Lathe Manual

Lathe ModuleGibbsCAM 2009, v9.0

version 1.1, February 2009

Proprietary NoticeThis document contains propriety information of Gibbs and Associates and is to be used only pursuant to andin conjunction with the license granted to the licensee with respect to the accompanying Gibbs and Associateslicensed software. Except as expressly permitted in the license, no part of this document may be reproduced,transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, inany form or by any means, electronic, magnetic, optical, chemical, manual or otherwise, without the priorexpressed written permission from Gibbs and Associates or a duly authorized representative thereof.

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

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

© 1996-2009 Gibbs and Associates, a Cimatron® Company. All rights reserved. The Gibbs logo,GibbsCAM, GibbsCAM logo, Virtual Gibbs, Gibbs SFP, MTM, SolidSurfacer, and “Powerfully Simple.Simply Powerful.” are either trademark(s) or registered trademark(s) of Gibbs and Associates in theUnited States and/or other countries. Windows Vista and the Windows logo are trademarks orregistered trademarks of Microsoft Corporation in the United States and/or other countries. All otherbrand or product names are trademarks or registered trademarks of their respective owners.Contains Autodesk® RealDWG by Autodesk, Inc., Copyright © 1998-2008 Autodesk, Inc. All rightsreserved.

Gibbs and Associates323 Science Drive

Moorpark, CA 93021

Modif ied: February 10, 2009 10:37 pm

Table of Contents

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Table of ContentsINTRODUCTION TO LATHE 1How to Learn the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Help Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Text Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PART SET-UP 5Document Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Part Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Machine and Stock Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TOOL CREATION 11Tool Creation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Lathe Tool dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Tool Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Insert Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Insert Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Insert Orientation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Tool Holder Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Tool Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Turret Shift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Tool Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Cutter Radius Compensation (CRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Tool List Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

MACHINING 23Machining Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Creating an Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Multiple Tool Dragging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26What is a Cut Shape?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Multiple Process Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Modifying an Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Machining Palette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PROCESSES 29Process Dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Contour Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Contour Cut Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Contour Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Contour Style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Rough Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Roughing Cut Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Rough Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Clearance Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Rough Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Stock Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Roughing Feeds and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Cut Direction Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Thread Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Thread Cut Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Thread Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Thread Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Thread Clearance Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Thread Machining Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Holes Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Holes Entry/Exit Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Holes Drilling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Holes Clearance/Drill Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Holes Machining Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Thread Dimensions - Defining the kind of thread to cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Cut Information - Defining how to cut the thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Depth Of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Thread Location - Defining where to cut the thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Cutting standard NPT Pipe Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.5" - 8 NPT External Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492.5" - 8 NPT Internal Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

American National Standard Taper Pipe Thread (NPT) Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Pre-Defined Process Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

OPERATIONS 53Clearance Moves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Auto Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Fixed Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Clearance Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Approaches from Tool Change Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Exits To Tool Change Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Same Tool Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Canned Cycles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Machining Markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

How Machining Markers Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Start and End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Selected Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Using The Profiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Material Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Operation Tiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Touch-Off Point Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

CUT PART RENDERING 71Cut Part Rendering Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Comparing Standard and Flash CPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Rendering Palette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Cut Part Rendering context menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Optional Stop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Current Display Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Fast Update. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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Flash Cut Part Rendering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Flash CPR Context Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Flash CPR/Simulation Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Printing the Cut Part Rendered Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

POST PROCESSING 81Post Processing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Post Processor Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Posted Output Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Post Output Preferences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Lathe Post Label Definitions and Code Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 852-Axis Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Label Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Code Issues: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3 & 4-Axis Mill/Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Label Definitions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Code Issues: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

COMMUNICATIONS 89About Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Adding a Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Changing a Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Removing a Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Communicating with a CNC Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Communications Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Sending a File to the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Sending Other .NCF Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Receiving a File from the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

LATHE TUTORIAL 95Exercise #1: Lathe Tutorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

This tutorial explains how to:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Part Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Custom Stock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Creating the Operations - OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106Creating Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Multiple Process Group Op 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Multiple Process Group Op 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Creating the Operations - ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Multiple Process Group Op 9-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Op 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Cut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Op 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Post Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Exercise #2: Form Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Form Tool Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Table of Contents

iv

PART PRINTS 133

INDEX 137

INTRODUCTION TO LATHE

Introduction to Lathe

3

CHAPTER 1 : Introduction to LatheHOW TO LEARN THE SYSTEMCongratulations on your purchase of the most productive programming system available! The most effectiveway to learn the system is to look through the Getting Started Guide to become familiar with the system andhow it works. After going through Getting Started you should complete the exercises in the Geometry Creationmanual followed by the tutorials contained in this manual. For simple explanations of on-screen items andtheir purpose, use Balloons and Prompting provided in the Help menu. The Common Reference Guide willhelp you with items contained in the menu bar.

This manual is intended for users of a basic 2-Axis Lathe; however, the lessons learned are applied across moreadvanced C-Axis and Multi-Task Machines. This manual covers information specif ic to Lathe machines;however, most of the interface concepts are similar to other types of machining. After elaborating the conceptsof creating geometry, this manual proceeds with information on part set-up, tools, toolpath generation,Posting and communications with a CNC.

HELP SYSTEMSOnline Help, Balloons and Prompting are built-in documentation and training information, also known asC.A.T. (Computer Aided Training). They are accessed from the Help menu or with a shortcut key (Ctrl+B).They provide reference information, rules, and assistance in using the system. For more detailed informationon Balloons and Prompting, see the Common Reference guide.

TEXT CONVENTIONSIn this and all other GibbsCAM manuals you will f ind a number of standards used in the text, known asconventions.

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

Keystrokes: Words that appear like this refer to a keystroke or mouse action, such as right-click orCtrl+C.

Term: Words that appear like this followed by a colon refer to a word or phrase used in GibbsCAM.

Introduction to Lathe

4

PART SET-UP

Part Set-Up

7

CHAPTER 2 : Part Set-UpDOCUMENT DIALOG

Clicking on the Document button will bring up the Document dialog. This dialog is actually acombination of two linked dialogs. The top dialog contains general information about the part such as the

Machine and Material information. In addition, the top dialog provides f ile management options which givethe user control over where the f ile is stored on the computer. The bottom dialog provides specif icinformation about the part such as stock size, clearance moves and Tool Change positioning.

1. Machine list2. Part Material3. File Control4. Measurement Units

Top section of the Document Control dialog, the Part Details.

5. Stock Size diagram6. X Dimension Style7. Auto Clearance Option8. Fixed Clearance

Positions9. Tool Change Position10. Lathe Shank Size11. Mill Tool Holder Class12. Part Comment

Bottom section of the Document Control dialog, the Machine and Stock Details.

Part Set-Up

8

PART DETAILSThis part of the dialog contains a part’s basic parameters including the type of machine to be used, the materialthe part is made of, whether the part is metric or imperial. This section of the dialog also contains commandsfor opening, closing and saving part f iles.

File Control: The buttons used for f ile management described below are also available under the File menu.

Open (Ctrl-O) : Clicking on the Open button will bring up the Open dialog which allows the user to selectwhich f ile to open. If a f ile is currently open, it will be closed and the selected f ile will be opened.

New (Ctrl-N) : This button will create a new f ile by opening a dialog and asking for a f ile name and alocation to save the new f ile. If there is a f ile open, it will be closed.

Save (Ctrl-S) : If there have been any changes made while the f ile was open, this button will save thechanges.

Save As : This button will open a dialog asking for a f ile name and a location to save the current f ile. Thechanges made since the last Save command will be written into the new f ile. The original f ile will not beaffected. The new f ile will become the current, open f ile.

Save Copy : This button is very similar to the Save As button. The system will create a duplicate copy of theopen f ile. The original f ile remains the current, open f ile. The name of the duplicate f ile can be changed.

Close : This button closes the current f ile. If the f ile has not been saved before clicking on the Close button,a dialog will come up asking if the f ile should be saved.

Machine list: Clicking on the Machine pop-up menu will produce a list of all machines the software is set up tohandle. A copy of the Machine Type selection is stored with the part f ile. Thus, if you have a custom MDD(machine type f ile) you may easily transfer the part f ile to another system. If the Mill, Advanced CS or Multi-Task Machining modules have been installed, there will be additional choices.

Part Material: The information in this box is used to specify the material of the part. This will help in thecalculation of feeds and speeds for the machining processes. The calculations will come from either theCutDATA Material Database (which is an option that can be purchased with the system) or from the defaultmaterial database. A custom material database can also be created. Refer to the “Material Database” section inthe Common Reference Guide for more information.

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

MACHINE AND STOCK DETAILSThe bottom section of the Document dialog is specif ic to the type of part being made. This section of thedialog will change to reflect the part def inition requirements as different machine types are selected. Thus, ahorizontal or vertical turning part’s setup is different from a 3-axis mill part which is different from a 4-axismill part which is different from a Multi-Task Machining part. In this manual we will strictly concern ourselveswith the turning settings.

Part Set-Up

9

Stock Size diagram: This section of the dialog is used to specify the starting size of the part stock. The stock sizeentered here will be used by the system to determine positioning moves when using the Auto Clearancefunction. The stock dimensions will also be taken into account when generating toolpaths with the MaterialOnly option selected in the Process dialog. If custom stock has been created, the system will use the customstock size for toolpath and positioning moves. In that case, the values entered here will only be used to drawthe stock outline and origin marker correctly. The text box for the X dimension will be a radius or diametervalue depending on which option is selected for the X Dimension Style.

X Dimension Style: These two radio buttons determine whether the X values for the part are input as radii ordiameters. Some text boxes in particular dialogs specify that the value entered is either a radius or a diametervalue, regardless of the selection made here.

Tool Change Position: If the Tool Change option is turned “on” the turret will be sent to the X and Z dimensionsspecif ied when a tool change occurs. If Tool Change is not on, it is assumed that either f ixture offsets are beingused or the operator will hand input the tool change moves.

Auto Clearance Option: When the Auto Clearance option is turned on, the system will calculate positioningmoves between operations. These positions will be dynamically calculated, meaning that they will change asthe material conditions of the part change. The value entered is an offset amount from the current part stockthat the system will use to maintain adequate clearance from the material. Refer to “Clearance Moves” onpage 55 for more information.

Fixed Clearance Positions: Fixed Clearance positions must be entered when the Auto Clearance option is turnedoff. When the Auto Clearance option is on, the f ixed clearance position text boxes will be grayed out. The Xand Z values entered specify the location the tool will rapid to and from during a tool change. This positionwill also be used when moving from one approach type to another. Refer to “Clearance Moves” on page 55 formore information.

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

Lathe Shank Size: This is the shank size of lathe tool holders for the current machine. This setting controlswhat tool holders are actually available when def ining tools.

Mill Tool Holder Class: This is the class or standard size of the mill tool holder on the current machine.

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

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

Recommendations: Having Tool Change enabled is best for newer machines which use generic offsets or Work Fixture Offsets. Having Tool Change off is best used with older machines which use G50 offsets.

Part Set-Up

10

TOOL CREATION

Tool Creation

13

CHAPTER 3 : Tool CreationTOOL CREATION OVERVIEWThe tools button in the main palette will open the Tool List. The Tool List can hold up to 999 tools in a partf ile. To create a tool double-click on an empty tile location to open a Tool Creation dialog. This dialog is usedto create and modify tools. Once the tool information has been entered and the dialog closed, a Tool Tile willbe created in the Tool List which displays the tool type and insert width. To index through the various toolsthat have been created, click on the scroll arrows located at the top and bottom of the Tool List.

Tools can be reorganized in the list at any time, even after operations have been created, without reprocessingthe operations. To reorganize the order of tools, click once on the Tool Tile to be moved and drag it to aninsertion point. The system will automatically adjust the operations to reflect the change in tool order andnumber. For more information on Tile Lists, refer to the Getting Started Guide.

Tool specif ications can be modif ied at any point during part creation. However, if operations have beencreated using the tool, those operations must be reprocessed. To reprocess an operation, double-click on theOperation Tile in the Operation List and click on the Redo button. The new tool specif ications will beincorporated into the operation toolpath.

Tool Creation

14

LATHE TOOL DIALOGIn order to def ine lathe tools a Lathe machine type must be selected in the Document dialog. The basicturning tools are created using the Tool Creation dialog shown below. Each of the items contained in the dialogis described in the following section.

TOOL TYPEThis button is used to toggle between mill tools and lathe inserts. Mill tools should only be usedwith the face drilling function unless you have the Mill/Turn or Multi-Task Machiningmodule(s) installed.

INSERT TYPESThis area is used to select the type of insert used with the tool holder. The Insert Specs will change dependingon the selected insert. Below is a list of Insert Types with each type’s available specif ications. In many cases,checking Other brings up different options. The alternate options are listed after Other and any additionalmodif ications are noted. See the Insert Specif ications section for a detailed description of each option.

80° Diamond Insert (80° C): Tip Radius, Inscribed Diameter, Thickness, Other

55° Diamond Insert (55° D): Tip Radius, Inscribed Diameter, Thickness, Other

1. Tool Type2. Insert Types3. Insert Specifications4. Insert Orientation Diagram5. Tool Holder Definition6. Tool Options7. Turret Shift

Tool Creation

15

35° Diamond Insert (35° V): Tip Radius, Inscribed Diameter, Thickness, Other

Round Insert (rnd. R): Tip Radius, Thickness, Included Angle, Other

Square Insert (sqr. S): Tip Radius, Inscribed Diameter, Thickness, Other

Triangle Insert (tri. T): Tip Radius, Inscribed Diameter, Thickness, Other

Trigon Insert (tgn. W): Tip Radius, Inscribed Diameter, Thickness, Other

Pentagon Insert (pent. P): Tip Radius, Inscribed Diameter, Thickness, Other

55° Parallelogram (55° K): Tip Radius, Width, Thickness, Other, Length

Rectangle (rect. L): Tip Radius, Size, Thickness, Other, checking Other replaces Size with insert Length(L) andWidth(W)

Grooving Insert (groove): Tip Width, Tip Radius, Insert Width, Full Radius, Deflection Compensation, Other,checking Other replaces Full Radius with Length

Cut Off Insert (cut off): Tip Width, Tip Radius, Face Angle, Other, Length

Groove Style Threading Insert (thd. N): Style, TPI, Insert Width, Insert Type, Other, checking Other removes theTPI option and replaces Insert Type with Length

Lay Down Style Threading Insert (thd. LT): Style, TPI, IC

35° Profiling Groove Style Insert (35° VN): Tip Radius, Width, Thickness, Other, Length

Form: Thickness, Entry/Exit Angle (Please see the FormTool section for additional data)

INSERT SPECIFICATIONSThis information will change depending on the currently selected insert type. Each of the pop-up menus willlimit the selections available in the pop-up menus that follow it. For example, selecting a Tip Radius will limitthe number of available Inscribed Circles and Thicknesses. Selecting an IC will further limit the number ofThicknesses available. These settings will limit the number of available tool holders and boring bars in theholder diagram. If no tool holders or boring bars are available, the None choice will be automatically selected.

Tool Creation

16

When the Other checkbox is checked, the user can enter any tool specif ications they wish. When Other isselected, the holder diagram is automatically set to None.

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

Entry/Exit Angle: The angle used for plunging into and retracting out of material before and after cutting.

Face Angle: The angle of the insert’s cutting face.

Face Relief: The angle of the insert’s approach, changing affects the Diameter Relief.

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

IC: The inscribed circumference of the insert, effectively the size of the insert.

Included Angle: Used to def ine the touch off point and automatically calculate the Face Relief and DiameterRelief settings for Round inserts.

Inscribed Diameter: The inscribed circle of the insert.

Insert Type: The type of insert.

Insert Width: The width of the insert.

Length: The length of the insert.

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

Size: The IC size of the rectangle. If the Other button is turned on with this type of insert, the length and widthof the insert need to be entered instead of the size.

Thickness: The thickness of the insert.

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

Tool Creation

17

Tip Radius: The tip radius of the insert.

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

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

Style: The thread style of the insert.

Width: The width of the insert. This is utilized when the tip width and the insert width would be the samemeasurement.

FormTool: The system supports custom form tools for Lathe parts. Unlike Mill parts, Lathe form tools must bea closed shape. Be sure to create the shape with the part origin in mind. The origin is used as the touch-offpoint for the tool. All posted output with this tool is relative to this point. The Touch-off point is shown as ared cross in the tool diagram.

The Steps To Make a Form Tool:

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

2. Select the geometry (double click it).

3. Create a new tool, designate it as a Form Tool.

4. Click on the Apply button.

Tool Creation

18

INSERT ORIENTATION DIAGRAMThis diagram is used to specify the orientation of the insert in the tool holder or boring bar.Changing the information will not affect the availability of other items in the dialog, but it willchange the orientation of the drawing in the Holder diagram.

TOOL HOLDER DEFINITIONTool Holder: This option will display the tool holders available for the specif ied insert type and size, as well asfor the machine’s shank size.

Boring Bar: This option will display the Boring Bars available for the specif ied insert type and size. All shanksizes will be displayed.

Custom Holder Definition: This option is onlyrecommended if you need to create a custom holdershape. Holders can be def ined by a geometry prof ile(similar to creating a custom tool shape), by a solidmodel of the holder or by numeric values (Custom). Bydefault the holder is set to None, meaning a holder willnot be used. To use a geometry shape, select thegeometry, select Profile and click OK. To use a solidmodel, select the solid, select the Solid option andclick OK. The Apply To All Selected Tools option willapply the current tool holder def inition to all the tooltiles currently selected. The Show Solid option willshow the solid model that is currently set to be theholder. Clicking the Make Profile button will create ageometry prof ile from the Custom tool holderdef inition.

None: If None is selected, the insert will be drawn without a holder. This is automatically selected if there areno tool holders or boring bars available in the database for the selected insert. The face and diameter reliefangles must be entered. The cross hair marker indicates the Touch-off point of the insert. The radio buttonsbelow the holder diagram designate whether the holder will be shown at its actual size, or at a calculated sizethat is scaled to f it in the diagram.

Tool Diagram: The tool diagram provides information about the touch off and type of holder or boring bar thatwill be used for the insert. The None choice is used for holders not in the software’s database. Use the scroll barto scroll through the list of available holders. The holder selection is used to determine the diameter relief andface relief angles. The red circle on the insert shows the location of the Touch-off point. The radio buttonsbelow the holder diagram designate whether the holder will be shown at its actual size, or at a calculated sizethat is scaled to f it in the box.

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

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

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

Tool Creation

19

Deflection Compensation: If this option is turned on, all contour and rough toolpaths generated with this toolwill contain deflection tool offset utility markers at every location in the toolpath where deflection occurs.This will allow the user to f ine tune the deflection compensation that occurs while using this particular groovetool.

Offset #: When Deflection Compensation is used, this is the offset that we will switch to at the end of thestroke.

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

Insert Material : This is a pop-up menu used to specify the material of the tool. The information given here isused by the Material Database as another factor in determining speeds and feeds. The default setting for Latheparts is Carbide Insert, Coated.

Notch Ramp: By selecting a notch ramp amount in a Tool Dialog, the toolpath will be created by adding theramp value to alternating strokes: one with, one without. In Roughing Operations, this will reduce the depth ofcut on one stroke and increase it on the next. Please ensure that the ramp value is smaller than the depth ofcut. (Notch Ramp is not available for Groove, Cut Off or Thread tools.)

Comment : This is a comment associated with the tool. It will be output in the f inished code at the beginningof every operation that uses this tool.

TURRET SHIFTThis enables a Turret Shift (see below). It is used to specify the preset point for the tool. It can also be used toset up different tool change positions for each tool.

Default Tool Change: This is a reference to the setting in the Document Control Dialog.

Preset Point: This information is only required on some older machines. The two boxes are for entering the Xrand Z distances from the preset point to the default tool change position. They are absolute values. These valesare unique to each tool This function is useful for pre-programming G50 offsets in the off ice using GibbsCAMrather than on the floor.

Turret Shift Dialog: This dialog is used to specify the distance from the preset point (also known as the Touch-off point or the theoretical tip of the tool) of the tool to the center of the turret. It can also be used to specify adifferent tool change position for the tool.

1. Default Tool Change2. Preset Point3. Turret Shift

Tool Creation

20

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

CUTTER RADIUS COMPENSATION (CRC)In the File > Preferences > Machining Prefs dialog there are options to control the CRC types for Milling andTurning ops. Tool Center is the recommended option because that is the method used by the system to displaythe toolpaths and cut part rendered images regardless of the setting of the Contour Cutter Comp, which onlyaffects the posted output.

When the Tool Center item is selected, the numbers generated in the posted code will be the geometry offsetby a tip radius (providing the Stock amount is 0). Tool Center is the recommended selection for thispreference. When the Tool Edge item is selected, the numbers generated in the posted code will be the same asthe blueprint numbers.

Roughing operations will always be calculated from the tool center. If the Tool Edge item is selected for thispreference, CRC should be turned off in all roughing operations.

When using Tool Center, the offset in the CRC register at the control should be the difference between the tipradius of the actual insert used and the tip radius of the insert programmed in the system. If the inserts areidentical, the CRC offset number should be zero. If the actual insert is smaller, a negative value can be used.

When using Tool Edge, the offset in the CRC register must be the full tool radius. Toolpath is to the tool edge,including tool geometry. You also need a post processor that supports Tool Edge output. If your post processoris incompatible, the system will warn you if this incompatibility.

When using Finish Profile, the output path is the prof ile that follows the selected geometry. The CRC registermust contain the full tool radius and any desired stock amount.

!

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

Tool Creation

21

TOOL LIST SUMMARYSelecting Tool List Summary from the Window menu displays the Tool List Summary dialog which providesinformation in spreadsheet form about each tool contained in the Tool List. The information in the dialog caneither be saved as a text f ile or printed out. To save the summary as a text f ile, select the Tool List Summaryitem from the Save Special submenu in the File menu. To print the summary, select the Tool List Summaryitem from the Print submenu in the File menu.

Tool Creation

22

MACHINING

Machining

25

CHAPTER 4 : MachiningMACHINING OVERVIEWClicking the Machining button will bring up the Process List, the Machining palette, and theOperation List. The Process List is used to create sets of operations to be performed on cut shapes. TheMachining palette contains Function Tiles that when used in conjunction with Tool Tiles create Process Tiles.The Process List is a “staging area” that is used to generate f inished operations which contain the toolpaths forcutting the part. When an operation is f inished and placed in the Operation List, the items in the Process Listcan be thrown away or reused with a different cut shape. The Operation List contains the completedoperations that will be output during post processing.

CREATING AN OPERATIONEach tile in the Process List will be applied to the selected geometry. A Process Tile is created by dragging aFunction Tile from the Machining palette and a Tool Tile from the Tool List to the same location in theProcess List. They can be dragged in any order. When a Process Tile is complete, a Process dialog specif ic tothe chosen machining function will appear. This dialog contains detailed information about the way theoperation’s toolpath will be created.

To def ine multiple processes with the same machining type, hold down the ALT key and drag a machining tileover any selected process tile. This will apply the machining process to all selected tiles.

Contouring and roughing functions require that geometry be selected to act as the cut shape for the operation.Machining Markers are used to select the portions of the geometry to be used as the cut shape when creating atoolpath. The markers will appear on the geometry when it is selected. If a drilling or threading function isbeing used, no geometry is required to create an operation.

1. Tool List2. Process List3. CAM palette

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After the information in the Process dialog has been entered, place the machining markers in the correctlocations on the geometry. Machining Markers are not used for drilling and threading functions. Clicking onthe Do It button will create an operation(s). The operation(s) will be placed in the Operation List. If anycompleted operations are selected (in yellow), the Redo button is available. If the Redo button is depressed,the selected operations will be replaced by the new operations. Clicking on an empty operation location or aninsertion point between operation locations will deselect all the operations.

Operations contain the f inished toolpaths. A toolpath consists of the actual moves the tool will make. Thetoolpath is based on the cut shape. The data contained in the operation is what the post processor will use tomake G-code.

MULTIPLE TOOL DRAGGINGThere are two behaviors to consider when dragging multiple tools. First, by selecting multiple tools (shift-clickor CTRL-click) and dragging the group to the machining palette, the tools will f ill in wherever they aredropped. If there are machining tiles present, they will be populated. If the machining tiles are blank, the toolswill populate wherever they are dropped (including between tiles if placed on an insert point.) If you holddown the ALT key when dropping tools on top of machining tiles, the tool (or tools) will populate all selectedtiles.Holding down ALT and dragging also works to populate multiple tools with process tiles at once.

WHAT IS A CUT SHAPE?A cut shape is used to generate a toolpath. It is not drawn on the screen, but can be visualized as the f inishedshape left after the removal of material by the toolpath. A cut shape (not the original geometry) is used tocreate a toolpath because programming the toolpath to the geometry as it is def ined on the blueprint willusually gouge the part. The software automatically generates the cut shape. Various specif ications andlimitations are taken into consideration in the creation of the cut shape.

The machining markers (the start and end point and start and end feature markers) allow the user to specifythe portion of geometry (or the entire shape) that will act as the initial outline of the cut shape. The systemthen takes into account the physical attributes of the tool being used in the process, such as insert type, toolholder, relief specs, etc. in order to prevent possible tool interference when applying the tool to the cut shapebeing machined. The cut shape is further governed by information entered in the Process dialog, such asEntry/Exit Radius, Stock Shape, Axes, etc. The system employs the concept of a cut shape so that it is notnecessary to create different geometry for different operations in order to avoid gouging the part.

MULTIPLE PROCESS PROGRAMMINGThe Material Only option available in the Contouring and Roughing Process dialogs is particularly useful whendoing multiple process programming. Material Only provides for “no air cutting.” When selected, the systemoptimizes the toolpaths created by only making feed moves where there is material that needs to be removed.The system takes into account the material conditions in terms of what has already been cut in previousoperations, including those contained in the same Process List.

MODIFYING AN OPERATIONDouble-clicking on an item in the Operation List will recreate all of the information in the Process List. It willalso select the geometry and place the markers exactly as they were when the Do It button was pressed. Anyoperations that were created at the same time as the selected operation will become selected and theirinformation will also be placed in the Process List. Click on the Redo button after the changes have been made.This will replace all selected operations in the Operation List with the newly created operations.

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

The order of machining in the f inished NC program is the same as in the Operation List. This means that theorder of Operation Tiles in the Operation List is very important. Eff icient use of multiple processprogramming may produce operations in a less-than-optimal machining order. The Operation List can beorganized as the part is being created or when all operations to cut the part have been completed. Clicking onthe Sort Operations menu item from the op tile right mouse menu reorganizes the operations by tool numberand creation order. Operations created in the same Process List will maintain their order to ensure thatf inishing passes cannot be moved in front of roughing passes, etc. The Operation List can also be manuallyrearranged by moving tiles to different locations in the list.

While the Operation List can be reorganized to create a more optimal machining order, there are some otherconsiderations. When using the Auto Clearance option and/or the Material Only option, the system takes intoaccount the material conditions when it creates the positioning moves and toolpath for each operation.Changing the order of operations has the potential to change the initial material conditions for existingoperations. If the order of operations is changed or operations are added or removed from the list, thetoolpaths and positioning moves should be checked. Rendering the part is a good way to check if changes needto be made to the tool moves due to tool interference or unnecessary incorrect positioning moves. Ifadjustments need to be made, the operations must be reprocessed. Reprocessing all operations in a part f ile isvery easy using the Redo All Ops item under the Edit menu. When the operations are reprocessed, the systemwill recalculate all of the toolpaths and positioning moves based on the new order of operations.

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PROCESSES

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CHAPTER 5 : ProcessesPROCESS DIALOGSProcess dialogs appear on the screen when a Function Tile from the Machining palette and a Tool Tile fromthe Tool List are placed in a Process List location. There are four types of Process dialogs that correspond withthe four types of functions available in the Machining palette. The options available with each of theseprocesses are described in this section.

CONTOUR PROCESSThe Contour process is used to take a single pass along a shape. When a Contouring Function Tile iscombined with a tile from the Tool List, the following Process dialog will appear.

Contour Cut OptionsApproach Type: This should be the f irst selection made in any Process dialog. The Approach Type selectiondesignates the axis (Z or X) along which the tool will approach the part. The OD and Front ID options specifythat the tool approach and retract along the X axis, while the Front Face option requires that the tool approachand retract along the Z axis. Also, selecting one of these radio buttons will change the Clearance Diagram thatappears in the middle of the Process dialog.

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

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

1. Contour Cut Options2. Contour Entry and Exit3. Contour Style

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Entry Clearance specif ies the diameter or radius location the tool will make a rapid move to before feeding tothe operation start point. The Exit Clearance position specif ies the location the tool may rapid to aftercompleting its toolpath for that operation. Both boxes are labeled with arrows going towards and away fromthe part, respectively.

Forward: This indicates the direction the tool will move along the designated cut shape. If the Forward optionis selected, the tool will move from the start point to the end point of the selected cut shape as designated bythe machining markers. Left unchecked, the tool will move from the end point to the start point of the selectedcut shape.

Square Corners: This checkbox determines the external corner moves for a cut shape. When this option isturned on, the system does not add a radius move at the corners of the cut shape. Instead, the tool only makessharp moves when going around a corner and will leave contact with the f inished shape, possibly creating aburr at the corner. If this option is not selected, the system automatically makes a radius move when roundinga corner so that the tool always stays in contact with the part.

No Drag: A checkbox that indicates how the contour will be cut. When this option is selected, the chosen cutshape is automatically broken up into segments that will be cut along the positive insert angle direction. Allcutting will be “pushing” the insert, not “pulling” it.

Deflection Compensation (Groove Tool): By choosing a “No Drag” styletoolpath you have the option to specify a deflection compensation amount.The tool motion is modif ied whenever the deflection compensation is ineffect. This will break a contour into (possibly) several toolpaths so that theinsert is always cutting in a “forward” direction. This eliminates drag or cutting with the back side of the insert.

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

Contour Entry and ExitThe Entry and Exit options can create additional movements that will be added to the tool path. When the f irstoption is selected, a 90° arc of the specif ied radius value will be added to the toolpath. This arc will be tangentto the start feature at the start point. If a value is entered in the Line text box, a line of the specif ied length willbe created tangent to the arc. Also, if this is selected and the radius value is zero, the line will not be

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perpendicular but instead will be parallel. When the second option is selected, a line of the specif ied lengthwill be added to the cut shape. This line will be perpendicular to the start feature at the start point.

Selecting the Advanced option allows you to def ine custom Entry and Exit Moves using the Entry/Exit Tab.The options and behavior of these moves are similar to Mill entry/exit except that there are no Z Ramp movesfor Lathe. You may def ine moves for Entry and Exit independently. Checking the Exit option enables the Exitmoves, which can be set to the defaults or to advanced options.

Radius Entry/Exit: Select this option to base your entry/exit move on a radius.

CRC Line: This generates a line that allows Cutter Radius Compensation to activate. The CRC line can betangent or perpendicular to the Off Part Line depending on your machining preferences.

Off Part Line: This is generated after the CRC line, and generates a line that feeds into (or off for exit) the part.

Entry/Exit Radius: This determines the radius of the entry/exit curve.

Off Part Dist: This determines how far the system should follow the radius of the entry/exit curve. If this valueis equal to the entry/exit radius, a 90-degree curve will result.

Line Entry/Line Exit: Line entry or exit will be based on a custom angle. The entry/exit axis will beperpendicular to the feature.

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Contour StyleThe Contour Style selection affects the toolpaths created for the current operation. If the Material Only optionis selected, the system takes into account the current stock conditions, including custom stock specif ications,when creating the toolpaths for an operation. When Material Only is on, the toolpath will only feed over areasthat have not yet been machined in previous operations. The system keeps track of material removed inprevious operations and generates the current toolpath based on that information, providing for “no aircutting.”

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

The Clearance value specif ies an offset amount from the material that the system uses to calculate where thetool can safely rapid during an operation. If the tool is within the clearance amount, only feed moves will beallowed.

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

Corner Break: The value entered in this text box specif ies a radius that will be put on every outside sharp cornerof the selected cut shape. A value of zero will not break the corner, but will keep the tool in contact with thepart as it moves to the next feature. Note that Corner Break is only available when Square Corners is notselected.

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

Xr Stock: The Xr Stock value allows the user to specify any additional stock amount for the X axis. The valueentered here specif ies the amount of material that will be left on the cut shape along the X axis only.

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

Cutter Radius Compensation On: A checkbox that indicates whether Cutter Radius Compensation is turned onor off. GibbsCAM has a number of rules for when and where it will generate CRC markers. These rules havebeen chosen so as to be as safe as possible for the widest range of machines. This means that while a specif icmachine may be able to handle different CRC rules, we will not generate markers for all cases by default. CRCrules on arcs are the primary example of this.

For new toolpaths, GibbsCAM will do the following:

1. CRC will be activated on entry moves, before the entry arc. If there is no move before the entry arc, CRCwill be activated on the arc. GibbsCAM has a warning that will tell the end user when they are using CRCwithout a line move. In general we consider CRC activation on an arc to be an invalid case, because it doesnot accurately cut the arc.

2. CRC will be activated on exit moves, after the exit arc. If there is no move after the exit arc, the CRCdeactivation will be made on the Depth move. Again, GibbsCAM will warn when a user does not have aline move. In general we consider CRC deactivation on an arc to be an invalid case, because it does notaccurately cut the arc.

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3. Some Operations have the option of deferring CRC activation until later in the toolpath (roughing with af inish pass.) Rules 1 and 2 will be applied to the f inish pass only.

For old Toolpaths, GibbsCAM will only follow rules 1 and 2. No markers will be added for rapids imbedded inthe toolpath.

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

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

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

The SFPM and Feed values can be automatically calculated based on the material selected if the CutDATAMaterial database is installed. In order for these values to be calculated and entered in the appropriate boxes,the SFPM and Feed buttons must be clicked. If no material is selected or the CutDATA Material database is notinstalled, the user will need to manually enter values for the feed and speed.

Entry Feed: By clicking on the Entry Feed button, the software will calculate the value based on our materialsdatabase. Alternatively, you may manually override the calculated value by inputting your own value. The entryfeedrate is written to the toolpath for output in G code.

Contour Feed: This will calculate the best feedrate based on the material type selected using CutDATA.

Cut Direction Axes: The Cut Direction Axes checkboxes allow the user to regulate the axes and directions of thecut shape. Deselecting an axis will prevent cut shape moves in that axis direction. The default settings shouldhave all axes selected.

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ROUGH PROCESSRough processes are used to take multiple passes on a shape. When the Rough function tile is combinedwith a Tool tile, the following Process dialog will appear.

Roughing Cut OptionsApproach Type: The Approach Type selection designates the axis (Z or X) along which the tool will approachthe part. The OD and Front ID options specify that the tool approach and retract along the X axis, while theFront Face option requires that the tool approach and retract along the Z axis. Also, selecting one of theseradio buttons changes the Clearance Diagram that appears in the right-hand corner of the Process dialog.

Cut Direction: These checkboxes indicate the direction the tool will move along the designated cut shape. If theForward option is checked, the tool will move from the start point to the end point of the selected cut shape asdesignated by the machining markers. Otherwise the tool will move from the end point to the start point ofthe selected cut shape. When the Back & Forth option is turned on, the tool will cut in both directions withoutrapiding to the beginning of the toolpath after each pass.

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

1. Roughing Cut Options2. Rough Type3. Stock Options4. Roughing Feeds and

Speeds5. Clearance Diagram6. Rough Style7. Coolant8. Cut Direction Axes

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Rough TypeThe Rough Type radio buttons indicate what type of roughing cycle will be used for the current process. Thethree available rough types are Turn, Plunge, and Pattern Shift. Each rough type has a corresponding ClearanceDiagram. The Plunge and Pattern Shift options will bring up dialogs asking for additional information specif icto the selected rough cycle. The information required for each rough type is detailed below.

Turn: When the Turn option is selected, a Cut Depth amount must be entered that specif ies the depth of cutthe tool will make on each roughing pass. Depending on the Approach Type selected, the cut depth will eitherbe an Xr or Z value. Please note that Notch Ramp (set in the tool dialog) will reduce the depth of cut on onestroke and increase it on the next. Please ensure that the ramp value is smaller than the depth of cut.

Pull Off Wall: Checking this box will cause the tool to pull off the wall instead of machining the wall. This willresult in a “stair-step” toolpath as the tool pulls up and retracts.

Cleanup Pass: A cleanup pass will go back and remove any material left by Pull Off Wall.

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

Plunge dialog: This dialog allows the user to input specif ications forPlunge roughing cycles. The Plunge Angle specif ies the angle at whichthe groove tool will plunge into the part. The default value for thePlunge Angle is 270°, which causes the tool to plunge straight down.There are two options available for the Cut Width. When the Exactoption is selected, the user enters a distance in Z that the tool will stepover on each plunge. The Calculate option will vary the cut width asnecessary so that the toolpath hits the endpoints of every feature in theselected cut shape. When the Center Out Cuts option is selected, thetool will make its f irst plunge in the center of the groove, and thenproceed to rough out each side. The Multi-Pass option performs“breadth f irst style plunging.” This will take cuts across at the samelevel X and then drop down by the step amount. The Plunge Typeoptions allow the user to select the type of move the tool will makewhen it f irst enters the part in a plunge roughing operation. ThePlunge Type options include Feed, Peck Full Out and Peck Retract andare described in detail below.

Plunge: This option designates that the f irst plunge will be acontinuous feed move from the clearance position to the bottom ofthe groove. The First Feed percent value specif ies the percentage ofthe feed rate setting for the Process.

Figure 1: Toolpath generated with Pull Off Wall and a Cleanup Pass.

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On First Plunge Only: For Peck Full Out and Peck Retract, you may designate these options for the f irstplunge only.

Peck Full Out: This option designates that the f irst plunge be a peck. The user specif ies a Peck Amt and aClearance amount. Because it is a Peck Full Out, after each peck the tool will retract all the way out of thegroove to the clearance position. The tool will then reenter the part and begin its peck move a clearancedistance away from the remaining material.

Peck Retract: This option also designates that the f irst plunge be a peck. A Peck Amt is again specif ied. Inaddition, the user specif ies a Retract amount which specif ies how far the tool will come out of the actualcut instead of coming all the way out of the part.

Pattern Shift: This dialog allows the user to input specif ications for Pattern Shiftroughing cycles. The Xr Cut and Z Cut values specify the amount of material to beremoved on each roughing pass. The cut amount in each axis does not need to bethe same.

If the Full option is selected for the Rough Style, the user must enter a Cycle StartPoint and designate the number of passes to be made. The Cycle Start Pointspecif ies the coordinate the tool uses as the beginning point for the Pattern Shiftroughing cycle. This point should be clear of the part. The Fixed option, whenturned on, designates that the tool will return to the Cycle Start Point after eachpass. When this option is not on, the tool will return to the Cycle Start Point minusthe Xr Cut and Z Cut after each pass. The Passes value specif ies the number of cutsnecessary to remove the desired amount of material in this process.

If the Square Corners option is selected, the system will not add a radius move at the corners of the cut shape.Instead, the tool will only make sharp moves when going around a corner and will leave contact with thef inished shape, possibly creating a burr at the corner. If this option is not selected, the system will always stayin contact with the part when moving around corners.

Offset Contour: This type of roughing produces passes that follow the shapeof the part prof ile on every pass, using a decreasing offset for each pass. Thisshould be used when it is desirable to follow the shape of the f inal contourwith all roughing passes. This is advantageous in that each pass removes a consistent amount of material forthe entire pass, unlike other roughing types which can intersect the part prof ile at different positions along thepass. This is particularly important for materials that work-harden due to the fact that these materials cancause too wear or breakage if any of the cutting is performed with a thin amount of material being removed.

Clearance DiagramThe picture will change depending on various options such as the Approach Type selected and the Clearanceoption selected in the Document dialog. Auto Clearance will calculate the clearance positions automatically ifit is the selected option. If not, the user must enter Entry and Exit Clearance Positions which are useddifferently depending on the Approach Type selected.

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

If Material Only is selected as the Rough Style, the diagram will haveoptions for Entry and Exit Clearance Positions as shown in the picture.The Entry Clearance Position specif ies the location the tool will makea rapid move to before feeding to the operation start point. The ExitClearance Position specif ies the location the tool may rapid to aftercompleting its toolpath for that operation. Both boxes are labeled witharrows going towards and away from the part, respectively. The use of the values entered for the EntryClearance Position and Exit Clearance Position changes depending on the Approach Type selected. Refer to theClearance Moves section in this chapter for more details.

The X Stock Start Position designates the position the f irst cut will becalculated from. This position will only need to be specif ied if the Fulloption is selected for the Rough Style (instead of Material Only). Themove from this position to the f irst cut will be the amount of the cutdepth. It will be a rapid move if the Rapid Step option is turned onunder the Full option. Otherwise, it will be a feed move.

The Entry Clearance Position specif ies the position the tool will retract to between each pass. The use of thisvalue changes depending on the Approach Type selected. The use of the value entered for the Exit ClearancePosition changes depending on the Approach Type selected. Refer to the Clearance Moves section in thischapter for more information.

The X Stock Start Position only needs to be specif ied when the Full option is selected for the Rough Style. Thisposition will only be used when either Peck Full Out or Peck Retract is chosen for the First Plunge option.When that is the case, the value entered will be used as the point the f irst peck will be calculated from. Theaxis will change depending on the Approach Type selected.

Rough Style The Rough Style selection affects the toolpaths created for the current operation. If the Material Only option isselected, the system takes into account the current stock conditions, including custom stock specif ications,when creating the toolpaths for an operation. When Material Only is on, the toolpath will only feed over areasthat have not yet been machined in a previous operations. The system keeps track of material removed inprevious operations and generates the current toolpath based on that information, providing for “no aircutting.”

Because of this, the order of operations directly affects how the part will be cut. If the order of operations ischanged or operations are added or removed, all operations should be reprocessed in order to calculate for thechange. The Redo All Ops item in the Edit menu makes reprocessing all operations of a part a very easyprocess.

The Clearance value specif ies an offset amount from the part geometry that the system uses to calculate wherethe tool can safely rapid during an operation. If the tool is within the clearance amount, only feed moves will

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be allowed. This Clearance amount will be looked at along with the Auto Clearance amount when creating anynecessary entry and exit moves.

The Full option gives the user more control over toolpath creation. When the Full option is selected, thetoolpath generated will simply feed over the selected cut shape from the start point to the end point asdesignated by the machining markers. If the Rapid Step option is turned on, the tool will make rapid movesbetween each pass, otherwise all moves in the toolpath itself will be feed moves.

Stock OptionsCorner Break: The value entered in this text box specif ies a radius that will be put on every outside sharp cornerof the selected cut shape. A value of zero will not break the corner, but will keep the tool in contact with thepart as it moves to the next feature. Corner breaks are only calculated with turn and pattern shift roughingcycles.

Fin. Stock ±: The Fin. Stock value specif ies the minimum amount of material that will be left on the cut shapeafter a toolpath is completed. The Fin. Stock amount affects the cut shape which in turn affects the toolpathcreated in a canned cycle.

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

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

Roughing Feeds and SpeedsCSS (Constant Surface Speed): Selecting the CSS item will activate Constant Surface Speed (CSS). CSS will causethe spindle RPM to constantly change based on the diameter the tool is at and the SFPM used. The Max RPMsetting is used to set an upper safe limit on the spindle RPM. If CSS is off, the specif ied RPM value will be usedfor the spindle speed.

The SFPM and Feed values can be automatically calculated based on the material selected if the CutDATAMaterial database is installed. In order for these values to be calculated and entered in the appropriate boxes,the SFPM and Feed buttons must be clicked. If no material is selected or the CutDATA Material database is notinstalled, the user will need to manually enter values for the feed and speed.

Entry Feed: By clicking on the Entry Feed button, the software will calculate the value based on our materialsdatabase. Alternatively, you may manually override the calculated value by inputting your own value. The entryfeedrate is written to the toolpath for output in G code. This value affects every potential entry move of atoolpath.

CoolantFlood: This is the standard coolant option. Additional coolant options are available with custom postprocessors.

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

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Cut Direction AxesThe Cut Direction Axes checkboxes allow the user to regulate the axes and directions of the cut shape.Deselecting an axis will prevent cut shape moves in that axis direction. The default settings should have allaxes selected.

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THREAD PROCESSThread processes are used to create ID and OD threads. When the Threading Function tile is combinedwith a Tool tile, the Process dialog shown below will appear. For more information on thread creation,see “Threading” on page 47

Thread Cut OptionsCut Direction: The selection made for this option determines the direction the tool will move when creating thethread. If the Z- option is selected, the tool will move towards the spindle. If the Z+ option is selected the toolwill move away from the spindle. The Run In and Run Out distances and the actual thread start and end willchange positions in the Clearance/Thread Diagram depending on the cut selection.

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

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

Nominal Xd: The value entered in this text box is the diameter location of the thread as specif ied on the partblueprint.

TPI: The value entered in this text box specif ies the number of threads per inch.

Pitch: TPI and Pitch are interactive inputs. Entering either the TPI or Pitch calculates the value for the otherinput. For example, entering a TPI value of 1.0 will calculate a Pitch value of 25.4 (and vice versa.)

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

1. Thread Cut Options2. Thread Definition3. Thread Depth of Cut4. Thread Clearance

Diagram5. Thread Machining

Parameters

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

The NPT specif ication def ines the taper as 1/16, or 1” vertical for 16” horizontal, with the horizontal measuredon the diameter. This entry requires a radial slope, or 1/32. You may type in 1/32 or you may type in .03125,the decimal equivalent. If your taper is def ined as a radial angle, the slope = arctan (angle).

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

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

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

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

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

Thread Depth of CutThe selections made in this box allow the user to designate the cut depth for each pass of the threadingoperation. The One Finish Pass option specif ies that the tool will make a single pass over the thread. Itsprimary use is to remove burrs or small excesses of material on an existing thread. Selecting One Finish Passwill grey out the Last Cut dialog, as there is only one pass. The Const Cut selection allows the user to designatethe Depth Of Cut that the threading tool will make on each pass. The value is measured as a radius and isentered in the text box labeled 1st. The Const Load selection allows the user to specify the depth of the cutmade on the f irst pass. This value is also measured as a radius and entered in the text box labeled 1st. Theamount of material (the load) removed for that depth of cut will be calculated, and on each successive pass thedepth of cut will decrease while the tool pressure remains constant.

The Last Cut option is selected to prevent any cut from removing less than a given amount of material on thelast pass. The value entered is measured as a radius value and specif ies the minimum cut for the constant loadto diminish to. The Spring Pass option can be used in conjunction with any of the depth of cut selections. Itwill create additional passes equal to the number entered after the thread has been cut.

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Thread Clearance Diagram

If the Auto Clearance option is on, no Entry and Exit Clearance Positions need to be entered. If Auto Clearanceis off, the Entry and Exit Clearance Positions must be entered to specify where the tool will move to whenapproaching and retracting from the part.

Run In values are used if the threading tool needs to begin a certain distance away from the actual thread startin order to accelerate to the proper feed rate. The Z Run In distance allows the user to designate a distancealong the Z axis to begin the threading pass. The X Run In distance can be used in conjunction with the Z RunIn distance to start the thread at an angle. The Run Out values allow the user to designate a distance and anglefor the threading tool to come off the thread and function the same as the Run In values.

The Run In and Run Out labels and values will change positions in the diagram depending on whether the toolis cutting towards the spindle or away from the spindles which is determined by the selection made for cutdirection (Z+ or Z-).

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

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

Prefer Canned: A checkbox that will output threading passes as canned cycles if the lathe being programmed iscapable of handling canned cycles.

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

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

HOLES PROCESSHoles Processes are used to make holes on center (X0). When the Drilling Function tile is combinedwith a Tool tile, the following Process dialog will appear.

Holes Entry/Exit CycleThe selections made here determine the cycle the tool will use to make its hole features. The choices include:Feed In-Rapid Out, Feed In-Feed Out, Tap, Rigid Tap, Peck Full Out, and Peck Chip Breaker. Additional Entryand Exit Cycles are available with custom post processors.

1. Auto Clearance2. Thread End3. Thread Start4. Z Run Out5. Z Run In6. Entry Clearance7. Exit Clearance

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

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

Retract: This text box is only active if Peck Chip Breaker is the selected Entry/Exit Cycle. The value entered herespecif ies the amount the tool will retract after each peck.

Holes Clearance/Drill Diagram

Entry and Exit Clearance Positions will need to be entered only if the Auto Clearance option is turned off, inwhich case these values specify the positions the tool may use when approaching and retracting from the part.The other four values described below are all interactive, automatically calculating the unknown values.

Sharp Tip Z: Specif ies the absolute Z depth of the tool tip, and is the number that will be used in the postedoutput of the f inished code.

Drill Surface Z: Specif ies the absolute Z value of the surface of the part.

Spot Diameter: Specif ies the diameter of the hole at the Surface Z. This is useful when counter-sinking, forinstance.

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

1. Holes Entry/Exit Cycle2. Holes Drilling Options3. Holes Clearance/Drill Diagram4. Holes Machining Parameters

1. Auto Clearance2. Drill Surface Z3. Spot Diameter4. Entry Clearance Plane5. Exit Clearance Plane6. Sharp Tip Z7. Full Diameter Z

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Holes Machining ParametersDwell: The value entered in this text box allows the user to specify the length of time the drill will pause at thehole bottom with the spindle on. The value can either be measured in seconds (entered in the text box labeledsec) or in revolutions per second (entered in the text box labeled revs). Because the two boxes are interactive, avalue only needs to be entered in one and the system will calculate the other.

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

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

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

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

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

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THREADINGThis section is intended to assist in calculating the correct parameters for cutting both straight threads andstandard NPT pipe threads using the system. First, an overview of general thread cutting using the system willbe outlined. There are three things the user must def ine in order to properly cut a thread using the system:what kind of thread to cut, how to cut the thread, and where to cut the thread.

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

Nominal Xd: This is the nominal thread diameter.

TPI: This is the number of threads per inch, (per millimeter for metric parts).

Taper (Slope): This is the decimal slope of the thread taper, measured radially. For straight threads, this valueshould be zero. For standard NPT pipe threads, this value should be 1/32 or 0.03125 (the slope of NPT threads is1/16 of an inch per inch on diameter, which is 1/32 of an inch per inch radially). If you are creating a taperedthread with Run In, Canned Cycles should not be used. This is because most machines cannot handle thissituation.

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

Major Xd & Minor Xd: These values will default to the theoretical major and minor diameters based on a perfectsharp thread. The value as calculated is primarily for reference; this value can be changed as required for theparticular thread class and f it desired. For OD threads, the minor diameter is critical as this will be thediameter that the tool will cut on the f inish pass. On ID threads, the opposite is true. The major diameter iscritical as this will be the diameter that the tool will cut on the f inish pass of an ID thread.

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

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

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

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

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

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

Alternate: This option is only available when the Thrd Angle is selected for the In feed. It will alternate thein feed, resulting in the tool f irst cutting with the leading edge, then alternating to the trailing edge, andthen back to the leading edge, etc. This provides even tool wear, in turn providing maximum tool life.

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

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

One Finish Pass: This option specif ies that the tool only take one cut at the f inish thread depth. This wouldnormally be used to re-cut a thread as part of a de-burring process.

Const Cut (Constant Cut): The Const Cut option will cause the roughing cycle to step in the amount specif ied in1st Xr on each subsequent pass until the tool reaches the Last Cut amount. A larger 1st Xr will result in fewerpasses, while a smaller 1st Xr will result in more passes.

Const Load (Constant Load): The Const Load option is the most commonly used type of thread roughing cycle.This cycle will take a constant volume of material on each pass, resulting in a smaller depth of cut on eachsubsequent pass until the tool reaches the Last Cut amount. The volume removed on each pass is calculatedbased on the depth of cut specif ied in the 1st Xr f ield. This can also be considered a constant amount of toolpressure.

Last Cut: When selected, this option will prevent the roughing cycle from taking any rough passes at less thanthe value specif ied. In addition, the rough cycle will always leave exactly this amount for the last pass.

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

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

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

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

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

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

Z Run Ou: This value will extend the thread by the amount entered. If the threading tool needs to pull out fromthe thread on an angle, enter a value for the Z Run Out and the X Run Out. Typically, a zero would be entered.

X Run Out: When used with Z Run Out, will cause the tool to pull out of the thread on an angle. For example, tospecify a thread pull out of 3/20” at 45 degrees enter 0.150 X Run Out and 0.150 Z Run Out. A pull out move at45 degrees for a distance of 0.150 will be added to the thread cycle.

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

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

First, a given horizontal value must be established to act as a gauge point. Since the Machinery Handbooksupplies the pitch diameter at the start of the thread, the horizontal value most commonly used is Z0 (the faceof the part). The system also assumes this value for the major and minor diameters, and will calculate themajor and minor diameters at the start and end of the toolpath based on this assumption. The advantage ofthis is that only one value needs to be calculated; in the case of external pipe threads, only the minor diameterat the face of the part is needed, and with internal pipe threads only the major diameter at the face of the partis needed.

2.5" - 8 NPT External Pipe Thread1. Find the Pitch Diameter at Beginning of External Thread (E0) from Machinery Handbook: American Pipe

Threads: Table 3 (Basic Dimensions, American National Standard Taper Pipe Threads). For a 2.5" - 8 NPTexternal thread this value is 2.71953

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

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

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

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

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2.5" - 8 NPT Internal Pipe Thread1. Find the Pitch Diameter at Beginning of External Thread (E1) from Machinery Handbook: American Pipe

Threads: Table 3 (Basic Dimensions, American National Standard Taper Pipe Threads). For a 2.5" - 8 NPTinternal thread this value is 2.76216

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

3. Find the Major diameter at the start of the thread. To calculate this value, simply add the nominal threadheight to the Pitch diameter (E1). For a 2.5" - 8 NPT internal thread this would be 2.76216 + 0.096375, or2.858535

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

PIPE SIZE EXTERNAL THREADS INTERNAL THREADS

Nominal Pipe Size TPI Minor Major Minor Major

1/16” 27 0.2439 0.2985 0.2539 0.3085

1/8” 27 0.3362 0.3908 0.3463 0.4009

1/4” 18 0.4360 0.5188 0.4502 0.5330

3/8” 18 0.5706 0.6534 0.5856 0.6684

1/2” 14 0.7045 0.8124 0.7245 0.8324

3/4” 14 0.9138 1.0216 0.9349 1.0428

1" 11 1/2 1.1475 1.2797 1.1725 1.3047

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

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

2" 11 1/2 2.2029 2.3351 2.2302 2.3624

2 1/2” 8 2.6232 2.8159 2.6658 2.8585

3" 8 3.2442 3.4370 3.2921 3.4849

3 1/2” 8 3.7411 3.9339 3.7924 3.9852

4" 8 4.2380 4.4308 4.2908 4.4835

5" 8 5.2944 5.4871 5.3529 5.5457

6" 8 6.3497 6.5425 6.4096 6.6023

8" 8 8.3372 8.5300 8.4037 8.5964

10" 8 10.4489 10.6417 10.5246 10.7173

12" 8 12.4364 12.7286 12.6208 12.7142

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14" OD 8 13.6786 13.8714 13.7763 13.9690

16" OD 8 15.6661 15.8589 15.7794 15.9721

18" OD 8 17.6536 17.8464 17.7786 17.9714

20" OD 8 19.6411 19.8339 19.7739 19.9667

24" OD 8 23.6161 23.8089 23.7646 23.9573

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PRE-DEFINED PROCESS GROUPSAll machining operations are created from the information contained in the Process List. Processes are createdby combining a Function tile with a Tool tile and entering the necessary information in the Process dialog. AProcess Group is the collection of Process tiles contained in the Process List at any one time. A Process Groupcontains all of the tooling and machining information needed to generate a specif ic set of operations.

A Process Group can be saved as an external f ile that can then be loaded into other part f iles. This capabilityallows user to access and reuse common machining and tool data for multiple part f iles quickly and easilywithout having to recreate tools and processes.

Process Groups can be saved by selecting Save from the Processesmenu when the Process List contains the completed Process tiles thatwill compose the group. The system will ask for a f ile name and alocation to save the f ile. Once a Process Group f ile is saved, it can beloaded into any part f ile by selecting the Load item from theProcesses menu. Another way to quickly load Process Groups is bychoosing a directory that contains Process Group f iles. The directoryis chosen by selecting the Set Directory item from the Processesmenu. When a directory is set, all the Process Group f iles containedin that directory will appear in the Processes menu. For a quick load,simply select the name of the Process Group f ile to be loaded from the list.

When a Process Group is loaded into a part f ile, any Process tiles currently highlighted in the Process List willbe removed and replaced by the loaded Process Group (if this removes process tiles that were needed, simplyselect Undo from the Edit menu). If the Tool List contains Tool tiles, those tools will become deselected butnot removed from the list. The system will search through the existing Tool List to f ind the necessary tools forthe loaded Process Group. If the system f inds an exact tool match, that tool will be used. If an exact match isnot found, the necessary tools for the loaded Process Group will be created and added to the Tool List in thef irst available positions. Added tools will be highlighted.

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

OPERATIONS

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CHAPTER 6 : OperationsCLEARANCE MOVESThis section contains information and diagrams on rapiding and feeding around lathe parts. It is veryimportant when working with lathes to avoid tool interference with the part, the spindle, etc., while at thesame time quickly and eff iciently maneuvering around the part. Clearance positioning is the term used forvarious positions the tool will move to when not actually cutting the part.

The primary tool change position is specif iedin the Document dialog. This position can beoverridden on a tool by tool basis using theTurret Shift function in the Tool Creationdialog. For more information on Turret Shift,refer to the Tool Creation chapter. If ToolChange is turned off, it is assumed that thef inished code will be manually edited to handlethe tool change. Otherwise, the tool will startat the Tool Change position entered in thisdialog.

In addition to specifying the position of theturret when tools are changed, the Documentdialog provides the user with two options forhandling part clearance, Auto Clearance orFixed Clearance. The selection made willdetermine how the system will calculatepositioning moves between operations.

AUTO CLEARANCEThe Auto Clearance option performs several functions when it is turned on. It will calculate the part clearancesin both Z and X that are used to position the tool between each operation. These positioning moves will bedynamically calculated for each operation. This means that as the stock conditions of the part change asmaterial is removed, the clearance positions will adjust accordingly. When Auto Clearance is on, the systemwill also take into account where the tool needs to be to begin the next operations’ toolpath when calculatingthe positioning moves. Additionally, the Auto Clearance function may add entry and/or exit moves to thetoolpath in order to safely maneuver around the part. The Auto Clearance function generates the mosteff icient positioning moves around a part. However, canned cycles cannot be used in conjunction with AutoClearance. In order to use canned cycles, which are turned on in Process dialogs by selecting the Prefer Cannedoption, Fixed Clearance positions must be used.

The Auto Clearance option requires the user to enter an offset amount from the part stock that the systemuses to calculate the clearance positioning moves between operations. Because the stock conditions areconstantly changing as material is removed from the part, in order to optimize the toolpaths, an offset amountis used for positioning rather than absolute positions. Fixed clearance, which is used when Auto Clearance isturned off, uses absolute positions.

FIXED CLEARANCEWhen the Auto Clearance option is turned off, f ixed clearance positions are used by the system to calculateclearance moves. The user must enter an overall part clearance in the Document dialog, as well as Entry and

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Exit Clearance Positions in the Process dialogs for each operation. When using canned cycles, f ixed clearancepositioning should be used.

The overall part clearance is entered in the Document dialog in the X and Z text boxes that become activewhen Auto Clearance is turned off. They designate the position the tool will rapid to and from during a toolchange. This position will also be used when moving from one approach type to another between operationsthat use the same tool. The absolute positions specif ied in the X and Z text boxes are locations the tool canrapid to when moving around the part. One or both of these f ixed positions are used whenever a tool is movingto the start point of the toolpath or exiting from the toolpath. Where the tool moves when approaching andretracting from the part depends on the Approach Type selected and the positions specif ied in the ClearanceDiagrams in the Process dialog.

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

Once the Approach Type is selected, the corresponding Clearance Diagram appears in the Process dialog. Theboxes with the arrows next to them represent the Entry and Exit Clearance Positions that the tool may usewhen approaching and retracting from the part. The Entry and Exit Clearance Positions are only requiredwhen Auto Clearance is turned off.

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

CLEARANCE DIAGRAMSThe tool will use some or all of the clearance positions depending on which Approach Type is selected. WhenAuto Clearance is selected, the tool will still move to the positions indicated in the diagrams shown below.However, the system will calculate these positions and they will change as the material conditions of the partchange. Also, when Auto Clearance is on, the system may add additional entry and exit moves as necessary toprevent tool interference. The following conventions are used in the clearance diagrams.

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

Dashed Line Rapid Move

Solid Line Feed Move

SP - Start Point The f irst move of the operation. Not necessarily the Start Point Machining Marker.

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

OP1 Operation 1 (the f irst series of cuts made on the part)

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

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

OD Approach From Tool Change

Face Approach From Tool Change

ID Approach From Tool Change

1. Tool Change2. SP Z, Part Clearance Xd3. SP Z, Entry Clearance Xd4. SP Xd

1. Tool Change2. SP Z, Part Clearance Xd3. Entry Clearance Z, SP Xd4. SP Z

1. Tool Change2. Part Clearance Z, Part Clearance Xd3. Part Clearance Z, SP Xd4. SP Z, Entry Clearance Xd5. SP Xd

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

OD Exit To Tool Change

Face Exit To Tool Change

ID Exit To Tool Change

1. EP Xd2. EP Z, Part Clearance Xd3. Tool Change

1. EP Z2. Part Clearance Z, EP Xd3. Part Clearance Z, Part Clearance Xd4. Tool Change

1. EP Z2. EP Z, Part Clearance Xd3. Part Clearance Z, Exit Clearance Xd4. Part Clearance Z, Part Clearance Xd5. Tool Change

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

OD To Face

OD To OD

Face To ID

1. EP Z2. EP Z, Part Clearance Xd3. Part Clearance Z, Part Clearance Xd4. Part Clearance Z, SP Xd5. Entry Clearance Z, SP Xd6. SP Z

1. EP Xd2. EP Z, Exit Clearance Xd3. SP Z, Exit Clearance Xd4. SP Z, Entry Clearance Xd5. SP Xd

1. EP Z2. Part Clearance Z, EP Xd3. Part Clearance Z, Entry Clearance Xd4. SP Z, Entry Clearance Xd5. SP Xd

Op #1

Op #2

Op #1Op #2

Op #1

Op #2

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Face To OD

Face To Face

ID To Face

ID To ID

1. EP Z2. EP Z, Part Clearance Xd3. Part Clearance Z, Part Clearance Xd4. SP Z, Part Clearance Xd5. SP Z, Entry Clearance Xd6. SP Xd

1. EP Z2. EP Z, Part Clearance Xd3. Part Clearance Z, Part Clearance Xd4. Entry Clearance Z, SP Xd5. SP Z

1. EP Xd2. EP Z, Exit Clearance Xd3. Part Clearance Z, Exit Clearance Xd4. Part Clearance Z, SP Xd5. Entry Clearance Z, SP Xd6. SP Z

1. EP Xd2. EP Z, Exit Clearance Xd3. SP Z, Exit Clearance Xd4. SP Z, Entry Clearance Xd5. SP Xd

Op #1

Op #2

Op #1

Op #2

Op #1

Op #2

Op #1

Op #2

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CANNED CYCLESThe Auto Clearance and Material Only functions of the system calculate more eff icient toolpaths than cannedcycles. Auto Clearance is activated in the Document dialog and designates that the system dynamicallycalculate clearance positioning moves for the part. The Material Only option is located in Process dialogs anddesignates that toolpath calculation for an individual process take into consideration the material conditionsof the part to provide for no “air cutting.” If either of these options are being used, the Prefer Canned optionfound in the Process dialogs will not be available.

Using canned cycles will output shorter processed code however, the Auto Clearance and Material Onlyfunctions will produce more eff icient toolpaths in general. To generate canned cycles in the posted code, turnAuto Clearance off and enter f ixed X and Z clearance positions in the Document dialog, and select the FullRough Style in the Rough Process dialog.

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

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

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

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

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

Move Start\End Point by . . .: The right-click context menu for a start or endpoint includes the Move Start\End Point by . . . option. By selecting this option,you will be prompted by a dialog to enter a new value (+ or -) by which toextend or trim the point from the beginning or end of the last feature. The options presented will depend onwhether you select a Start Point or and End Point machining marker.

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

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

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

START AND END POINTSThe Start and End Points do not necessarily have to be on the part geometry. There may be times when it isdesirable to have the tool start or end its toolpath off the part. This can be done by moving the markers. Ageometry feature (e.g. line or circle) is trimmed between two connectors. When the Start Point marker isdragged off the part, it automatically snaps to the nearest extension of the Start Feature. The nearest section ofthe Start Feature may be a section that was trimmed away, so the Start Point will snap to an extension of theStart Feature. This is also true for the End Feature. The end feature markers may be quickly set using a

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

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Ctrl+Shift click. When performing a Ctrl+Shift click the end point markers will snap to the locationyou clicked.

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

The prof iler may also be used to create the geometry for lathe processes from a solid. For detailed informationon this process please see the 2.5D solids manual or the Solid Surfacer manual.

USING THE PROFILERYou can use the prof iler at Z0 to select a cut shape prof ile directly from a solid. The prof iler acts just likegeometry except that it is volatile and will not be shown when prof iler is turned off. If you create an operationin the prof iler and subsequently turn it off, double clicking on the operation will turn the prof iler back on anddisplay the machining markers.

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MATERIAL DATABASEThe Material Database is used for storing and quickly retrieving feeds and speeds for various types of materials.The calculations will come from either the CutDATA Material Database (which is an option that can bepurchased with the system) or from the default material database. A custom material database can also becreated. The information in the database can be changed by selecting Materials from the File menu. To use theinformation, click on the Material button in any of the Process dialogs. Below is a picture of the Materialsdialog. It is used for both creating and editing materials as well as placing feeds and speeds information intoProcess dialogs. These values can be directly overridden by typing in the speed or feed info in the Processdialog at any time. The Material database is fully detailed in the Common Reference guide.

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OPERATION TILESThe operation list context menu contains several useful functions as detailed in thefollowing paragraphs.

Operation Data: It is possible to edit certain operation specif ications in theOperation Data dialog. Values are locked by clicking once on the lock next to thetext box. Unlocked values will return to their original values if the operation isreprocessed. Locked items will retain the values entered in this dialog even if theoperation is reprocessed. Changes that affect the toolpath can be seen in thetoolpath drawing and the rendered image. The information in the Process Tile thatcreated the operation will not be modif ied to reflect the changes made in theOperation Data dialog.

Information entered in the Op Comment text box willappear in the posted output before the selected operationit refers to. Utility data can also be entered in this dialog.Custom posts allow the user to input custom commandsin the At Op Start and At Op End text boxes that willtrigger actions inside the post processor. In addition, anytext that appears in quotations in the At Op Start and AtOp End text boxes will appear in the posted output. Eachset of quotes will be on a separate line in the postedoutput.

The Program Stop checkbox is only available in theOperation Data dialog. If it is turned on, a program stopcommand will be added at the end of the operation in theposted output. The default position is off.

If operations contain locked values, a small lock symbol

will appear on the Operation Tile. If utility data is

entered in the At Op Start text box, a small recessedsquare will appear on the Operation tile in the upper lefthand corner. If utility data is entered in the At Op Endtext box, a small recessed square will appear in the lower left hand corner of the Operation Tile.

Utility Markers: The Utility Markers menu item allows editing of variousposition-dependent toolpath data. When chosen, the dialog shown willcome up as well as the current operation’s toolpath.

For each operation, you may select a variety of utility marker types, manyof which have additional sub-options. The primary options are VariableFeed Rate, Spindle Speed, Tool Offset #, Text, CRC, Dwell and Tool SubPosition.

To add markers of any type to a toolpath, drag and drop the marker of thedesired type to a toolpath. The currently selected markers properties willbe displayed in the dialog, and the currently selected marker will be displayed in red.

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Additionally, you may select the checkbox to “Show All Markers.” When this checkbox is on, the icons for allutility marker types are displayed on the toolpath. When you step through the markers, the dialog performscontext switching so you can see the details of each utility marker. Each marker now has a unique icon.

All of the new markers will require a post processor upgrade, except for Variable Feed Rate and CRC. Pleasecontact the Tech Support Department for more information.

Variable Feed Rate: This marker allows you to set the feedrate for the elements of the toolpath following themarker. The f ive sub-options for this type of marker are User, Entry, Contour, Percent and Max. User allowsyou to explicitly set the feedrate to your desired value. Entry sets to feedrate to the operation’s def inedentry feedrate. Contour sets the feedrate to the operation’s def ined contour feed rate. Percent sets thefeedrate to a user def ined percentage of the last f ixed feedrate marker. Max sets the feedrate to themaximum feedrate def ined by the post processor.

Spindle Speed: For turning ops, this marker sets the spindle speed to the value def ined in the SMPM orSFPM f ield.

Tool Offset #: This marker sets the tool offset. There are three options available here Tl Offset, Deflect TlOffset and Explicit Offset. Tl Offset will set the offset to the Offset # def ined by the tool. Deflect Tl Offsetwill set the offset to the Deflection Compensation Offset # def ined by the tool. Explicit sets the offset to auser def ined value.

Text: This marker allows you to insert a comment into the posted output.

CRC: This marker is used to turn CRC on or off during an operation. There are three options available forthis marker, On, Off and Reverse. Please see the section on CRC in the Process portion of the manual forfurther details.

Dwell: This marker causes the program to pause (dwell) for the specif ied time. This marker has two option,Seconds or Revolutions. The Revolutions option uses the current spindle speed to compute the time.

Program Stop: This marker causes the post to output a program stop (M0). If the Optional Program Stopbox is checked the post will output an optional stop (M1).

Tool Sub Position: This option is only available for Lathe machines that allow tool sub positions. Thismarker allows you to set the tool sub position.

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

Open Tool: This brings up the tool dialog associated with the operation.

Operation To Geometry: This option converts the selected operations to geometry. This geometry can be editedand used as a centerline contour op if necessary.

Redo Selected Ops: This will reprocess the toolpath for any selected operation(s).

Redo All Operations: This will reprocess the toolpath for all operations.

Move To: This selection allows the user to move one or several of the operationtiles to the end of the list or to another tile location by entering the tab numberof the destination tile location and clicking Move To. It functions exactly thesame as the Move To item on the Tool and Process tiles.

Find: The Find option allows a user to locate a specif ic tile By Tile #, Tool # or tof ind the last tile. It functions exactly the same as the Find item from the Tile ListScroll Arrows.

Sort Operations: This command will change the order of all operations. Theoperations will be sorted by tool number, from low to high. Operations created inthe same Process List will maintain their order to ensure that f inishing passes cannot be moved in front ofroughing passes, etc.

Operation Manager: The Operation Manager is an expanded view of the Operation list. The Operation Manager canshow 31 different operation parameters, can sort operation data and can calculate accurate runtimes. Additionally theOperation Manager and the Operations list have synchronized selection meaning that as operations are selected or

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deselected in one they are also selected or deselected in the other. Double clicking on an entry will load the operation’sprocess tiles

Right clicking on a column header: The itemsdisplayed in the Operation Manager can becustomized. The Operation Manager supports 31different parameters but it is impractical to try andview all at the same time. Right clicking on one ofthe parameter headers, such as the Depth parameterseen in the previous graphic, allows you to choosewhich parameters are displayed.

Right clicking on the title bar: The title bar offersaccess to several very useful commands includingthe sort command and runtimes. Additionally, theOperation Manager can be printed from here.

Sorting: Selecting the Multi-Level Sort… commandopens a dialog where you can select how youwish to sort operations. Operations may besorted by up to four parameters and each maybe in an ascending or descending order. Thesorts are based on the parameters shown in the Operations Manager.

Right clicking on a cell entry: Right clicking on an entry brings up the same menu as right clicking a tile in theOperations list. From this menu you can access things like Operation Data, Utility Markers and Redo functions.

It is important to realize that performing a sort will change the order of your operations. If you are not careful you could tell the system to do something you do not want, such as tapping a hole before the hole is drilled. The system does have a reminder to warn you that performing a sort can be harmful but you should still be aware of the potential consequences.

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TOUCH-OFF POINT INFORMATIONAll post data is output to the theoretical tool tip. If the tool is machining parallel to the Z-axis, the X values areoutput to blueprint dimensions. If the tool is machining parallel to the X-axis, the Z values are output toblueprint dimensions. So, the theoretical tool tip only aligns with blueprint dimensions on faces anddiameters.

When the tool is machining at an angle, the X and Z-axis valueswill not match the blueprint dimensions. This is because thetheoretical tool tip is not always a blueprint dimension. So, inorder for the system to get the surface of the tool in position tocut the part, the theoretical tool tip is calculated closer to thepart, and in some cases inside the part.

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CUT PART RENDERING

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CHAPTER 7 : Cut Part RenderingCUT PART RENDERING OVERVIEWModeling is the process of def ining a three dimensional object. Rendering is the process of displaying a pictureof this model. A cut part model is def ined when the operations necessary to machine a part have been created.The computer has 3D knowledge of the inside of the model, even of the areas that are not visible.

The cut part rendering capability in the system is called Three Dimensional Real Time Cut Part Rendering.“Three Dimensional” refers to the fact that the model can be rotated around in space and viewed at any angle.“Real Time” refers to the speed at which the part is rendered. The cutting action is rendered as it is calculatedrather than calculating the rendered image and then playing back a “movie,” or just displaying a picture of thef inished model. Real Time does NOT mean actual feed rates are used. The tool can cut as fast as the computercan calculate the moves. “Cut Part” refers to watching the effect of the tools cutting, as opposed to seeing onlythe f inished picture. Seeing the cutting process is more valuable, in most cases, than the f inished picture.Rendering refers to the process of displaying the graphic image of the cut part model def ined by the machiningoperations.

The system has two distinct Cut Part Rendering (CPR) methods. The f irst is Standard CPR. Standard CPR is thesystem’s legacy rendering mode. The second mode is Flash CPR. Flash CPR is an OpenGL-based system whichis more powerful and flexible than Standard CPR. We have two modes for CPR because each has its ownstrength. You can use whichever suits your needs or use both modes. Additionally, if you have purchased theMachine Simulation option you can use that render mode.

All operations are rendered in their current order. Selected operations will render in shades of yellow, and allothers will render in shades of grey. Shades of red will be drawn when non-cutting tool surfaces or rapid moveshit the material. Selected tools will be drawn in shades of yellow. Deselected tools will be drawn in shades ofgrey. Smaller pictures will render faster and use less computer memory.

COMPARING STANDARD AND FLASH CPRThe two rendering modes are two completely different technologies. The primary difference between the tworendering modes is that Standard CPR is view dependent while Flash CPR is view independent. Basically, withStandard CPR the rendering process will start over whenever the view is changed or zoomed while Flash CPR isa “machined” solid model so it can be manipulated while being rendered.Flash CPR is far more useful for partanalysis despite its slower speed.

Function Standard CPR Flash CPR

Speed For any specif ic view Standard CPR is usually faster.

The speed of Flash CPR is dependent upon the image quality and size of the rendered image.

Change of View Restarts every time – it is best to select the view you want f irst.

Rendering is not interrupted by a change of view.

Quality A f ixed image quality. Image quality is user-controlled.

Transparency Tools may be set to transparent. Tools, f ixtures and stock can be transparent.

Collision Checking None. Yes.

Facet Bodies None. Create from rendered image and use as a stock condition.

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RENDERING PALETTEWhen the Cut Part Rendering button is clicked, the Cut PartRendering palette appears on the screen, and the stock shape will bedisplayed as a blue, solid image. The Cut Part Rendering palettecontrols the cut part rendering process. The functions of the items inthe palette are described below.

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

Rewind: This button sets the current operation to the f irst operation. If the Play button is down whenthe Rewind button is depressed, the part will be redrawn.

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

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

Play: When the play button is depressed, the part will be rendered from the current feature of thecurrent operation as listed in the Current Display box. Rendering will continue until one of the otherbuttons is depressed or the last feature of the last operation is rendered. The Stop and Step Forward buttonsstop the rendering and raise the Play button. Pressing the Play button during rendering will also stop therendering. The Next Operation and Rewind buttons will change the current operation being rendered, but willnot stop the rendering process. When the last feature of the last operation is complete, rendering will stop, butthe Play button will remain depressed. Anytime the rendering process stops, hitting the Play button again willresume rendering from the current location.

Next Feature: If the Play button is depressed, the current feature being rendered is f inished and theremaining features for that operation are skipped. The next feature to be rendered is the f irst feature ofthe next operation. If the Play button is not depressed, the current operation is set to the next operation. TheOperation Box will be updated, but nothing will be rendered until the Play button is depressed again.

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

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

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

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

During the cut part rendering process, if the screen is redrawn due to a view change or redraw, the renderingprocess will start over from the f irst operation. Therefore, it is good practice to set the desired view beforerendering the part.

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When the rendering process is stopped by pressing either the Stop or Step Forward button, the next time thepart is rendered the system will automatically stop the rendering process at the same location. User set stopsare maintained by the system. Anytime the rendering process is stopped, simply click on the Play button tocontinue.

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

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

Optional Stop controlSet Op Start/Stop #s... This option opens a dialog to specify a start and stoppoint before a specif ic operation begins.

Use Op Start: Placing a check mark on this option activates the Set Op Start #... option. Removing the checkmark will disable the stop point specif ied in the Set Op Start And Stop dialog.

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

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

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

FAST UPDATEThe Fast Update quickly gets you back to the last rendered state of your part after changing the view. If youhave begun rendering your part, press Stop then zoom or change the screen position of the part and press Play,the system will regenerate the rendering in the new viewing position and orientation as quickly as possible. Itdoes this by automatically setting the CPR speed to the fastest speed and hiding the tool when replaying the

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rendering. Once the render reaches the place it was last stopped the controls will revert back to your previoussetting.

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FLASH CUT PART RENDERINGFlash CPR is an OpenGL based rendering option that provides an alternative to thestandard rendering mode. Flash CPR is a non-view dependant option meaning that thepart can be rotated, zoomed and panned during the cut part rendering. There are severalother capabilities that go along with Flash CPR including the Rapid Cut option thatdisplays only the end condition of each operation, resulting in a much faster rendering,but at a lower display resolution. Flash CPR is activated and deactivated by right-clicking on the Render buttonin the Top Level palette and choosing the Flash CPR option. The Flash CPR option uses the same Renderpalette as the traditional rendering engine.

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

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

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

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

Rapid Cut: When enabled this will generate the f inished part in thebackground. The f inished result will be slightly less smooth than anormally rendered part. This will be disabled on any part with a rotarymove.

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

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

Skip Unselected Ops: Skip Unselected Ops will only render thecurrently selected operations.

Op Color Mode... This option utilizes color to enhance the functionalityof CPR and Simulation. The corresponding options sub-dialog has 3 color modes, cut color, tool numberand op number. The color palette is generated automatically to create a set of colors that are readilydistinguishable from one another. The color of the remaining material changes with each operation.

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

Collision Checking: Selecting Collision Checking enables the collision checking based on the options set inthe Preferences, See the section “Flash CPR/Simulation Settings” or the Common Reference Manual formore information.

Show Rapid Tool: When this mode is on (indicated by a check next to the menu item) the tool is renderedin a different color to show when it is moving in Rapid mode.

POV Lock: The choices here all control how the part (or part/machine) move during the simulation sequence. This givesthe user control over how the virtual camera moves aroundthe scene, def ining the point of view during animation.

The choices available for Point of View Lock will be differentdepending on the rendering mode. For CPR, Part Sim and ToolSim, the options are Fixed Part, Tool Rotary Axes, Tool LinearAxes and Too Rotary & Linear Axes. For Machine Sim, thechoices are Operator, Part, Machine Component, Tool RotaryAxes, Tool Linear Axes and Tool Rotary and Linear Axes.

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

Create Facet Body: The Create Facet Body function turns the current cut rendered condition into a facet body.The facet body will appear in the workspace as a transparent body. One of the few uses of facet bodies is thatthey can be set as stock for “display only” purposes, i.e. they cannot be used as a stock condition for creatingtoolpath but they can be shown in rendering for Flash CPR sessions. Looking at the properties dialog you cansee that essentially nothing can be done but setting the body as a part, f ixture or stock. Setting a facet body asstock can be quite useful for saving a rendered condition so you can instantly get to later operations.

Don’t Pre-Load Sub Spindles: Disables sub-spindle stock generation. This will improve performance at the costof not having accurate stock on the sub-spindle during the f irst run.

Reload Simulation: This option will reload the Flash CPR simulation.

Overlay Geometry: This will display the workgroup geometry on top of Flash CPR continuously. To display theGeometry temporarily, use CTRL+], which continues to work as in prior releases.

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Settings: Settings opens the Rendering Preferences dialog thatallows you to control the speed, quality and color of the FlashCPR display. Alternatively, this dialog can be accessed byopening the Display preferences tab (File->Preferences-Display)and clicking the Edit Flash CPR Settings . . . button which opensthe Flash CPR Settings dialog.

Flash CPR/Simulation SettingsCutting: The Cutting options section allow you to control thequality and responsiveness of Flash CPR.

Steps Per Update: Specif ies the maximum number of CPRfeatures to render before updating the display. Large numberswill increase the rendering speed but will result in a rougherrendering animation. With large numbers the tool may appearto jump ahead of rendering, which will suddenly snap to thetool. This may be jerky, but can be rather fast. A low numberprovides a smooth animation, but may be slow.

Cut Part Chord Height: This is the resolution for the part andtools displayed in Flash CPR. There are separate settings forinch and metric tools. The smaller the value, the higher qualityof the display and the more resources needed by the system,resulting in a slower rendering.

Body Chord Height: This option determines the resolution ofbodies (part, stock and f ixtures) in rendering. There are twoways this can be set, either by the Chord Height (which issetting a specif ic value), or by the % of Body’s Chord Heightoption. This second option uses the value set in the Propertiesdialog. A setting of 100% will use the body’s Chord Heightwhile a setting of 10% will is 1/10th of the body’s Chord Height.Any percentage between 1 and 100,000 is acceptable. As thepercentage is set higher the body will appear rougher but thedisplay will be faster.

Collisions/Limits: The items found in the Collisions/Limits section of the dialog provide control over how thesystem reports machining errors while rendering. A collision in Flash CPR occurs when the tool rapids into thestock or touches a f ixture or if a holder touches anything. Any combination of the three available alertmethods may be used. Please note that the Collision Checking option (in the Render Control palette) must beactivated for the system to check for collisions.

Alert Types: The Beep option provides an audible alert, Log To Display will output an error in a collision logwindow and Stock Flash provides a visual alert to the error by flashing the rendered stock. Stop Animation willcease the rendering at the point of a collision.

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Tolerance: The Tolerance setting allows a different value for metric and inch parts. Any collision within thespecif ied tolerance will generate a collision alert.

Slider: This item allows you to change the sensitivity of the render speed control. The render speed is basedaround the size of features being rendered.

Circular Threads: Activate this option to create fake, “circular”threads when using Flash CPR. The rendered thread will be a seriesof indented circles the size of the thread and will not be helical.This option renders much faster then drawing proper, accuratethreads. A comparison of normal and “circular” threads is seen tothe right.

Statistics: Select this option to open a window that shows the FlashCPR frame rate (how often the image is updated while rendering)and any errors that get logged. To close the window you need todeselect this option

PRINTING THE CUT PART RENDERED IMAGEAfter the rendering is complete, the rendered image can be printed in either black and white or color. Whenthe rendered image is on the screen, choose Drawing from the Print sub-menu in the File menu. To adjust theway the image will print, choose Printing from the Preferences sub-menu in the File menu. The PrintingPreferences dialog, shown below, allows the user to specify how the software will handle the background color.If the printer being used is a black and white printer, choose the Black on White option to ensure that allportions of the image, including those that are of a light color, can be seen in the print.

POST PROCESSING

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CHAPTER 8 : Post ProcessingPOST PROCESSING OVERVIEWOnce the operations to machine the part have been created, the f ile needs to be post processed. Postprocessing generates a text f ile (NC Program) that contains the machining operations and toolpathsfrom the part f ile (VNC.) This NC program is created using Post Processor f iles (PST Files) specif ic toindividual machine controls. Communicating the posted text f ile to the CNC machine is discussed in theCommunications chapter which follows this one.

POST PROCESSOR DIALOGThe Post Processor button in the Top Level palette becomes active once machining operations have beencreated in a f ile. Clicking on the Post Processor button will display the Post Processor dialog shown below.This dialog allows the user to select a specif ic post processor f ile, specify a program name and currently openpart.

The Process button will generate the NC program for the f ile currently open. The text f ile will be saved underthe f ile name displayed to the right of the Program Name button. If a f ile with that name already exists,clicking the Process button will erase the old f ile and replace it with the new one. To view the text f ile as itprocesses, click on the Text Window button. When this button is depressed, a window will appear that displaysthe posted text f ile as it is created. The program will scroll by in the window as it is being generated. The Pausebutton allows the user to stop the scrolling of the output as it is being processed. The Print button will beavailable after the program f ile is f inished processing.

1. Post Processor Selection2. Program Name3. Communications4. Text Window

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Before posted output can be generated, the post processor andprogram f ile name must be specif ied. When a f ile is post processed, atext f ile is created with the extension specif ied in the Post text box inthe File Extension dialog. By default, this extension is set to .NCF. Af ile can be post processed multiple times and saved with different.NCF f ile names. If changes are made to the part f ile, it must be postprocessed again in order to incorporate the changes into the postedoutput. As a default, the text f ile uses the part f ile name with an .NCFextension (e.g. EXAMPLE1.NCF). This f ile name can be changed byclicking on the Program Name button and entering a new name.

To specify an output f ile name for the f inished program, click on theProgram Name button. The system will automatically add theextension specif ied in the File Extension dialog. Selecting the File tabfrom the Preferences dialog will display the File Extension dialogshown above.

To select the post processor, click the Post Selection button. An Opendialog will appear that allows the user to access the directory orfolder where the post processors are stored in the system.

The actual f ile names of the post processors are different dependingon the operating system. However, when selecting a post processor,the full name (including the Control and Machine) will be displayedin the Open dialog.

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

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

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

Sequence from: This is the starting number for the block numbers or “N” numbers. The by box determines theincrement.

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

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

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

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POST OUTPUT PREFERENCESThe Post Processing preference allows the user to specify comment data that is output in the NCF f ilegenerated by the system. If an item is checked, that data will be output. This dialog can be found in the Filemenu under Preferences -> Post Processor Comments.

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

The general format of a post can be described as:

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

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

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

2-AXIS LATHELabel Definitions

L This designates a regular 2-axis turning post. A Lathe post has 2 linear axes (X and Z) that can positionand cut simultaneously.

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

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Code Issues:• Tool Tip

1. The system draws the toolpath to the center of the tool tip radius. The X and Z-axis values are output tothe theoretical tool tip if the system is able to calculate a touch-off point in both axes. X or Z-axisvalues are output to the center of the tool tip radius when the software is not able to calculate thetouch-off point in that particular axis.

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

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

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

• Canned Cycles

1. Lathe canned cycles are output when the Prefer Canned checkbox is checked. This checkbox will onlybe available if Auto Clearance and Material only are not selected. If Auto Clearance and/or MaterialOnly are selected, the system will not output Canned Cycles.

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

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

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

I This designates a Mill/Turn post that supports Polar and Cylindrical Interpolation. A Polar andCylindrical Interpolation Mill/Turn post will output a G2 or G3 with rotary moves.

Y This designation is for a 4-axis Mill/Turn machine that has a linear Y-axis.

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

Example: Fanuc 16T [VG] SML800.19.pst

Example: Fanuc 16T [VG] IML800.19.pst

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

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N This designates a Mill/Turn post that does not use subprograms. This is known as a “Long Hand post”.Subprograms are frequently used for multi-process drilling, C-repeat drilling, Z-repeat milling, C-repeatmilling, Patterns (OD only), etcetera.

B This designates a B-axis rotation post. This supports the creation of coordinate systems that has thetool rotate about the B-axis.

Code Issues:• Tool Orientation

1. When using a mill tool on the Face or OD, it is important to def ine the orientation of that toolcorrectly. When Milling or Drilling on the face, make sure the orientation of the tool is perpendicularto the face. When Milling or Drilling on the OD, make sure the orientation of the tool is perpendicularthe OD. If the tool is not oriented properly, the output will not be correct.

• C-Axis And Y-Axis Output

1. The radio buttons Position and Rotary Milling in the Rotate Tab determine whether C-axis moves or Y-axis moves are output during Rotary Mill operations. If the Position radio button is selected, the systemcalculates Y-axis moves. If the Rotary Milling radio button is selected, the system calculates C-axismoves.

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

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

• Rotary Feedrates

1. Most rotary feedrates are calculated in Degrees Per Minute per rotary segment based on its length.Since the length of each segment is variable, the system outputs a different feedrate for each segment.The resulting rotary feedrate can be a large value based on the Degrees Per Minute calculation.

2. Certain CNCs, such as Haas and Mazak, calculate rotary feedrates using Inverse Time. Any Mill/Turnpost can be modif ied to use Inverse Time for feedrates.

3. Polar Interpolation posts use inches per minute for rotary feedrate calculations. Any Mill/Turn postcan be modif ied to use Polar Interpolation with inches per minute feedrates.

Example: Fanuc 16T [VG] PML800.19.pst

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

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

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COMMUNICATIONS

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CHAPTER 9 : CommunicationsABOUT COMMUNICATIONSThe system contains integrated communications. Third party communications packages can also be used tocommunicate with CNC machines.

Before a f ile can be sent to the CNC machine, the parameters for a f ile transfer need to be set-up. This is donein the Com Set-Up tab in the Preferences sub-menu of the File menu. This dialog is used to set upcommunication protocols needed for sending a program (text f ile) to a control or receiving a program from thecontrol. Different controls have different protocols (parameters). Refer to the machine control manual for thenecessary protocol specif ications.

PROTOCOLSADDING A PROTOCOLA new protocol is added by typing in a new name and changing all of the settings to match those of the CNCmachine. Clicking on the Add button will add the protocol to the current database of protocols.

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After a protocol has been added, the name will appear in the upper left hand corner.Additional protocols can be entered and saved in the same manner. Saved protocolscan be accessed in the Protocol pop-up menu in the upper left-hand corner of thedialog.

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

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

COMMUNICATING WITH A CNC MACHINETo send a f ile to or receive a f ile from a CNC machine, click on the Communications button in the PostProcessor dialog.

COMMUNICATIONS DIALOGThe Communication dialog can also be accessed from the File menu. Files can either be sent to the machinecontrol or received from the control. The File type radio buttons indicate what type of f ile will be sent. When af ile is post processed, a text f ile (NCF f ile) is created. NCF (text) is the necessary selection when sending postedNCF f iles from the computer to the control or vice versa. The VNC (binary) selection allows users to send andreceive VNC f iles, which are the actual part f iles that contain the geometry and toolpaths. VNC f iles can becommunicated between computers that have the system installed. This is especially useful when the system isbuilt into the control of a machine tool. Part f iles (VNC f iles) can be communicated in their entirety from acomputer to the machine’s control, and from the control back to the computer.

SENDING A FILE TO THE CONTROLTo send a f ile, the Send Mode button must be depressed. The protocol is chosen by using the Protocol pop-upmenu. The program to be sent is specif ied by clicking on the Program Name button. When everything is setcorrectly, click on the Send button to send the f ile. While the program is being sent, the Send button becomesthe Stop button. Click on the Stop button to stop the communication. The Progress Bar shows the status of the

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f ile being sent. If the Text Window is opened from the Post Processor dialog, the program will scroll by as it isbeing sent to the control.

SENDING OTHER .NCF FILESAny text f ile that matches the extension set in the Post text box in the File Extensions Preference can be sent tothe control. Refer to the Post Processing chapter for more information on output f ile extensions.

RECEIVING A FILE FROM THE CONTROLTo receive a f ile from the control, open the Communication dialog from the Post Processor dialog or from theFile menu. The Receive Mode button should be depressed. Choose the correct protocol from the Protocol pop-up menu. The name of the received program is specif ied by clicking on the Program Name button. Wheneverything is set correctly, click on the Receive button, and then send the program from the control. If the TextWindow is open from the Post Processor dialog, the program will scroll by as it is received.

1. Send Mode2. Receive Mode3. Program Name4. Protocol Menu5. Progress Bar

It is recommended that edited NCF f iles received back from the machine control be saved under a different name than the original NCF f ile that was initially sent to the control. That way if the original VNC f ile is reprocessed, it won't affect the edited NCF f ile. For example, a part f ile named SAMPLE.VNC is post processed and a text f ile named SAMPLE.NCF is created. Changes are made to the program at the machine control and the new f ile containing those changes is sent back and received at the offline computer, but under the name SAMPLE1.NCF. If SAMPLE.VNC is reprocessed again at a later date, it won't destroy the SAMPLE1.NCF f ile that contains the changes that were made at the machine.

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LATHE TUTORIAL

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CHAPTER 10 : Lathe TutorialThe Lathe module is the most basic of the turning machines supported by the system. This chapterprovides instruction on how to create turning operations. Covered in this chapter are tool setup, processdef inition, operation creation, custom stock def inition, cut part rendering and form tool use.

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

EXERCISE #1: LATHE TUTORIALThe following tutorial shows how a simple lathe part is set up, tooled and output. Each step is bulleted andadditional information and tips are also provided. It is recommended that all the information contained inthis tutorial is read to gain the most thorough understanding. This part was created in the GeometryCreation manual and the dimensions for this part are also on page 135. Refer to the Geometry Creationmanual for details on constructing the Geometry for this part. You may convert the measurement unitswith the Modify > Scale command if necessary.

THIS TUTORIAL EXPLAINS HOW TO:1. Set up stock, clearance and tool change settings

2. Specify custom stock

3. Create a tool list with standard and custom tool settings

4. Generate different types of operations that rough, contour, drill and thread a part.

5. Render the machining operations.

6. Create posted code for the part.

PART SETUP• Open the Documents dialog.

The Document dialog contains information about the Machine Type, Material, measurement system,stock, Tool Change, clearance and a part Comment. It also has the f ile management tools to open,save, close, etc.

• Select Open in the Documents dialog.

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

This part was created in both the Geometry Expert and Free-Form CAD Exercises in the GeometryCreation manual. Either of the part f iles can be used. If the part was not created, go back to theGeometry Creation manual and do so or use the dimensions at the end of the book to create thegeometry.

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

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• Select the Auto Clearance option.

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

• Enter the stock, Auto Clearance and ToolChange positions shown.

Tool Change will send the tool to thespecif ied location for the tool change. IfTool Change is turned off, it is assumedthat f ixture offsets are being used or theoperator will manually input the toolchange moves.

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

• Open the View palette (Ctrl+5, F5).

• Choose Help > Balloons from the menu.

Balloons provide a reference to theinterface. A check mark will appear next to the Balloons item, indicating that it is on. Move the cursorover the object to see the information.

• Select Unzoom (Ctrl+U).

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

• Select the Isometric view (Ctrl+I).

The Isometric view is a 45° perspective of the part. This view givesthe best overall perspective of the current status of a part fromthe top, right and front view of the part.

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

• Choose Help > Balloons to deactivate them.

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

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

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• Switch back to the Top view.

• Click the View button again to close the View palette.

CUSTOM STOCKThe stock specif ications entered in the Document dialog simply creates a cylindricalstock shape using the X and Z coordinates entered. It is possible to def ine a custom stock shape by drawingthe stock shape in a separate workgroup designated for part stock. This is very useful because the stockshape affects the machining of the part in that the stock conditions are used to calculate the clearancepositioning moves when using Auto Clearance. The custom stock shape also appears when viewing therendered image of the part.

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

• Click the Workgroup list button in the Geometry Creation palette.

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

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

• Click New WG and rename it “Stock”.

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

• Right click the name of the workgroup, choose WG Info.

The Workgroup #2 dialog def ines whether the workgroup willcontain part geometry or a stock outline.

• Select the Part Stock Revolve option.

• Close the Workgroup #2 Info dialog.

In order to create the geometry for the stock outline, it will benecessary to view the part geometry that we have already created asa machining workgroup. The entry highlighted in the Workgroup Selection dialog is the activeworkgroup.

Other workgroups can be viewed by opening the eye next to their name in the Workgroup Selectiondialog. Geometry in inactive workgroups are gray and can not be edited while inactive.

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

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

• Close the Workgroup list.

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

• Click the Line button.

• Click the Mouse-Line button.

The Mouse-Line dialog contains Z and Xd valuesdetermined by the location of the cursor. The Gridvalue specif ies constraint spacing the lines willsnap to. For a review on using the Mouse-Line tool,refer to Exercise #5: Doodle in the Geometry ExpertSection of the Geometry Creation manual.

The initial stock is a cylinder with two different diameters for our stock outline. The stock does notneed to be perfect, but should not cross the f inish geometry def ined. The only condition is that thebottom line must be drawn at X0 to have a correctly revolved part.

• Draw a stock shape around thepart as shown.

This will be the stock conditionbefore cutting is preformed.

• Hold the Workgroup Selectionbutton down until the selectionmenu appears.

• Select Workgroup 1.

• Close the Geometry Creation palette.

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TOOL LIST• Open the Tool list button in the Top Level palette.

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

The Tool Creation dialog contains all tool specif ications necessary for the system tocalculate accurate toolpath and rendering. Tool information can be edited at any time byclicking on tool tiles and editing the information contained in the Tool dialog. For moreinformation, refer to “Tool Creation Overview” on page 13.

• Select the 80° C insert with the followingspecifications.

Values for insert specif ications, such as TipRadius, IC (Inscribed Circle), Thickness, etc.can either be selected from the list ofstandard inserts in the menus or manuallyentered by selecting Other.

Holders can be chosen by using the scrollbar next to the insert diagram. The text tothe right of the scroll bar displays the holderspecif ications which provide detailedinformation about the insert angle andholder type. For our part, the f irst positionprovides the desired selection. The red circleat the end of the insert indicates the touch-off point of the tool.

The selection of insert and tool holder alsoaffects the toolpaths created using this tool.The system uses the selections made herewhen constructing a toolpath to preventtool interference. Therefore, selections made here directly affect the machining of the part.

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

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

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

• Click the Milling Tool button.

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• Select the Drill tool with the followingspecifications.

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

• Click the Turning Tool type button.

• Select the 35° V diamond insert.

• Enter the tool information shown.

The position on the insert orientationdiagram remains the same as the previousinsert selection, so no adjustment isnecessary.

The insert angle and holder type selectionis the last one in the group.

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• Create this insert as tool #4.

Double-click the tool tile to open the newtool dialog. We will skip this step from hereon.

• Create this custom insert as tool #5.

The tool holder diagram is set to Custom.Only the insert is drawn in the diagramaccording to the values entered.

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• Create this insert as tool #6.

The Insert Orientation Diagram changes inappearance when the Boring Bar option isselected.

• Scroll down to reveal two empty tiles (ifnecessary).

The scroll arrows at the top and bottom oftile lists allow you to easily move throughthe tiles in the list. To scroll quicklythrough the list, hold down the button anddrag the mouse downward. This will changethe arrow to red and scroll a “page” at atime. Refer to the the Getting Started guidefor more information on tile lists.

• Create this insert as tool #7.

Once the Style and TPI (threads per inch)values are selected, the Insert Width andInsert Type will default to the desiredvalues.

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• Create this custom insert as tool #8.

• Close the Turning Tool #8 dialog.

The tools necessary to machine this parthave now been created. A good way toreview the tools contained in the list is byusing the Window > Tool List Summary.

• Choose Window > Tool ListSummary.

The Tool List Summarycontains all of the currenttool information.

The information may beprinted by choosing File >Print > Tool List Summary. While the Tool List Summary is the active window the print shortcutCtrl+P will work. The list is set up to print in landscape mode ONLY. When any of the summaries aredisplayed on the screen, they can be printed or saved as a text f ile with the Save Special command.

• Close the Tool List Summary.

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CREATING THE OPERATIONS - OD• Click the CAM button in the Main

palette.

The Machining palette, Process Listand the Operation List appear.

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

Process tiles are created by dragginga Tool Tile and a Function Tile to aProcess List location. Operation tilesare created from Process tiles whenthe Do It or Redo button isdepressed.

In order to machine this part, operations must be created. Operations are created from completedprocesses. To create a process, one tool and one process (roughing, contouring, drilling, threading) isneeded. In this tutorial, we will f irst describe the necessary machining operation, then we will detailthe steps necessary to create that operation.

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

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

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

When you place the Tool Tile in position #1, the tool number is displayed in thesmall box on the Contouring Process Tile. The Contour Process dialog appearsafter the Tool tile is added.

• Enter the information shown in the Contourdialog.

To position the tool to cut the face of thispart, we need the tool to approach andretract along the Z axis. Therefore, theFront Face option is selected.

For this process, the Material Only optionis selected so no toolpath will begenerated unnecessarily to cut the face.

• Close the Contour Process dialog.

When the Process dialog is complete, thecut shape must be def ined. Machining Markers (shownbelow) are used to designate a cut shape for contouringprocesses.

• Select the vertical line at Z=0.

The Machining Markers will appear on the selected feature. The markers allow youspecify the start and end feature and the start and end point of the cut shape. Theycan be “picked up” by clicking on them and dragging them to any location on the partgeometry. The arrows allow you to choose the cut direction. The two circles allow youto choose the side from which the tool will be offset.

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

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In this case, the start feature and end feature markers will stay in their initial positions because onlyone feature, the face, will be cut. The start point and end point markers will be moved to cut the entirelength of the face. The start and end point markers can rest anywhere on the selected line, even on thetrimmed sections. Refer to the Machining Markers section in the Machining chapter for moreinformation.

• Select the outside circle.

This is the OD side of the geometry.

• Click the arrow pointing down.

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

• Drag the start point marker above the workspace as shown.

Because Material Only is used in this process, the start and end point markers do notneed to be placed in exact positions as long as they clear the stock outline we def ined.

• Drag the end point marker down tothe location shown.

If markers are not properlyplaced a process may notgenerate the desired toolpath.The common mistake is to chosethe wrong cut side.

• Click the Do It button in the

Machining palette.

An Operation tile will be created and added to the Operation list and the approach andretract moves and the toolpath drawn. The orange lines represent the toolpath, while the

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dashed gray lines represent positioning moves. The solid lines for both the toolpath and positioningindicate feed moves. And the dashed lines of both colors indicate rapid moves.

The picture above on the right shows the toolpath without the Machining Markers so you can get abetter picture. To view the toolpath without the Machining Markers, simply click anywhere off thepart. The dashed gray line shows the tool rapiding from the tool change position (entered in theDocument dialog, to the start point of the toolpath).

The angled lines at the beginning and end of the toolpath are entry and exit positioning moves thathave been added because Auto Clearance is turned on. They are angled along the centerline of theinsert angle. The position the tool can safely rapid to before beginning the toolpath is determined bythe Auto Clearance value entered in the Document dialog.

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

Tiles are considered selected when they are highlighted in yellow. Deselected tiles arethe standard gray color.

CREATING OPERATIONS

• Drag the Process in position #1 to the Trashcan.

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

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

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The next group of operations will rough and f inish the outside contour of the part. This will beaccomplished using multiple process programming which allows multiple process tiles to be applied toone cut shape.

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

To properly position the tool to rough theOD of this part, we need the tool toapproach and retract along the X axis.Therefore, the OD option is selected forthe approach type.

Lathes use different roughing (multiplecut) cycles. There are three general types:Turn, Plunge, and Pattern Shift. Thesethree types of cycles will allow us tooutput the different canned cyclesdef ined in programming manuals forlathes. The software will output theseroughing cycles as canned cycles if thePrefer Canned option is selected and thelathe is capable of using canned cycles. Ifnot, the post processor will output everymove necessary to rough the part.

Turn roughing cycles are the standardcontour rough cycle. For turning cycles,the selection made for the approach type(OD, ID, Front Face) determines what type of contour rough style will be generated by the system.

Plunge roughing cycles are used to generate grooving operations. These cycles are used when it isdesirable to rough the part with a groove tool. Pattern Shift roughing cycles are commonly used whenroughing a cast part. This type of cycle generates the part contour and shifts the toolpath on eachsuccessive cut until the specif ied area is roughed.

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

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

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

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

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The value entered in the Fin. Stock ± text box designates the minimum amount of material that will beleft outside of the part geometry after the roughing cycle is completed. The toolpath created by thesystem will be offset from the part geometry in Z and in Xd. We will remove this excess with the f inishpass.

• Close the Rough Process dialog.

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

This process is included in this group torough the neck groove on the part. Again,an OD approach type is selected so thetool will approach and retract along the Xaxis. And a Turn rough cycle is selectedusing a Cut Depth.

Material Only is again selected for theRough Style so that the toolpathgenerated for this operation will only cutthe remaining material left on the partafter the previous operations have been completed. The Material Only selection is particularly usefulwhen utilizing the multiple process programming capabilities of the system. Feed moves will only bemade where it is necessary to remove material. The tool will make rapid moves whenever possiblewhile maintaining the clearance offset.

In addition to entering a f inished stock amount which will leave the designated amount of materialaround the entire cut shape.

• Close the Rough Process dialog.

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• In position #3 create this Contour processwith tool #3.

• Close the Contour Process dialog.

Now that the Process List is complete, wewill def ine the cut shape.

• Click the chamfer as shown.

The Machining Markers will appear on the selected feature.

• Click the outside circle.

• Click the arrow pointing up.

• Drag the Start Point Marker to the position shown.

The Start and End Point Markers do not need to be placed in exactlocations as long as they clear the material.

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

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

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

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

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• Drag the end point marker to theposition shown.

The Dark blue line represents thecutting path. Notice that the middleV groove and the O-ring groove arenot included in this cut shape.

• Click the Do It button.

This will create the toolpath. If anymistakes were made, edit the processand use the Redo button to makechanges to a selected operation.

Three operations are created.

The Operation list should have fouroperations now.

The positioning moves and toolpaths for each of the operations are also drawn onthe screen. In order to get a better picture of the toolpaths generated by the system,we will view the tool moves for the f irst roughing operation separately.

• Select Operation #2.

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

• Open the View Control palette.

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• Click the Redraw button (Ctrl+R).

Only the toolpath and positioningmoves for the selected operationare drawn. This is helpful if you usemultiple process programming andwish to view individual toolpaths.

Notice that the custom stockoutline was taken into accountbecause Auto Clearance is on andthe Material Only option was selected. Also, the toolpath created does not slope at all into the neckgroove because the X- Shape Axis was deselected in the Rough Process dialog that created thisoperation.

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

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

• Choose View > Isometric.

• Open the Rendering palette.

This changes the working mode to Cut PartRendering. The initial stock we def ined at thebeginning will display as a solid object. TheGeometry is hidden but can be viewed by usingView > Show Geometry ( Ctrl+[ ).

• Click the Play button.

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

• Click the Show Solid Tool button.

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• Click the Play button.

A part can be rendered at any time once operationshave been created. The stock will always be shown inshades of blue. Selected operations will render inshades of yellow, while all other operations will renderin shades of gray. Red will be displayed when non-cutting tool surfaces or rapid moves hit the material.Refer to the Cut Part Rendering chapter for moreinformation.

• Close the Rendering palette.

• Choose View Top from the menu or Ctrl+E.

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

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

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

You may also use the Delete key.

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Multiple Process Group Op 5-8• For Process 1 create this Rough process with

tool #4.

An OD approach type is selected so thetool will approach and retract along the Xaxis. Material Only is again selected forthe Rough Style. Also, a Finished Stockamount is left on this groove that will beremoved in the following f inish pass.

In this process, we will use a Plungeroughing cycle.

When the Plunge option is selected forthe Rough Type, the Plunge dialog willcome up on the screen. To make thePlunge dialog come up, click the Plungeoption in the Rough Type selections.

• Enter the information shown below in thePlunge dialog.

The Plunge Angle specif ies the angle at which the groove tool willmake its plunging moves. The default is 270° which has the toolplunging straight down.

For this process, we have selected the Details option for the Cut Width.This option will vary the Cut Width distance as necessary in order tohit the endpoints of each feature of the cut shape. The Z value enteredspecif ies the maximum distance the tool will step over on each pass.The Center Out Cuts option is selected so that the tool will make itsf irst plunging move in the center of the groove, and then proceed torough each side.

For this groove, the Peck Full Out option is selected because the grooveis relatively deep, and in order to remove all of the chips (material), thetool will need to come all the way out of the part after the peck. The value entered in the Peck Amt textbox specif ies the distance the tool will plunge into the part on each peck. The Clearance value specif iesthe distance away from the remaining material the next peck will begin.

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• For Process 2 create this Contour processwith tool #4.

The No Drag option is turned on in thisprocess so that the toolpath is created insuch a way that only the positive insertangle of the tool cuts material. Thedesignated cut shape is segmented intopieces to accomplish this.

• For Process 3 create this Rough process withtool #5.

An OD approach type is selected so thetool will approach and retract along the Xaxis. Material Only is again selected forthe Rough Style. Also, a Finished Stockamount is left on this groove that will beremoved in the following f inish pass.Plunge is selected for the Rough Type.

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• Enter the information shown below in the Plunge dialog.

The Exact option is selected for the Cut Width. The tool will step overon each pass regardless of the endpoints of the cut shape. The PeckRetract option is selected for the First Plunge. The Peck Amt specif iesthe depth of each plunge and the Retract amount specif ies thedistance the tool will come out of the groove after each peck.

• For Process #4 create this Contour Processwith tool #5.

Now we will def ine the cut shape for thisprocess list.

• Click the part geometry as shown.

The Machining Markers will appear onthe selected feature.

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• Right-click the last feature shown andchoose Move End Feature here so theMachining Markers appear as shown.

Make sure you select the outside circleand the arrow pointing left. The bluecut shape drawn should include the Vgroove and O-ring.

• Create the toolpath.

The toolpaths that are created willproperly rough and f inish both the Vgroove and the O-ring. Notice that thetoolpath contains no unnecessarymoves. Material Only takes fulladvantage of multiple processprogramming without makingunnecessary tool moves.

• Switch to the Isometric view. (Ctrl+I)

• Render the Operations.

During the rendering process, you will be able to bettersee the No Drag contour option at work. Notice thetool will f inish one side of the groove, rapid up andover, and then go down and f inish the other side of thegroove, always cutting along the positive direction ofthe insert angle.

• Exit Rendering mode.

• Switch to the Top view (Ctrl+E).

• Deselect any operations.

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

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

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

Multiple Process Group Op 9-11• Create this Holes process with tool

#2.

The depth the drill will feed to isspecif ied by the value entered inthe Sharp Tip Z text box. Valuesmay be entered in the text boxesspecifying the Full Diameter Zdepth and the Spot Diameter.These values will cause the SharpTip Z to be recalculated. TheSharp Tip Z is the value used inthe posted output.

The drill cannot feed through thepart in one pass. Therefore, the Peck, Full Out option is selected. Because it is a Peck, Full Out, the drillwill rapid all the way out of the part after each peck.

The value entered in the Peck text box specif ies the amount the tool will peck into the material on eachpass. The next peck will start a Clearance amount away from the material remaining after the previouspeck.

Drilling operations do not require the selection of geometry. In a standard lathe a drill can only feeds inat X=0. Therefore, the placement of the Machining Markers will only affect the toolpath created for theRoughing and Contouring operations.

L Remember to use the Balloons in the Help menu if you don’t understand the f ields.

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• For Process #2 create this Rough Processwith tool #6.

A Front ID approach type is selected sothe tool will approach and retract fromthe part along the X axis. A Turn RoughType is selected and separate stockamounts are entered for each axis.

• For Process #3 create this Contour processwith tool #6.

The Front ID approach type is selectedand Material Only is turned on in theprocess.

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• Position the Machining Markers as shown.

• Create the toolpath.

The dashed orange line at X = 0 showsthe tool rapiding out of the part after ithas pecked in to the Sharp Tip Z depthin the Drilling operation.

• Switch to the Isometric view.

• Render the Operations.

• Deselect the operations.

• Clear the Process list.

We will skip stating these last two steps in the future.

• Switch back to the Top view.

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

• Create this Thread processwith tool #7.

These values can be found inthe Machinery’s Handbook,and are calculated from thevalues entered for an “idealthread.”

The Minor Xd will default toa calculated value accordingto the Nominal Xd and thedesired pitch. The Thrd HtXr is calculated [(Major -Minor)/2]. Changing theNominal Xd will change thevalues in the Major Xd,Minor Xd, and Thrd Ht Xr.

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

Threading operations do notrequire the selection of geometry.The information entered in theThread dialog determines wherethe thread will be located on thepart.

• Create the toolpath.

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

• Create this Contour Process with tool #8.

An OD approach type is selected so thetool will approach and retract along the Xaxis. Material Only is selected for theRough Type with a Clearance of 0.25. TheClearance value is relatively large toensure that no tool interference occurswith our f inished part.

The Cut Off option is turned on so thepost processed output will contain thenecessary codes for removing the partfrom bar stock. Not all post processorssupport this option.

• Close the Contour Process dialog.

• Select the cut off line of the partand position the MachiningMarkers as shown.

Ensure the end point extendspast X0 and the start pointbegins above the stock.

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• Create the toolpath.

As the last step we will sort theoperations to have less toolchanges.

• Right click an operation in theOperations List and choose “SortOps.”

The only change that occurs isthe Drilling operation that usesTool #2 will be moved up in theOperation List to location #3.

• Select the Isometric view. (Ctrl+I)

• Render the Operations (F6).

For this case, changing the order of the operations doesnot cause any tool interference and does not appear toaffect the eff iciency of the toolpath and positioningmoves generated by the system. Had there been anyproblems, we would have needed to reprocess theexisting operations so that the system would haverecalculated the tool moves for each operation basedon the new conditions. Reprocessing the operations isvery easy using the Redo All Ops item in the Edit menuor the Operation list context menu.

L

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

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POST PROCESSINGNow that all of the operations to machine the part have been satisfactorily created and verif ied, weneed to post process the f ile. Post processing will create a text f ile that the CNC machine will use to cutthe part.

• Open Post Processor dialog.

From the Post Processor dialog a post processor maybe selected as well as generating a post f ile andcommunicating with a machine control. Refer to thePost Processing and Communications chapters formore information.

• Click the Post Processor Selection button.

• Select a Lathe post processor.

• Click the Open button.

The name of the selected post processor will appearin the dialog next to the button.

• Click the Program Name button.

The Program Name defaults to the name of thepart f ile. You can change the name or leave it as itis.

• Click the Save button.

Once you have selected a post processor andnamed and saved the program, the Process buttonat the bottom of the dialog becomes active.

• Click the Text Window button.

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This allows you to view the posted code as it is processing.

• Click the Process button.

This will create a post f ile that can then be sent to themachine.

The program will scroll by as it is being processed. You canclick the Pause button to momentarily stop the processing sothat you can read the program. Once the program has f inishedprocessing, the Print button becomes active and the postedcode can be printed.

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EXERCISE #2: FORM TOOLSThis exercise introduces you to creating and using Form Tools in GibbsCAM. We will start with an existing,very simple part f ile, create a Form Tool and apply a machining operation using the Form Tool.

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

The f ile contains geometry for the part, a tool and two roughing operations. The existing operationsface and rough the part. First we need to create geometry for the Form Tool.

• Create a new workgroup for the Form Tool.

• Use the data in “Form Tool Blueprint” on page 136 to create the geometry for the form tool.

Remember that the system uses theorigin as the tool’s touch-off point. Thetool should look like this image.

• Open the tool dialog.

• Select Form tool as the tool type.

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You are prompted to select a shape to usefor the tool’s prof ile.

• Double click the Form Tool geometry and clickApply.

The shape of the tool is displayed in theTool dialog. Note the touch-off point isshown in the tool diagram.

FORM TOOL CONTOURWe will now make a contour process usingthe form tool.

• Create this Contour Process with the formtool.

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• Position the machining markers as shown.

We have placed the start point marker above theroughed surface. The end point marker should be onthe connecting point to drive the tip of the tool to thatpoint.

Since we are contouring on a single linesome options become disabled whenusing a Form tool.

• Create the toolpath.

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The result should be a single feed line into the part.

• Switch to the Isometric view and render the results.

• Save this part, it is complete.

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PART PRINTS

135

Part

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Part

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INDEX

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139

SYMBOLS% of Body’s Chord Height: 79

NUMERICS3D Real Time Cut Part Rendering: 73

AAdvanced CS Module: 8Air Cutting: 26, 34, 39, 61Approach Type: 9, 56

Changing: 56Contour: 31Front Face: 56Front ID: 56OD: 56Roughing: 36Thread: 42

Auto Clearance: 9, 27, 31, 39–40, 45, 55–56, 61, 98

BBack & Forth Roughing: 36Balloons: 98Bar Stock: 32Body Chord Height: 79Button

Close: 8Do It: 26Document Control: 7Machining: 25Material: 44, 46New: 8Open: 8Post Processor: 83Receive: 93Redo: 26Save: 8Save As: 8Save Copy: 8Send: 92Tool List: 13

CC.A.T.: 3Canned Cycles: 40, 44, 46, 55–56, 61Chord Height: 79Circular Threads: 80Clearance

Auto, see Auto ClearanceContour operations: 31Data: 7Diagrams: 56Fixed: 9Fixed, see Fixed ClearanceMaster: 31Moves: 55

Clearance Moves: 9, 39, 55Approach From Tool Change: 57Exit To Tool Change: 58Same Tool Moves: 59

Clearance Positioning: 55Clearance Positions, Entry and Exit: 56Close File: 8CNC, Communication with: 92Collision

Alerts: 79Tolerance: 80

Collision, Flash CPR: 79Com Set-Up dialog: 91Comment: 9Communication

Stop: 92Communication dialog: 92Communication Protocol

Change: 92New: 91Remove: 92

Constant Cut: 43Constant Load: 43Constant Surface Speed, see CSSContour Cutter Compensation: 20Contour Feed: 35Contour process: 31Contour Style: 34

Index

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Full: 34Material Only: 34

Contouring function: 27, 31Control

Receiving files from: 93Sending files to: 91

Coolant: 35, 40, 46Corner Break: 34, 40CPR: 74

Controls: 74CPR palette: 74CRC: 20, 34CSS: 35, 40Current Display (CPR): 74Cut Depth: 37

Thread: 43Cut Direction: 36Cut Direction Axes: 35, 41Cut Off: 32Cut Part Chord Height: 79Cut Shape: 26CutDATA: 8, 64Cutter Radius Compensation, see CRCCycle Start Point: 38

DDecimal Slope: 47Depth Of Cut: 43Diameter Relief: 18Diameters, part size: 9Do It: 52Document Control dialog: 7, 31, 39, 55, 97, 99Drill Entry/Exit Cycle: 44Drilling: 120

Diagram: 45Dwell: 46Feed In-Feed Out: 44Feed In-Rapid Out: 44Full Diameter Z: 45Peck Chip Breaker: 44Peck Full Out: 44

Rigid Tap: 44Sharp Tip Z: 45Spot Diameter: 45Surface Z: 45Tap: 44

Drilling Function: 27, 44Drilling Process: 44Dwell: 46

EEntry Clearance

Contouring: 32Position: 56Roughing: 39

Entry Move90° arc: 32Contour operation: 34Line: 32

Exit ClearanceContouring: 32Roughing: 39

FFace Relief: 18Feed

Move: 56Plunge rate: 46

FileSend to Control: 92

File Extension: 84File Management: 7Find Operation: 67Finish Stock ±: 34, 40Fixed Clearance: 40, 55–56Form Tool: 17Forward: 32From Tool Center (CRC): 20From Tool Edge (CRC): 20Front Face Approach

Contour: 31Roughing: 36

Index

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Front ID ApproachContour: 31Roughing: 36

Full Radius: 16Function Tile: 31

GG50 Offset: 9G50 offset: 19G-code: 26Gouge Avoidance, see Cut Shape

HHelp: 3Holder

Diagram: 18Specs: 18

HoldersBoring Bars: 15None: 15Tool Holder: 15

Hole Diameter: 45

IID (Inner Diameter) Thread: 42–43In Feed: 43

Balanced thread: 48Insert

Face Angle: 16IC (inscribed circle): 16Insert Type: 16Material: 19Orientation diagram: 18Positive Angle Direction: 32Size: 16Specifications: 15Specifications of: 14Thickness: 16Thread Style: 17Tip Width: 17TPI: 17

Width: 16Insert Comments (Post): 84Insert Type: 14Invisible Tool (CPR): 74Isometric view: 98

LLast Cut: 43Lathe Inserts: 14List

Operation: 25Process: 25Scroll Arrows: 104Tool: 13

MMachine Type: 8Machinery’s Handbook: 49, 123Machining Markers: 25–26, 62, 107

How To Use: 62On Geometry: 63

Machining palette: 25, 27Making Operations

Geometry: 25Material Database: 8, 19, 44, 64Material Only: 9, 26–27, 34, 39, 61

Clearance: 39Material Only, Clearance: 34Max RPM: 35Measurement Units: 8Mill Class, back end holder: 9Mill Module: 8Mill Tools: 14Mill/Turn Module: 14Minimize (Post): 84Mouse-Line: 100Move Operation: 67Multi-Level Sort: 68Multiple Process Creation: 26Multi-Task Machining Module: 8, 14

Index

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NNC program: 27NCF file: 92New File: 8Next Operation (CPR): 74No Air Cutting, see Air CuttingNo Drag: 32Nominal Thread diameter, see Thread, Nominal XdNPT: 47

Chart: 50Cutting: 49

OOD (Outer Diameter) Thread: 42OD Approach

Contour: 31Roughing: 36

Offset # (Tool): 18One Finish Pass: 43Open File: 8Operation Data: 65Operation List: 25–27Operation Tile: 27Operations: 109

Deselecting: 26Order of: 27Reprocessing: 13, 27

Optional Stops (Post): 84

PPart

Comment: 9Material: 8Set Up: 7–8Stock: 9

Part ClearanceMaster: 56

Part Surface in Z: 45Part X Dimension: 9Pattern Shift

Cycle Start Point: 38Fixed: 38Passes: 38Square Corners: 38Xr Cut: 38Z Cut: 38

Pause Posting: 83Peck

Amount: 45Chip Breaker: 45Clearance: 46Full Out: 45Retract: 45

Play (CPR): 74–75Plunge

Angle: 37Center Out Cuts: 37Clearance: 38Cut Width: 37Feed: 37First Plunge: 37, 39Peck Amount: 38Peck Full Out: 38–39Peck Retract: 38–39Retract: 38

Plunge dialog: 37Post

From Part File: 83Name: 84Output: 84Requirements: 84Selection: 84Unit Conversion: 8

Post Output Preferences: 85Post Processing: 83Post Processor

Coolant: 46Custom: 32, 35, 40, 44, 46Drilling Cycles: 44

Prefer Canned: 40, 44, 46, 55, 61Auto Finish: 40

Preset Point: 19see also Touch-off Point

Print Post: 83

Index

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Printing: 21, 80Process

Loading Saved: 52Post: 83Stock Amount: 20

Process dialogs: 31Contour: 31Rough: 36Thread: 42

Process Group: 52Pre-defined: 52

Process List: 25–27, 31, 67Program Name button: 92Program Name, post: 83Prompting: 3Protocols: 91

RRadii, part size: 9Radius Move, contouring: 32Rapid

Move: 56Step: 39–40

Redo: 13Redo All Ops: 27, 34, 39, 125Render, checking the part: 27Rewind (CPR): 74Rough process: 36Rough Style: 39

Full: 38–40, 61Material Only: 39–40

Rough Type: 37Cut Depth: 110Pattern Shift: 37–38, 40, 56Plunge: 37Plunge Rough: 37Turn: 37, 40, 56

Roughing function: 27, 36RPM: 44, 46Run In: 42, 44Run Out: 42, 44

SSave

Duplicate Copy: 8File: 8File As: 8Special: 21

Saving Processes: 52Saving Tool Data: 52Selected Ops (Post): 84Send Mode: 92Sending a File: 92Sequence from (Post): 84Set Op Stop #: 75Shank Size: 9Slope, see Thread, TaperSort Operations: 27, 67Speed: 44Spindle Speed: 35, 40Spring Pass: 43Square Corners: 32, 38Start Side Extension: 36Starting Program Number (Post): 84Statistics, Flash CPR: 80Step Forward (CPR): 74–75Steps Per Update: 79Stock

Finish: 34Xr: 34Z: 34

Stock Size: 7, 9Stop (CPR): 74–75Surface Z: 45

TText Window, post: 83Theoretical Tool Tip, see Touch-off PointThread

# of Starts: 43, 471st Xr: 48Actual End: 44

Index

144

Actual Start: 44Alternate In Feed: 43, 48Approach Type: 47Balanced In Feed: 43, 47Constant Cut: 48Constant Load: 48Cut Direction: 42, 47Depth of Cut: 43, 48End Z: 48Front ID: 42Height Xr: 43, 47ID: 47Last Cut: 48Major & Minor Xd: 43, 47Nominal Xd: 42–43, 47OD: 42, 47One Finish Pass: 48Run In: 48–49Run Out: 49Spring Pass: 48Start Z: 48Style: 42, 47Taper: 42, 47Thread Angle In Feed: 43, 48TPI: 42, 47

Thread Angle: 43Thread Clearance: 42Thread Load: 43Thread Process: 42Threading: 42, 47Threading function: 27Threads Per Inch, see Thread, TPIThrottle Control (CPR): 74Tool

Comment: 19Custom, see Form ToolOffset: 20Other: 16Radius Offset: 20

Tool Change: 9, 55, 98Tool Change Position: 7, 19

Primary: 55Tool Creation dialog: 13–14Tool List

Summary: 21, 105Tool Movement: 55Tool Specifications, modifying: 13Tool Tile: 25, 31Tool Type Toggle: 14Toolpath: 26

Cutter Side and Direction: 62End Feature: 62End Point: 62Recalculate: 27Start and End Points: 62Start Feature: 62Start Point: 62

Touch-off Point: 17–18Transparent Tool (CPR): 74Trashcan: 109Turret Shift: 19, 55

UUndo: 52Units of Measurement: 8Utility data: 65

VVisible Tool (CPR): 74VNC file: 92

WWork Fixture Offset: 9

XX Dimension Style: 9X Stock Start, roughing: 39Xr Stock: 34, 40

ZZ Depth

Full Drill Diameter: 45

Index

145

Tool Tip: 45Z Stock: 34, 40

Index

146