‘OK’ button is clicked the
definition.
toolpaths will be calculated straight away.
Let’s look at the results in Zoom into the top left or bottom right corner of the job and you will notice that there
our example. is a strange ZIG ZAG movement in a small portion of the toolpath.
As you can see, passes
have been calculated at To remedy this undesirable movement we need
the desired pitch moving to tweak another parameter.
back and forth across the
job at a 45 degree angle. Go to the Transitions tab and look at the
parameter “Min.Step-over without lift off”.
Currently set at a value of 12mm. This value sets
the minimum acceptable toolpath length before
the tool will lift off the job. In this case the length
Parameters To Change. of the passes in these areas falls below the 12mm limit. Look at the dialogue below
Let’s make some subtle and change the value as shown. Click ‘OK’ to calculate the toolpath.
changes to the toolpath
by adjusting the
parameters of the
strategy.
Go to the Machining tab
and switch the direction to Unidirectional and click OK to calculate the passes.

Once calculated the toolpath should now lift


off from the job at the end of each pass as
shown in the image. The value of 0 ensures
that this will happen in all areas where there a
small pass lengths.
Note: - The rapids have been hidden to help clarify the image.

Parallel Plane – Pass Extension

One very useful feature inside the parallel


plane strategy is the ability to extend the
toolpaths beyond the limits of the machined
piece without the need to provide run off
surfaces.

Now note that each toolpath Open the file pass extension.wkf
lifts of at the end of each
pass to maintain motion in
one direction.
Add a new Paralell Plane toolpath to the project in the operation manager and On the Machining tab enter the basic parameters a shown below, adjusting the Step
select a tool from the existing default library. Choose T4 – 10mm Ball Nose cutter. Over and the Stroke angle values as indicated.

From within the Operation Manager enter the machining parameters for the strategy.
From the Transitions tab change the Pass Extension
value so that the toolpath will be extended beyond
the boundary.

Next, move to the Boundary tab to constrain the


toolpath to the XY bounding rectangle of the piece.

Double click here to access


the parameters for this
strategy.
Take a look at the result of the standard pass extension, as you can see the passes Semi & Finishing
are extended but will start to drop down the sides of the part as the toolpath is
extended. Ÿ Parallel Plane Cross Machining

To see an alternative result, try using the Tangential option. Go back to the Transitions This strategy builds on a set of existing
tab change the Pass Extension value so that the toolpath will be extended further. Parallel Plane passes. It creates a new set
of passes at right angles to the original
set. The new passes can be used to
machine gaps left in the original passes,
The toolpath now extends e.g. where the surfaces and the passes
beyond the machined piece
were approximately parallel.
but this time the extension is
tangent to the surfaces.
Open the file cross-raster.wkf

Start the Operation Manager and begin by adding a Parallel Plane toolpath.
Click OK to calculate the toolpath with the new extension
Machining > Operation Manager
Parameters.

Select the “New Operation”


menu to create the new
operation.

Pick the New Operation “Parallel Plane”


In this example, Select ‘T3 – 6mm Ball Nose’ from the available cutters list as shown Next add a restriction boundary to the strategy to stop the tool rolling over the edges
below. of the part.

From the lower split panel in the Operations manager double click on the Boundary
List item nested under the Parallel Plane strategy.

Double click the Boundary


list item to add a restriction
boundary to the part.

Now pick the boundary from the screen as shown in the image below.

Select the Profile boundary


from the screen

Now select the model from the screen area. Check that you are using similar values
to those shown below for the triangulation of the model for machining purposes, the
chordal tolerance is set at 0.05 for a finishing type of cutting Strategy.

The profile should now be added as a Cut Boundary under the Boundary list item.

Profile has now been added


as a cut boundary.
Let’s edit the parameters for this toolpath by double clicking on the Parallel Plane Cross Machining Passes.
strategy in the operation manager.
Go to the Machining tab and focus on the Cross Machining part of the form. Change
the option from “None” to “Standard” and click OK to calculate the passes.

If we Zoom in to the same corner again


you will notice that there are now extra
Double click here to access passes perpendicular to the original passes
the parameters for this where the spacing of the tool path was
strategy. sparse.

First let’s create a standard Parallel Plane toolpath on the part. Go to the Machining What do the options mean ?
tab and adjust the parameters as shown.
Please try changing the options to see the results!
Here we will use a Step Over of 1mm and a Stroke angle of 45 degrees, select OK to
calculate the basic passes.
The regular Parallel Plane passes are
Zoom into the corner of the part and take calculated, and then the Cross
note that the passes a quite sparsely Machining passes are added at the
spaced as the toolpath becomes almost end of the strategy.
parallel with the machined surfaces.

The cross machining passes are


calculated before the original Parallel
Plane passes.

Only the Cross machining passes are


calculated. (See image)

Let’s edit the toolpath to apply some cross machining passes and see how they can
help this situation.
Semi & Finishing In this example, use a 30mm diameter End Mill type cutter. Enter the cutter
parameters as shown in the dialogue below. Note: - If you are unsure how to access
Planar Face Machining the cutter parameters please refer to the Roughing tutorial or the Tool Libraries guide.
When you select Horizontal Area Passes, VISI Machining will find all the flat areas of
the geometry and put passes at the z-level of each area. Horizontal Area Passes act
only upon completely flat areas – if a surface has even a small gradient, it will not be
detected. However, you can use Axially Offset Passes with Horizontal Area Passes.
Axially Offset Passes machine the same passes a number of times, offset along the
tool axis.

Open the file horizontal area.wkf

Start the Operation Manager and begin by adding a Planar Face Machining
toolpath.
Machining > Operation Manager

Select the “New Operation”


menu to create the new Add some default feeds and speeds from the “Cutting parameters page” and set
operation. the tool defaults. An example is shown below.

Pick the New Operation “Planar Face Machining” and select ‘OK’
Now select ALL the model from the screen area. Check that you are using similar Here are the parameters for the Planar Face machining toolpath set in the Machining
values to those shown below for the triangulation of the model for machining tab.
purposes, the chordal tolerance is set at 0.05 for a finishing type of cutting Strategy.

Let’s edit the parameters for this toolpath by double clicking on the Planar Face
Machining strategy in the operation manager.

Significant Parameters Used

Double click here to access Stock Oversize: - We have set a value of zero here so the flat areas are finished to
the parameters for this component size.
strategy. Step over range: -This is the range of the size of spaces between the passes, defined
by the minimum and maximum value you set here. VISI Machining will pick the largest
value possible within that range that does not leave unwanted upstands between
the passes. You can lower the min and max range value to have narrower passes.
Auto Rebuild: - With this switched checked and when the ‘OK’ button is clicked the
Enter the parameters on the Machining tab as shown on the next page and select
toolpaths will be calculated straight away.
‘OK’ to calculate a basic toolpath.
The result of the Planar Face Machining should be similar to the image shown below. Open the file 2Leadingcurves.wkf

In fact there are not so many parameters that will influence this type of path so no
further parameter changes will be discussed.

Start the Operation Manager and begin by adding a Parallel Plane toolpath.
Machining > Operation Manager

Select the “New Operation”


menu to create the new
operation.

Pick the New Operation “2 Leading Curves”

Semi & Finishing


2 Leading Curves

2 Leading Curve passes are passes that "flow" across the surface and are virtually
parallel to each other, rather like raster passes, but the shape and direction of the
passes are controlled by the boundaries around them.

Each pass echoes the shape of the preceding one but also takes on some
characteristics of the following pass, and so the paths "morph" or gradually change
shape from one side of the boundary to the other.

This machining strategy is most effective on areas that include shallow surfaces as the
passes are spaced along the xy-plane (stepover), and not the z-plane (stepdown).
In this example, Select ‘T3 – 6mm Ball Nose’ from the available cutters list as shown Using the ‘Block Control’ icon to pick the 2 Leading curves needed for the machining.
below.

NOTE :

It is also possible to depress the


Block control control (CTRL) key instead of
using the ‘Block control’ icon.

Select the 2 curves starting with the curve on top of the radius and then the curve
around the bottom of angled walls.

Pick this curve first

Now select the model from the screen area. Check that you are using similar values
to those shown below for the triangulation of the model for machining purposes, the
chordal tolerance is set at 0.05 for a finishing type of cutting Strategy. Pick this curve second

NOTE :
The order in which you pick the curves is important, as this will determine the
machining direction.

The status of the curve is also very important when using this strategy. If the start and
end points do not coincide on both curves and the curves do not travel in the same
direction, then the toolpath will not give the required result. Some of the common
problems will be described later.
Let’s edit the parameters for this toolpath by double clicking on the 2 Leading Curve Some Useful Tips to consider before calculating a 2 Leading Curve toolpath.
Machining strategy in the operation manager.
Some common problems encountered with this strategy are shown below. All
problems are due to the condition of the curve. I.e. Start points and direction.

Double click here to access


the parameters for this Both curves OK
strategy. Start points OK, Curves in
same direction
Perpendicular flag in-active
Enter the parameters on the Machining tab as shown below and select ‘OK’ to
calculate a basic toolpath. Later other options will be changed to see the
differences.

Both curves OK
Start points OK, Curves in
same direction
Perpendicular flag active

Both curves OK
Start points OK, Curves in
different direction
Perpendicular flag active

Many of the parameters on this dialogue are common to some of the strategies
already used. Here we will explain parameters unique to this strategy.
Both curves OK Both curves OK
Start points OK, Curves in Start points are different,
different direction Curves in different
Perpendicular flag in-active direction

Both curves OK
Start points are different,
Both curves OK
Curves in different
Start points are different,
direction
Curves in same direction
Perpendicular flag in-active

Once all the options are set to obtain the correct result, select ‘OK’ to calculate the
toolpath.

Display the toolpath and see the results. Use the Display and Clear Toolpath icons to
show the toolpath. The result will be as shown below.

Toolpath morphs from one


curve to another and flows
around the shape, parallel to
the drive curves.

Both curves OK
Start points are different,
Curves in same direction
Perpendicular flag active
Investigating the options We are now going to use the segments to synchronise the toolpath

Go to the Machining tab and activate the option Perpendicular mode. Expand the option in the ‘Drive curve’ option from within the operations manager
and double click on ‘Synchronisation Lines’

Perpendicular Mode
With this option flagged the system will calculate the machining perpendicular to the
2 drive curves. The difference can be seen in
the image opposite.

Toolpath morphs from one


curve to another and but is now
orientated perpendicular to the
curves
Double Click the
Synchronisation lines item
under the drive curve node.
Synchronisation Lines

If we look at the toolpath from the plan view, Now select the 8 segments. It does not matter what order these lines are selected.
you will see that the toolpath looks OK.
However it is possible to improve the quality of
the toolpath using ‘Synchronisation Lines’.
Currently the toolpath between the upper and
lower curves is moving diagonally to & from the points along the curve. This is shown
below
Gradual
diagonal
movement

Select the 8 lines Once


selected use the right
hand mouse button to
‘Confirm Selection’
After defining the synchronisation curves, you will notice the toolpath has turned Semi & Finishing
purple within the operations manager. This means that something has changed and
the toolpath needs to be re-calculated. 3D Stepover
Constant Surface Stepover passes are 3D passes. The passes are at a constant
distance from each other along the surface of the job (regardless of the direction).
This is an ideal strategy to use on the boundaries generated by rest machining, or in
any circumstances where you want to ensure a constant 3D distance between
Click the Batch Build icon passes.
to recalculate the toolpath
using the Synchronisation Open the file constantstepover.wkf
Lines.
Start the Operation Manager and begin by adding a 3D Step Over toolpath.
The operation is coloured Machining > Operation Manager
purple to indicate
modifications have taken Select the “New Operation”
place and recalculation is menu to create the new
required. operation.

Display the toolpath and see the results. Use the Display and Clear Toolpath icons to
show the toolpath.
Pick the New Operation “3D Step Over”

The toolpath is now


constrained between the
Syncronisation lines and
flows around the corner in a
more controlled manner.
In this example, Select ‘T4 – 10mm Ball Nose’ from the available cutters list as shown Next add a restriction boundary to the strategy to stop the tool rolling over the edges
below. of the part.

From the lower split panel in the Operations manager double click on the Boundary
List item nested under the Parallel Plane strategy.

Double click the Boundary


list item to add a restriction
boundary to the part.

Now pick the boundary from the screen as shown in the image below.

Select the “RED”


Rectangular Profile
boundary from the screen

Now select the model from the screen area. Check that you are using similar values
to those shown below for the triangulation of the model for machining purposes, the
chordal tolerance is set at 0.05 for a finishing type of cutting Strategy.

The profile should now be added as a Cut Boundary under the Boundary list item.

Profile has now been added


as a cut boundary.
Let’s edit the parameters for this toolpath by double clicking on the 3D Step Over Here we have adjusted only the Horizontal Step Over and the Vertical Step Over to
strategy in the operation manager. 0.5mm respectively.
Toolpath is stepping over at
a constant pitch and follows
the rectangular boundary
shape.

Double click here to access


the parameters for this
strategy.

Enter the parameters on the Machining tab as shown below and select ‘OK’ to
calculate a basic toolpath. Later other options will be changed to see the
differences.

As you can see from the result, the toolpath maintains a constant 0.5 mm step over
regardless of the contours on the machined piece. Also note that the shape of the
toolpath follows the rectangular boundary shape.

Inverting Step Over and Direction

Continuing with the toolpath already created it is possible to edit the parameters and
change the direction of the toolpath in several ways.

To see this effect more clearly change the Machining Strategy from Zig-Zag to Uni
Directional.

Go to the Machining tab and change the setting, then re-calculate toolpath.
Cutter Direction,
Animate the cutter motion using Anti Clockwise Try calculating the remaining cutter direction / step over combinations from the
Toolpath Simulated Display Approach / Retract tab.

icon .The toolpath now


maintains a constant direction
and can clearly be seen moving
Anti clockwise, from the inside of
the part. You can also see the
step over link moving downwards
towards the bottom of the part.
Step over direction, inside to
out. Cutter Direction,
Clockwise

Step over direction, outside


to inside.

Click on the Approach / Retract tab and now adjust the following options, check the
invert direction box, now recalculate the toolpath.

And finally the 4th combination

Step over direction, inside to


out.

Cutter Direction,
Anti-Clockwise

Cutter Direction,
Clockwise Step over direction outside
to inside.
Options to change the shape of the toolpath. Notice that the toolpath now follows
the definition of the Drive boundary
Using Drive Boundaries shape. Even though we still have
the rectangular boundary selected
Using the Operation manager it is possible to add a Drive boundary(s) to influence as a cutting boundary, it is ignored
the shape of the toolpath but also place restrictions on the toolpath. Let’s see how because the Drive is inside of the
this works. Cutting boundary (limit boundary).

Double click on the Drive


Boundaries item to add a Here is another scenario using a
new Drive boundary. combination of Limit and Drive
boundaries that will control the
shape of the toolpath.

We will be using a different set of


Now select the Green Profile boundary as the Drive boundary definition. Limit Boundaries and Drive
Boundaries.

Click on the Green Profile From the operation manager


Boundary item to add this Double click the Boundary list
perform the following modifications:-
as a new Drive boundary. and then select the smallest
yellow boundary in the centre.

Recalculate the passes by clicking the Batch


Build icon from the Operation Manager, it is
not necessary to go back into the machining
parameters.
Click on the Batch Build
icon to recalculate the
toolpath. Double click on the Drive
Boundaries item to add a
new Drive boundary and
select the Green profile.
Now recalculate the toolpath using the batch build icon from the operation Semi & Finishing
manager.
Radial
Click on the Batch Build
icon to recalculate the Radial passes converge on a central point. The stepover is calculated along the
toolpath. circumference of the circle of a radius you define. This machining strategy is most
effective on areas that include shallow curved surfaces and circular areas as the
passes are spaced along the xy-plane (stepover),
and not the z-plane (stepdown). The z-height of
The result of this Limit and Drive boundary each point along a radial pass is the same as the
combination can be clearly seen in the z-height of the triangulated surfaces, with
image below. adjustments made for applied thickness and
cutter definition.
The toolpath is now restricted to the Yellow
limiting boundary but it is taking on the Open the file radial.wkf
shape of the Drive boundary
even though the Drive Start the Operation Manager and begin by
boundary is clearly outside of adding a Radial toolpath.
the cutting boundary. Machining > Operation Manager

Select the “New Operation”


menu to create the new
operation.

Pick the New Operation “Radial”


In this example, Select ‘T4 – 10mm Ball Nose’ from the available cutters list as shown Let’s edit the parameters for this toolpath by double clicking on the Radial strategy in
below in the default library. the operation manager.

Double click here to access


the parameters for this
strategy.

Enter the parameters on the Machining tab as shown below and click ‘OK’ to create
a toolpath.

Now select the model from the screen area. Check that you are using similar values
to those shown below for the triangulation of the model for machining purposes, the
chordal tolerance is set at 0.05 for a finishing type of cutting Strategy.
Significant Parameters For this Strategy Take a look at the calculated toolpath. It looks a bit messy as some of the passes are
creeping over the edge of the part.
Stepover
Editing the Options
The stepover is the spacing between the passes along the circumference of the
circle. The maximum radius you set on this dialogue page defines the circle. The To make the toolpath significantly tidier
stepover is calculated from the blue line in the diagram - passes are evenly spaced the end radius value can be adjusted
by the amount that you set in the stepover field. so that the toolpath is limited from
falling over the edge of the part.
Centre
Open up the operation parameters
You must specify the xy-position of the centre-point of your circle. and go to the Machining tab.
The Radial passes will start or end at this centre-point. To help you to
work out the coordinates, you can zoom in, and look at the position Focus on the “Geometrical Definition”
of your cursor from the xy information fields on the status bar and area of the form.
use the geometry picker to define the centre point.

Angle
Click the Maximum radius
The minimum and maximum angles act as limits to your passes. They control the button to enable picking
angle span of the operation, that is, how much of a complete circle will be from the screen.
machined.

Each radial pass starts at the centre point and ends at the circumference of your
circle, unless changed in the radii field (below). Looking down your cutter axis (z-
view), a line with an angle of 0 is parallel to the x-axis, and a line with an angle of 90 Use the Quadrant point icon to pick the point on the model that defines the
degrees is parallel to the y-axis. An angle of 360 degrees is a full revolution around the maximum radius.
circle, and the line is parallel with the x-axis. Any angle of a value in between 0 and
360 degrees will be a rotation pivoting anticlockwise from the centre point

The minimum angle is the first radial pass to be created, and the maximum is the last
radial pass to be created. A range of 0 to 360 will give the full circle, a range of 0 to
180 will give half of a circle, and so on Pick a Quadrant Point on
this edge.
The Maximum radius should
measure 54 as shown below.
0° min, 90° max: 80° min, 200° max:
The toolpath should look like the one in Semi & Finishing
the image shown here.
Spiral
If you display the toolpath simulation you
can see that the tool starts in the centre This machining strategy is most effective on areas that include shallow curved
of the job and the tool moves in an anti surfaces and circular areas as the passes are
clock wise direction. spaced along the xy-plane (stepover), and not
the z-plane (stepdown).
Open the machining parameters again
and go to the Approach/Retract tab. Open the file spiral1.wkf

Click the Invert Step-over checkbox to


machine the part in a clockwise
direction. Invert direction is only in use if Start the Operation Manager and begin by adding a Spiral toolpath.
the toolpath motion is Unidirectional so Machining > Operation Manager
will have no influence in this case.
Select the “New Operation”
menu to create the new
operation.

Specify a Plunge area co-ordinates as shown below, this will enable the toolpath to
start from outside of the cavity. Pick the New Operation “Spiral”
Toolpath now
moves clockwise
and starts from the
outside.
In this example, Select ‘T3 – 6mm Ball Nose’ from the available cutters list as shown Let’s edit the parameters for this toolpath by double clicking on the Spiral strategy in
below in the default library. the operation manager.

Double click here to access


the parameters for this
strategy.

Enter the parameters on the Machining tab as shown below and click ‘OK’ to create
a toolpath.
Notice that the dialog box is very similar to the one used in creating radial passes. Fill
in the parameters as shown and click OK.

Now select the model from the screen area. Check that you are using similar values
to those shown below for the triangulation of the model for machining purposes, the
chordal tolerance is set at 0.05 for a finishing type of cutting Strategy.
We should now have a toolpath that machines to the exact outer edge of the part
The result should look like this image: as shown below.

Significant Parameters used in this


machining Strategy.

Semi & Finishing


Here we can set the maximum
radius to be considered by the
Contour Projection
Here we can set the centre point
spiral path. for the spiral toolpath. A Contour Projection pass is created by dropping the cutter onto the surface and
Editing the Parameters Value = 0, 0 running it along a single boundary or a set of boundaries to produce the effect of
engraving.
If you look closely at the passes, the default settings have not rendered an optimal
result. In this example we will alter two of the parameters in order to achieve a better Open the file boundary.wkf
result. The first parameter we must change is the maximum radius of the part. The
system as a default uses the extents of the surfaces and places the value in the Radii
dialog box.

In this example, we will generate


boundary passes on existing
In order to find the correct radius value to use, we will have to measure one on the geometry. The curve geometry
part. Now in order to re-calculate our existing passes, we must re-generate them that exists in the file was
using this new value and a new contact angle. Click on the Spiral Passes 1, right click generated in a CAD system, and
and select Properties. is a typical example when doing
Select the pick point icon to cavity engraving.
allow picking of a point
from the screen. Start the Operation Manager and
begin by adding a Contour
Projection toolpath.
Pick a Quadrant Point on
Machining > Operation Manager
this edge.
The Maximum radius should
measure 34.5 as shown Select the “New Operation”
below. menu to create the new
operation.
Pick the New Operation “Contour Projection” and select ‘OK’ Add some default feeds and speeds from the “Cutting parameters page” and set
the tool defaults. An example is shown below.

In this example, use a 1mm diameter Ball Nose type cutter. Enter the cutter
parameters as shown in the dialogue below. Note: - If you are unsure how to access
the cutter parameters please refer to the Roughing tutorial or the Tool Libraries guide.

Now select ALL of the model from the screen area. Check that you are using similar
values to those shown below for the triangulation of the model for machining
purposes, the chordal tolerance is set at 0.05 for a finishing type of cutting Strategy.

Now select the projection Curves to use in the strategy.

Drag a window around the profiles inside the component.


Let’s edit the parameters for this toolpath by double clicking on the Contour Significant Parameters
Projection strategy in the operation manager.
The engraving is required to be 0.3 mm deep into the cavity, we will input that as a
negative value in the Stock Oversize parameter box.

Also here the Machining Strategy is Unidirectional meaning the cut will always be in
one direction only.

Double click here to access


the parameters for this
Check the results of the toolpath, they should look like the following image.
strategy.
Remember that the passes are 0.3mm below the surface so shading the file will not
be any help!
Enter the parameters on the Machining tab as shown on the next page and select
‘OK’ to calculate a basic toolpath.

Editing the Machining Parameters

If this is very hard material and you would like


the cutter to stepdown using a few passes, go
back to the Machining Tab and focus on the
Engraving Mode parameters. The stepdown we
will use is 0.1mm and the number of offsets will
be 3.

From the Approach / Retract tab set the


approach and retract modes to Axial, so that
the tool enters and leaves the job in a vertical
motion.
Finally go to the Transitions tab to edit the retraction methods. Change the Rapids Semi & Finishing
Management to Safety Distance. This will mean that the cutter only retracts to a
minimum safety height and not back to the clearance plane every time it lifts off the Tracing 3D
job, this will reduce the machining time significantly.
Open the file ‘3D Curve Example.wkf’

Tracing 3D is purely a Curve based


machining strategy and does not
require and solid or surface
information. It can be useful for
engraving or cutting round trim lines
of components.

The file consists of one closed profile.

Open the operations manager and


select ‘New operation – Tracing 3D’

Select the “New Operation”


menu to create the new
operation.

Here is the result of the edited Contour Projection strategy showing the multiple levels,
vertical entry and exit, plus the rapid moves at the safety distance.
Select ‘T3 – 6mm Ball Nose tool’ Let’s edit the parameters for this toolpath by double clicking on the Tracing 3D
strategy in the operation manager.

Double click here to access


the parameters for this
strategy.

Now select the profile


Enter the parameters on the Machining tab as shown on the next page and select
START POINT ‘OK’ to calculate a basic toolpath.
END POINT

Select the middle of the top part of the profile as the start and end point of the
machining

Accept the machining direction, confirm using the RHM button.


Flag the ‘Auto Rebuild’ check box and select ‘OK’
Check the result from the calculated Semi & Finishing
toolpath. You should see only a single pass
moving from the start to the end point in the ISO Machining
direction specified. It should look like the
image below. ISO Machining is the process of cutting
individual surfaces which belong to a larger
Editing the Parameters solid or surface model. Although the strategy is
The ‘Engraving’ option works within this effectively cutting single surfaces the toolpath
strategy and this is the same as the is still fully gouge checked against the
‘Engraving option’ from the ‘Contour machined piece.
Projection’ strategy.
The following example shows some of the
features and parameters used in the ISO
Machining toolpath.
Go to the Machining tab and change the operation parameters to the following
options and re-calculate the toolpath.
Open the file “ISO-MACHINING.wkf”

Create a new profile on the bottom face using


the profile from face command.

The engraving option will allow the user to enter the depth of cut ‘Step Down’ and the
number of cuts above and below the selected profile, ‘Levels on Surface’ and ‘Levels
under Surface’

The toolpath should look like the one in the image below. Double click here to access
the parameters for this
strategy.
Open the operations manager and select “New Operation – ISO Machining The first area to look at is the Pattern drop down box accessed from the Surface paths
tab. The “Pattern” options determine the toolpath shape and are as follows:-

Parallel cuts – Parallel option

Parallel cuts

Select “OK” and then Select the “T3 – 6mm Ballnose” and select “OK”

We will now be presented with the new ISO machining layout.


Parallel cuts – Constant Z option
Cuts along curve option The principle behind how the ISO machining works can be shown in the following flow
chart.

Morph between 2 curves option


Select the “Parallel” option to set the machining angle in Z to 90 and then select the Click “OK” to confirm the list of selected surfaces.
“Drive Surfaces” option to pick up the surfaces to machine.
NOTE

This list only contains the surfaces to machine and


does not include any surfaces that are used for the
gouge checking. The gouge check surfaces MUST be
selected from the separate tab in the new interface

Select “OK” once more and then expand the tree in the operations manager and
calculate the toolpath by highlighting in the tree and then selecting the
“Toolpathbatch build” icon

Pick the surfaces as shown in the image below.


The result will look like the following The toolpath will now lift with a portion of feed move and a portion of rapid move as
image. Next we will change some shown in the image.
options to deal with the amount of lift
off. The exact distances for the feed
and rapid movements can be
adjusted with the

button from the


Link tab as shown below.

To change the options for the lifting off


along the passes the linking options
need to be changed. Go to the Link
tab and adjust the following options.
Then rebuild the toolpath.

Changing the Pattern type – Cuts along curve

Double click the operation parameters to change the settings for the second option
and toolpath pattern.
Change the pattern type to “Cuts along curve” and we must now select the “Edit Select “OK” on the main interface and then rebuild the toolpath, the result will be as
curves - Lead” icon and pick the profile at the top of the part. shown in the image.

To overcome lift-offs
along the cut or in
between the slices then
the linking options need
to be changed.

Edit the parameters of


the linking tab and
change the following
option from 110% to
200% and then
recalculate the
toolpath.

Enter the machining


parameters and swith
to the Link tab.

Select the Top Profile


and then click OK.
Here is the result of changing the ‘Link between slice option’ as previously described. Here you can see that if the
There are now no lifts between each toolpath link. motion is bigger than the gap
size the tool path is set to
"broken". If the motion is smaller
than the gap size the tool
movement is "direct". The gap
size is set to 50 % of tool diameter.
The tool diameter is 20 mm so the
small gaps are 10 mm and the
big gaps are all gaps bigger than
10 mm.

LINK BETWEEN SLICES

Similar to gaps along cut you differ between small and large links. This difference size
is calculated as a percentage of the user given maximum step over value.E.g. if this
value is set to 150% and the maximum step over value is 0.1mm the gap threshold is
Some Information about the linking and lifting options 0.15mm. That means, all step over moves from one tool path slice to the next slice are
checked against this 0.15 mm and determined whether the gap is smaller or larger
GAPS ALONG CUTS than this value. If you don’t want the gap size depending on the maximum step over
just activate "as value" and set your value.
If gaps along a tool path are detected, then you have different choices how the tool
should pass the gap and pursue machining. Depending on the size of the gap it is
possible to set two different options on whether it is a big or a small gap. The value in
the field "Small Gap Size in % of tool diameter" sets the threshold for small and large
gaps along a tool path segment. The value is defined as the percentage of tool
diameter. All gaps along tool path segment, which are smaller than this threshold
value, are considered as small gaps and the action defined for small gaps is
executed. All other gaps that are larger than this value are larger gaps and the
action defined for large gaps is performed.

E.g. if tool diameter is 20mm and the gap size is set to 10%, then the threshold is 10% of
20mm, which is 2mm. All gaps which are smaller than 2mm are considered as small
gaps. All gaps greater than 2mm are considered large gaps. If you don’t want the
gap size depending on the tool diameter just activate "as value" and set a value.
Toolpath Pattern – Morph Between 2 Curves For this operation we will also add more surfaces to machine.
Click the “Drive surface” icon and from the dialogue box select the “New” icon to
The third and final toolpath pattern and the one where will add the collision control is add additional surfaces.
“Morph between 2 curves” Double click the operation parameters to change the
settings for the third option and toolpath pattern.
Change the pattern type to “Morph between 2 curves” and we must now select the
“Edit curves – First and Second” icons and pick the profiles at the top and bottom of
the part.

Select the Drive Surfaces


button to begin adding
new surfaces.

Use this icon to add the


new surfaces to the drive
surfaces group.

Pick the side walls as


additional machining
surfaces.

Select the Top Profile as


the first curve.

Select the Bottom Profile


as the second curve.

Click OK to confirm the selection of the surfaces.


From the main dialogue window click “OK” and rebuild the toolpath, the result should Double click the operation parameters and activate the “Gouge Check” tab.
be as follows:-

NOTE
Although the toolpath looks fine there is no collision checking applied at present and Up to 4 sets of surfaces can be defined for gouge checking but we will use only 1.
this MUST be done to stop any gouging on the part. From the picture below, a section Activate the option for set 1 and pick the surface selection icon.
view of the above toolpath shows the collision when no checking is applied.

Any number of surfaces can be selected for gouge checking from only 1 additional
surface to all the surfaces that make up the part model or from additional models if
needed.

For this exercise we will select the whole model.


Gouge Area
Use the “Selection inside of a window” icon from the left hand side of the screen and
drag a window around the whole model.
Drag a window around the whole part as shown below to select all the surfaces for
collision checking.
Finishing
Steep & Shallow

Open the file steepshallow.wkf

The purpose of this new strategy is to replace the operation


“FINISHING COMBI” and to overcome the discovered
problems and the limitations. This function machines in a
synchronous manner switching between steep and shallow
strategies based on the shape of the geometry.

It is possible to define an angle (Reference angle) to split


the Steep areas from the Shallow areas. Areas that lie
between 0 degrees and the “Reference angle” are
considered shallow areas and are machined using a
“constant step-over” like strategy. Areas that are greater
than or equal to the “reference angle” are considered steep
and are machined using a “constant Z finishing” like strategy.

From the left menu, select the operations manager icon, and from the Operations Manager
select NEW OPERATION,

Select ‘OK’ to confirm the check surface selection.

Click “OK” and recalculate the toolpath. The result will now have the collision
detection applied and will not gouge the part as shown in the image.
Scroll down the list of strategies and select STEEP & SHALLOW, then select OK. The toolpath will now be listed in the operations manager……..

Double click the operation, and the toolpath dialog box will appear.

Select a 6mm ballnose from the library, then select OK.

Select the geometry…..then confirm the selection.


The stepdown and stepover can be different
values, in this example, we will use 1mm for The stepdown can be constant, or adaptive.
both.

If adaptive is selected as the step-down mode,


As a default, the system performs the you can adjust some parameters under the
stepover as an increment. If Scallop mode is Advanced settings tab. The corners
turned on, a Theoretical scallop value can be management is also accessed in this area.
defined and will be used.

Adaptive parameters

This reference angle splits the steep and


shallow areas.

Corner management

The angular control allows a minimum and


maximum angle to be used. In this example, the
system will ignore any areas less the 0.1deg. (ie: The shallow areas can be machined in the
flat areas) following ways:

Unidirectional
Zig-Zag
Downward
Upward

The steep areas can be machined unidirectional


or Zig Zag. NOTE:
If the upward or downward strategy is
selected, the advanced settings tab will be
available in order adjust specific
parameters associated with those toolpath
The cutting mode can be climb or conventional. types.
Offset type: Once the parameters have been inputted, select OK. Select the toolpath, right click with the
mouse, and select Toolpath Batch build.
The following options are
available:

Upper type: the upper


waterline pass is offset and
Depending on which offset method is trimmed to the lower
used, the system will render a completely waterline pass.
different result. The type of offset that Lower type: the lower
should be used is solely dependent on the waterline pass is offset and
geometry being machined. Below are trimmed to the upper pass.
some illustrations which will show the Both type: both lower and
different types of behavior. upper passes are offset
together. The offsets will
If you turn on the toolpath display and zoom into some areas…..
be looped.

You will notice the toolpath machines all areas using both a steep and a shallow strategy.
Unlike the traditional strategies, this one will machine the part in a synchronous matter.

Upper Offset Lower Offset

If the toolpath is animated, you will notice that


the system is machining both steep and shallow
areas at the same time. In older strategies,
such as Finish Combi, the steep areas were
completely machined first, then the shallow
Both Offset areas, which was not as efficient as this new
strategy.
Welcome to Visi Machining

In this training documentation it is assumed that the user is familiar with the basic navigation
of Visi and only parameters relative to the machining strategy will be explained in detail.

Once you have created the first toolpath, you will notice that the dialog boxes remain
consistent for all toolpaths, which considerably reduces the learning process.

What is Covered in this Chapter?

Rest Machining
RestMachining Rest Material
Corner Rest Machining
Pencil Milling
Theoretical Rest Areas
Rest Material COMBI
Rest Material contours
Rest Machining
Rest Material

Open the file Rest material.wkf

The term, rest machining, refers to one of several strategies


used to calculate areas of the job where material remains
after running previous toolpaths. Some of the rest
machining strategies work out the areas where material will
be left and create the toolpath to machine those areas.

From the left menu, select the operations manager icon, and from the Operations Manager
select NEW OPERATION,

Once the local library appears, select a 4mm ballnose then select OK.

(NOTE: If a 4mm ballnose tool does not exist, one must be created)

Scroll down the list of strategies and select REST MATERIAL, then select OK.
The Rest material toolpath will now be listed in the operations manager….

The left/right
distance is the
amount the system offsets the initial pencil pass that is
created at the surface intersections. In this example it will
offset the original pass 1mm on either side.

If you wanted to create additional passes in order to


gradually machine the material, you could change the
Double click the operation, and the toolpath dialog box will appear horizontal & vertical stepover to 0.2mm and leave this value
set to 1mm and the result would look like the image below:

The system maintains a 1mm total offset


on either side of the original pass but adds
more offsets in between at 0.2 mm
increments.

A steep/shallow angle can be enabled in order to avoid vertical or near vertical areas by
checking the angular control box and applying the minimum/maximum angles. In this
example we will set a minimum of 0 deg and a maximum of 89 degrees.

The vertical and horizontal stepover can be adjusted


independently. In this example we will set them both to
1mm
The machining strategy can be changed: The toolpath will now be calculated and the progress can be monitored when the process
manager pops up.

In this example, Zig-Zag will be used.

The default computation method is set to the Quick method, which is what we are using in
this example, but if required, if you can change this to the Rest area method which will use a
reference cutter size: When the toolpath calculation is completed, you can visually see the result by either clicking
the box beside the toolpath or by selecting the toolpath display icon.

OR

The approach can be toggled to work from outside in, or , inside out. In this example the
toolpath will run from outside in.

Once these parameters have been set, select OK. Select the toolpath, right click with the
mouse and select Toolpath batch build:
Select a 6mm ballnose tool, then click OK.
Rest Machining
Corner Rest Machining

Open the file corner rest.wkf

This function allows the computation of a particular type


of toolpath that will remove all the un-machined areas of
a Theoretical reference tool.
The strategy uses an internal pencil milling strategy
which is computed using the theoretical previous tool Then, select the geometry to be machined, and confirm the selection.
diameter being programmed. This means that if, on the
model, there are radii with a value greater than or equal
to the “previous tool radius”, theses areas will not be
machined.

Please note that for this release


the “Reference tool” can only be a
“Ballnose” type

From the left menu, select the operations manager icon, and from the operations manager
select NEW OPERATION….. Scroll down the list of strategies and select Corner Rest
Machining, then select OK.

The Corner rest machining dialog page will appear……


The stepdown and stepover can be different By default all areas are machined, but this can be
values, in this example, we will use 1mm for toggled to output either Steep or shallow areas
both. independently.

The previous tool is the Theoretical reference


The angle used to identify and split the steep and
tool mentioned earlier. Once again, a
shallow areas.
BALLNOSE tool is only supported.

This will control the precision when searching for Setting 90° will machine all the rest material areas along the corner (image 3).
areas to be machined. If you reduce this value the Setting 0° will machine all the rest material areas will be machined across the corner (image 4).
system will begin to find many more areas due to Setting 45° will machines areas between 0 and 45° along the corner, while areas between 45 and 90° will be
machined across the corner (image 5).
the triangle variations, however this value is
dependant on the piece been machined.

It is very useful to solve situation where the blend


radius of the model is more or less equal to the
reference radius (so in theory there is no material to be
removed). In this situation the system normally
creates the pencil passes but the rest material
passes will not be made in order to avoid any Image 3 Image 4 Image 5
creation of unnecessary rest machining passes.
(see Image A)

R tool = R blend
The Steep machining strategy can be toggled,
Image A but the Shallow machining strategy only supports
climb milling at this time. In this example, it will be
set to climb.

This parameter allows the max Z height of material to


be removed to be set. The tool is not allowed to Linear: allows the option to have direct movement
machine the passes lower than this value on the between the passes
theoretical areas found on the part. This parameter is
very important to prevent tool brakeage when it is Spiral: allows the option to have a smooth
necessary to machine hard material. Situations, like movement between the passes similar to a “spiral”
that shown in Image2 can be dangerous for the tool
life. Flying Spiral: The linking movements between the
Image 2
passes are not projected on the model.

The default value should be 1/3 of the Tool radius. It Linear


is suggested not to set the “max depth of cut” larger
then the tool radius. Spiral
Allows the splitting of the rest machining passes if the
This option allows the organisation of the
angle deviation of the pencil passes is bigger than the
pencil passes in the way to generate more
programmed value.
connected and uniform passes.

Max angle deviation =130° Max angle deviation =136°


Planar:
The system looks at the pencil passes from
the tool axis (from +Z) and connects the
passes that have the angle deviation less
than the value set in Max Angle deviation.

Angular:
The system looks at the pencil passes from
Once the parameters have been inputted, select OK. Select the toolpath, right click with the
any directions (3D point of view) and
mouse, and select Toolpath Batch build.
connects the passes with angle deviation
less than the value set in Max Angle
deviation.

No Sorting:
The system follows exactly the pencil passes.
For any part of the pencil pass there will be a When the calculation is completed, you can animate the result by selecting the Toolpath
group of Rest machining passes. The risk in Simulate icon.
this case is that uncut material could be left in
the corners or were more part of the pencil
passes converge at one point.

Select “All Step” to view the


entire toolpath.
Notice during the simulation the vertical areas on the part are being machined using a
Constant Z strategy and the shallow areas are being machined using a 3d stepover strategy. Rest Machining
Pencil Milling

Open the file pencil.wkf


This function will create a toolpath that will calculate
a single pass on all corners of a part giving an
excellent finish. The area to be machined is
determined by the diameter of the tool selected. If
there is a radius on the model and the radii value is
larger than that of the tool diameter this area will not
be machined.

Constant Z
From the left menu, select the operations manager
icon, and from the operations manager select NEW
OPERATION….. Scroll down the list of strategies
and select Pencil Machining, then select OK.

3d Stepover

From the local library select a 4mm ballnose tool, then click OK.
Select the geometry to be machined, then confirm the selection. Toggling this parameter will limit the toolpath
from 0 to 45 degrees. For this example use
these values.

The machining strategy can be changed. If


an UpWard or Downward strategy is used, the
ADVANCED settings become available. In
this example use Unidirectional.

The Upward milling strategy will force the tool to always machine
Double click on the toolpath in the operation manager…….. in an upward direction, and conversely, when Downward is
selected, the tool machines in a downward motion.

This utility can be used for roughing out


the corners by stepping down in Z
increments. In this example disable this
option.
The Bi-Tangency control is a special angular
tolerance that you can use to control the system Rest Machining
precision while searching for areas to be Theoretical Rest Areas
machined. All machining operations have a
tolerance and the smaller the value, the more
accurate the calculation.
Open the file theoretical.wkf
This is an extra thickness that can be temporarily applied to the
cutter in addition to the normal thickness. You can use
Overthickness to make passes along fillets where the radius is A set of 3D boundaries can be generated from rest
greater than that of the cutter. areas left by an imaginary reference cutter. This gives
For example, if you have a surface with fillets of corner radius 8 mm good results when used for machining operations at the
and you want to create a Pencil Milling along it with a 10mm ball- semi-finishing and finishing stages of a job. You can
nosed cutter, you can apply an Overthickness of 4 mm to it. The then use these boundaries to limit another set of passes
Pencil Milling will be made for a ball-nosed cutter of size 18 x 9 mm made with a cutter of an equal or smaller size.
(which will detect this fillet), and then projected back onto the
surface to make a toolpath for the 10 x 5mm cutter.

Once the parameters have been inputted, select OK. Select the toolpath, right click with the
mouse, and select Toolpath Batch build.

From the menu, open the operations manager………………

Once the calculation is complete, you can animate the toolpath to view the result. Inside the operations manager, there is an icon which will
access the Geometrical tools in Visi……..
Once the “Theoretical rest boundaries” are selected, click OK. The Local library will then The system will then prompt to use boundaries…….In this example we will create
open and will require that a reference tool be selected. In this example, a 4mm ballnose boundaries on the entire part, so press RHM
tool will be used……….

If you wanted to create boundaries only in


specific areas of the part, you could use 1 or
more profiles as “containment areas”. This is
especially useful are large parts.

Select all elements, in order to create boundaries on the entire geometry…

The Theoretical rest area dialog box will then appear.

Define if the status of the stock

Set the min/max angles.

Define the Previous tool that


was used. This can be either a
ballnose or Toroidal type.

Then confirm the


selection………
On the advanced tab, other parameters can be adjusted…… If we remove the shading, and view the geometry in wireframe mode, you will see the new
boundaries that were
created……..
The smallest amount of material to be found in
areas included in the rest area boundary prior to
rest machining. If the reference cutter left parts
of the job with less than this amount of material,
those parts of the job would not be included in
the rest area boundaries.

This is the granularity of the calculation. The


smaller the value, the finer the detail of the
boundaries made, but the slower the
calculation.

The diameter is the span of the


boundary, the distance between two
points on either side. Boundaries that
have a diameter smaller than this value
are discarded
The boundaries are offset outwards
along the surface by this amount after
they have been made.

Once all the parameters have been imputed, the system will begin calculating the
boundaries……..

These boundaries can now be used as containment when creating the different toolpath
strategies that are available…..

When the calculation is finished, a message will appear indicating the number of
boundaries that we created……
Select a 6mm ballnose tool, then click OK.
Rest Machining
Rest Material COMBI

Open the file restmaterialcombi.wkf

This function allows the machining of un-machined areas


left behind from a previous tool using different machining
strategies for Steep and Shallow areas.
Then, select the geometry to be machined, and confirm the selection.
The most important features are:
x Ability to machine the Steep areas using Constant
Z or 3D Step Over or Parallel Plane strategies.
x Ability to machine the Shallow areas using 3D
Step Over or Parallel Plane strategies.

Please note that the “Reference tool” can


either be a Ballnose or Toroidal Type

From the left menu, select the operations manager icon, and from the operations manager
select NEW OPERATION….. Scroll down the list of strategies and select Rest Material
COMBI, then select OK.

Double click on the operation……..the Rest material Combi dialog page will appear……
can be changed………
Define the reference tool. This can be a
Ballnose or Toroidal type. In this example,
we will use a 10 mm ballnose.

The stepdown type can be toggled.

Corner smoothing can be enabled.

These parameters are identical to


those explained in the theoretical rest From the tab, there are different ways the toolpath can move from one Z level to
areas section. the next.

Defines the steep/shallow angle being used.


An overlap angle can be used to avoid
marks where the two different strategies
meet. In this section, it is possible to select different
strategies to machine shallow areas.

The 2 strategies are:

In this section, it is possible to select different Parallel Plane


strategies to machine steep areas. 3d Stepover

The 3 strategies are:

Constant Z (most common)


Parallel Plane (used in 3+2, shallow geo)
3d Stepover (used in 3+2, shallow geo)
can be also changed for shallow strategies……..

From the tab, there are different ways the


toolpath can be linked when it steps over.

A minimum pass length can be defined. This will


discard any passes that are less then this amount.

Once the parameters have been inputted, select OK. Select the toolpath, right click with the
mouse, and select Toolpath Batch build. Constant Z strategy

3d stepover strategy

If we RHM on the toolpath and turn off the transition and rapid motions, we can see the
different strategies used to machine the part.
The Geometrical tool dialog box appears, and unlike before, the Rest material contours
Rest Machining option is now visible (this is because we selected an operation prior to selecting the icon).
Rest Material Contours

Open the file restmaterialcont.wkf

Similar to theoretical rest areas, this strategy requires that


one reference OPERATION be used instead of a
hypothetical tool. The system will create a set of 3D profiles
from rest areas left by the selected operation. It is possible
use these profiles to limit another set of operations made with
a tool of an equal or smaller size.
Make sure it is selected, then click OK.

The profile manager will appear………..

From the left menu, select the operations manager icon. In the operation manager, there is a
parallel plane toolpath we will use as the reference operation. Click on the toolpath, then Minimum thickness
select the Geometrical tools icon……..
It is the smallest amount of material to be found.
If the reference operation left parts of the job
with less than this amount of material, those
parts of the job would not be included in the
Rest material profiles. The min material depth
should be greater than the "scallop height" left
by the reference operation.

Contour type
3D profile: the rest area profile will be made in 3
dimensions.
2D profile: the rest area profile will be made on the
current work plane.

Once the parameters have been set, select OK. The system will calculate the rest areas and
a message will pop-up and display how many profiles (rest boundaries), were created.
If we look at the part we can see the boundaries………

If we toggle the reference toolpath display on………

You can zoom into areas were the boundaries were created.

In these areas the thickness


exceeded 0.2 mm, and the
boundaries were created.
Welcome to VISI Machining 3D
The geometrical tools presented in this document add an extra set of functionality to
the creation of boundaries for machining purposes.
The geometrical tools are not extra toolpath strategies but are profile/mesh creation
type tools that can be used in conjunction with the machining strategies contained
within VISI Machining 3D.

The following guide will show you how and where these can be used with hands on
examples. Familiarity with VISI Machining is assumed so every single step will not be
documented.

What is Covered in this Chapter?

Rest Machining
Rest Material Contours

3DCAMGeometrical
Theoretical Rest Boundaries
Shallow Area boundaries
Silhouette Boundaries
Cutter Contact Areas

Tools
Fillet Surfaces
The Geometrical tools can be accessed from the Operation Manager icon bar. The The results should be the same as below.
following is guide for each option available.

Rest Material Contours

Open the file Rest Material Contours.wkf

Make sure the Radial Strategy is selected from the operation manager before selecting
the geometric tools icon.

The outer profile in this case is not needed and can be deleted. The rest of the profiles
can be used individually or nested.
The ‘Rest Material Profile Manager’ option will then appear.
These profiles can then be used as machining or limiting boundaries if required.

Try different values to view the different results.

Enter ‘0.1 into the minimum thickness and 2D Profile’ into the Contour type.

Minimum Thickness - This value relates to the minimum thickness of the scallops that the
system will use when generating the rest material profiles. The system is using an
imaginary reference toolpath on the component and generating the rest material
profiles from the cusp height (Minimum Thickness) used on the toolpath.
In practice the smaller the value the more rest material areas will be identified and
more profiles generated.

Contour Type - This option relates to how the profiles will be generated. After the rest
material profiles have been generated the profiles will be created either projected
onto the component and therefore 3D profiles, or the profiles can be projected onto
the active workplane and therefore 2D profiles.

Select ‘OK’
Theoretical Rest Boundaries Resolution This is the granularity of the calculation. The smaller the value, the finer the
detail of the boundaries made, but the slower the
This option allows the creation of 3D profiles from rest areas left by an imaginary tool. calculation time.
This gives good results when used for machining operations at semi-finishing or finishing
Minimum diameter: The diameter is the span of
stages of a job. You can then use these boundaries to limit another set of toolpaths
the boundary, the distance between two points
made with a cutter of an equal or smaller size.
on either side. Boundaries that have a diameter
smaller than this value are discarded
User interface
This option is available in the following situations when the: Offset: The Shallow Area boundaries are offset
outwards along the surface by this amount after
x Focus is on the project item
they have been made. Sometimes it may be
x Focus is on the tool item advantageous to put in a small offset value; you
x Focus is on the operation item can prevent jagged boundary edges where an
area of a surface is at an angle similar to the
Contact Angle
Step 1:
Define your tool - the smaller, secondary one with which to machine inside the rest Include corner areas: If switched on, the system
areas and create the boundaries. If previously the focus was on an already used tool, will include in the areas detection also the areas
the system will use this tool. were more the one edge meet together.
See example:
Step 2:
Holder clearance: Defines the safety distance between the holder and the model
Select the model geometry on which you want to find the rest material areas (using geometry.
the same dialog box used for the geometry definition for 3D machining operations).

Please note that “Holder clearance” is automatically switched on if has been


Step 3:
selected tool + tool holder.
Select profiles as boundary limitation for the Theoretical rest areas profiles.
Step 4:
The system will display the following dialogue box:

Stock oversize: The distance between the surface


Corner Areas= ON Corner Areas= OFF
and the cutter (and the boundary) If you set the
distance to be zero, the boundary will be based on
calculating the movement of the cutter along the
surface itself. If a positive number, it will be above
the surface, if a negative number, it will be below
the surface.

Angle Max and Angle Min allows you to force the


area detection only between the specified Max Try it out
and Min angled you have entered.
Using this option will allow you to isolate, for Open the file shallow_areas.wkf
example, only the “shallow” areas of the whole
model. Use a 6mm Ball Nose Tool to as the actual cutter to be used. Set the Parameters as
shown.
Previous Tool : This allows you to specify a cutter
with which the Theoretical Rest Areas will be P.T.O….
calculated against. This cutter is usually larger than
the cutter being used to cut the rest areas. The
reference cutter represents the tool used in the imaginary toolpath.
Theoretical Rest - Try it out cont………………….
Shallow Area boundaries

This new option allows you to make profiles around the shallow (flat) areas of the
selected model. The system produces 3D profiles
User interface
This option is available in the following situations when the:
x Focus is on the project item
x Focus is on the tool item
x Focus is on the operation item
Step 1:
Define your tool - the tool that you will use to machine inside the Shallow area
boundaries. If the focus was on a previously used tool, the system will use this tool.
Step 2:
Select the model geometry on which you want to find the Shallow area (using the
same dialog box used for the geometry definition for 3D machining operations).
Step 3:
Select profiles as a boundary limitation for the Shallow areas boundaries.
Step 4:
The system will display the following dialogue box:

100 Rest Material Boundaries are detected.

Stock oversize: The distance between the surface and the cutter (and the boundary) If
you set the distance to be zero, the boundary will be based on calculating the
movement of the cutter along the surface itself. If a positive number, it will be above
the surface, if a negative number, it will be below the surface.

Use vertical oversize: If selected, this parameter allows you to specify an additional
oversize value only on the vertical faces.

Angle Max and Angle Min allows you to Set the contact angle range of your tool by
setting the minimum and maximum contact angle. Boundaries will be drawn around
areas where the angle is within that range. For Shallow Area boundaries, the range
should typically be between 0 and 30 degrees, but where surfaces are very close to the Step 5:
minimum or maximum angle, you may get an undesirably jagged edge so you may
want to alter the range slightly. Alternatively, you can sometimes get rid of jagged After computing, the system will display the following dialogue box and will create the
edges by giving the boundary a small offset Shallow area boundaries on the working layer as shown.

Max Z level: This is the highest positions of the tool along the z-axis
Try it out
Min Z level: This is the lowest positions of the tool along the z-axis
Open the file shallow_areas.wkf
Contact Areas Only: This option should be selected (ticked) to limit your boundary to
the surface, with no major material clearance. If you want to create boundaries that Use a 6mm Ball Nose Tool to define the shallow area boundaries. Set the Advanced
include non-contact areas, then the option should not be selected (box not ticked). Parameters as shown.
Shallow area boundaries created.
Resolution: This is the granularity of the calculation. The smaller the value, the finer the
detail of the boundaries made, but the slower the calculation.

Minimum diameter: The diameter is the span of the boundary, the distance between
two points on either side. Boundaries that have a diameter smaller than this value are
discarded

Offset: The Shallow Area boundaries are offset outwards along the surface by this
amount after they have been made. Sometimes it may be advantageous to put in a
small offset value; you can prevent jagged boundary edges where an area of a
surface is at an angle similar to the Contact Angle

Holder clearance: Defines the safety distance between the holder and the model
geometry.

Please note that “Holder clearance” is automatically switched on if has been


selected tool + tool holder.
Isometric view
Silhouette Boundaries

This new option allows you to create a profile that has as shape the perimeter that you
see when you looking at the selected model from the Z axis.

User interface
This option is available in the following situations when the:
x Focus is on the project item
x Focus is on the tool item
x Focus is on the operation item
Step 1:
Select the model geometry on which you want to find the Silhouette area (using the
same dialog box used for the geometry definition for 3D machining operations). Top view
Step 3:
Select profiles as boundary limitation for the Silhouette areas boundaries.
Step 4:
The system will display the following dialogue box:

Try it out
Resolution: This is the granularity of the calculation. The smaller the value, the finer the
detail of the boundaries made, but the slower the calculation.
Use the reference material as a guideline for this exercise.

Open the file littleman.wkf and create the boundary from the STL mesh file.
Please note that using a bigger value it is possible get a more smoother silhouette
boundary

Step 5:
After computing, the system will display the following dialogue box and will create the
Silhouette boundaries on the working layer as shown.
Step 4:
Cutter Contact Areas The system will display the following dialogue box:

This option allows you to make profiles around areas where the cutter is in contact with
the selected model. The system produces 3D profiles.

Please note that the Cutter Contact Area does not work on vertical or near-
vertical surfaces. The steepest angle you should use for best results is 80 degrees.

The following example shows how it is possible to set a clearance distance from the
faces which you don’t want to touch (and mark) with the tool.

Yellow profile= working area limit.


Green profile= cutter contact area profile computed inside the working area ( yellow Stock oversize: The distance between the surface and the cutter (and the boundary) If
profile) you set the distance to be zero, the boundary will be based on calculating the
“D” = Clearance distant from the vertical faces. This distance has been made setting movement of the cutter along the surface itself. If a positive number, it will be above
the vertical oversize on the parameters window. the surface, if a negative number, it will be below the surface.

User interface Use vertical oversize: If selected, this parameter allows you to specify an additional
The option is available in the following situations, when : oversize value only on the vertical faces.
Focus on project item
Focus on tool item Constraint: Most machining operations or 3D boundary creation constrains or limits the
Focus on operation item tool centre to the edge of the boundary or surface; it can move no further than this. But
when creating a boundary with Cutter Contact Areas, you can constrain or limit the
Step 1: tool contact point to the boundary instead, in effect the machinable area is offset by
Define your tool - the tool you will use to machine inside the Cutter contact areas the radius of the cutter.
boundaries. If previously the focus was on an already used tool, the system will use this Centre Point: The point where the cutter contacts the surfaces is always within the
tool. boundary

Step 2:
Select the model geometry on which you want to find the Cutter contact area (using
the same dialog box used for the geometry definition for 3D machining operations).

Step 3:
Select profiles as boundary limitation for the Cutter contact areas.

Contact Point: An edge of the cutter is always within the boundary.


Offset: The Shallow Area boundaries are offset outwards along the surface by this
amount after they have been made. Sometimes it may be advantageous to put in a
small offset value; you can prevent jagged boundary edges where an area of a
surface is at an angle similar to the Contact Angle

Holder clearance: Defines the safety distance between the holder and the model
geometry.

Please note that “Holder clearance” is automatically switched on if has been


selected tool + tool holder.
Step 5:
After computing, the system will display the following dialogue box and will create the
Angle Max and Angle Min allows you to Set the contact angle range of your tool by
Contact area boundaries on the working layer as shown.
setting the minimum and maximum contact angle. Boundaries will be drawn around
areas where the angle is within that range. For Shallow Area boundaries, the range
should typically be between 0 and 30 degrees, but where surfaces are very close to the
minimum or maximum angle, you may get an undesirably jagged edge so you may
want to alter the range slightly. Alternatively, you can sometimes get rid of jagged
edges by giving the boundary a small offset.

Try it out
Use the reference material as a guideline for this exercise.

Open the file cutter contact.wkf

Use a 6mm Ball Nose Tool and the following settings

Max Z level: This is the highest positions of the tool along the z-axis
Min Z level: This is the lowest positions of the tool along the z-axis
Contact Areas Only: This option should be selected (ticked) to limit your boundary to
the surface, with no major material clearance. If you want to create boundaries that
include non-contact areas, then the option should not be selected (box not ticked).

Resolution: This is the granularity of the calculation. The smaller the value, the finer the Should create 39 cutter contact boundaries.
detail of the boundaries made, but the slower the calculation.

Minimum diameter: The diameter is the span of the boundary, the distance between
two points on either side. Boundaries that have a diameter smaller than this value are
discarded
Step 3:
Fillet Surfaces Select profiles as boundary limitation for the Fillet surface. In our case we can click the
Right Mouse Button to continue.
This option allows you to create fillet surfaces (mesh format) on all the edges of the
selected model. Step 4:
Selecting mesh fillets entities in your model geometry definition, allows you to reduce The system will display the following dialogue box:
sharp changes in cutter direction and machine more quickly. By adding curves to the
internal corners, the cutter does not have to dramatically change direction while
rotating, and this helps to prevent damage to tooling and the machined piece thus
allowing for faster feedrates.

Tolerance: The tolerance to which the new fillet surfaces will be triangulated. A lower
value will give more accurate results, but will increase the calculation time.
User interface
The option is available in the following situations: Resolution: This is the "granularity" of the calculation. Using a smaller value will give the
x Focus on project item finer detail but will increase the calculation time.
x Focus on tool item
Number of facets: This is the number of flat faces (triangles) across the radially curved
x Focus on operation item
section of the fillet.
Step 1:
Define your tool – the system will use his shape to Bitangency angle: This is the minimum angle required between the two contact point
generate the fillet geometry. It is possible to select End of the tools to find edges. If the contact points have an angle less than the “Bitangency
mill, Ball nose, Bull nose (also tapered) and eventually a tool holder. Select the tool as angle”, the fillet surface will not be generated.
shown below.

End Mill Conic End Mill Ball Conic Cutter

Max Z level: This is the highest positions of the tool along the z-axis
Min Z level: This is the lowest positions of the tool along the z-axis
Holder clearance: Defines the safety distance between the holder and the model
Step 2: geometry.
Select the model geometry on which you want to create Fillets (using the same dialog
box used for the geometry definition for 3D machining operations).
Please note that “Holder clearance” is automatically switched on if has been
selected tool + tool holder.
Step 5:
After computing, the system will display the following dialogue box and will create the
Fillet surfaces on the working layer as shown.

Try it out

Use the reference material as a guideline for this exercise.

Open the file filletsurface.wkf

Use a 10mm Ball Nose Tool to define the fillet surfaces and the settings shown.

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