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Reference Help
By Delcam plc
Disclaimer
Delcam plc has no control over the use made of the software described in
this manual and cannot accept responsibility for any loss or damage
howsoever caused as a result of using the software. Users are advised that
all the results from the software should be checked by a competent
person, in accordance with good quality control procedures.
Information contained in this manual is subject to change without notice
and does not represent a commitment by Delcam plc. The software
described in this manual is furnished under licence agreement and may be
used or copied in accordance with the terms of such licence. No part of
this manual may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying and recording,
for any purpose without the express permission of Delcam plc.
Copyright 1995-2008 Delcam plc. All rights reserved
Acknowledgements
This documentation references a number of registered trademarks and
these are the property of their respective owners. For example, Microsoft
and Windows are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries.
Restricted Rights Legend
The Program and Program Materials are provided with Restricted
RIGHTS. Use, duplication, or disclosure by the United States
Government is subject to restrictions as set forth in subparagraph
(c)(1)(ii) of the Rights in Technical Data and Computer Software Clause
at DFARS 252.227-7013, Manufacturer is the Licensor: Delcam plc.
Permission to Copy for Licensed Users
Delcam plc grants permission for licensed users to print copies of this
manual or portions of this manual for personal use only. Schools that are
licensed to use FeatureCAM may make copies of this manual or portions
of this manual for students currently registered for classes where
FeatureCAM is used.
FeatureCAM Version: 15.0 Date: 23/12/2008 12:13
Contents
Import/Export
15
Importing files..............................................................................................15
Importing *.dwg, *.dxf files ................................................................17
Importing dimensions from *.dxf and *.dwg files ..............................18
Simplifying 3D AutoCAD data for 2D import....................................18
Importing ACIS files ...........................................................................19
Importing Parasolid files......................................................................19
Importing Autodesk Inventor files ......................................................20
Importing Solidworks files ..................................................................20
Importing Solidworks assemblies........................................................20
SolidWorks and Autodesk Inventor automatic hole recognition example
..............................................................................................................21
Inventor hole recognition.....................................................................23
SolidWorks hole recognition ...............................................................24
SolidEdge hole recognition..................................................................25
Importing Unigraphics files.................................................................25
Importing CATIA V4 files ..................................................................26
Importing CATIA V5 files ..................................................................27
Importing Pro/E files ...........................................................................27
Importing STEP files ...........................................................................27
Importing SolidEdge files....................................................................28
Importing STL .....................................................................................28
Importing DMT ...................................................................................28
Digitized data import/export options...................................................28
Format of digitized files.......................................................................29
Importing IGES files............................................................................29
Working with imported geometry .......................................................31
General Import/Export Options ...........................................................32
Import/Export Options.........................................................................34
SolidWorks Export settings .................................................................34
AutoCAD Export settings....................................................................36
Exporting files..............................................................................................37
Exporting DXF and DWG files ...........................................................37
Exporting IGES Files...........................................................................38
Save STL dialog ..................................................................................38
Contents i
Import/Export Options.........................................................................39
Generating/simulating toolpaths
40
Part documentation
63
Manufacturing reports..................................................................................63
Reports .................................................................................................63
Operation List ......................................................................................64
Manufacturing tool detail sheet ...........................................................65
Changing the fonts for the reports in the Manufacturing Feedback
window.................................................................................................65
Op List tab....................................................................................................65
Simulation control using the Op List tab.....................................................66
Breakpoints in Op List tab ...........................................................................66
Display a single Z level ...............................................................................66
Viewing centerlines for an operation...........................................................67
Viewing intermediate shaded simulations ...................................................68
ii Contents
Tooling
72
Contents iii
Spot drills.............................................................................................89
Center drills..........................................................................................90
Taps......................................................................................................90
Thread mills .........................................................................................91
Twist drills ...........................................................................................91
Using a form tool or insert drill for drilling operations.......................92
Selecting tools by diameter..................................................................92
Turning tools................................................................................................92
Turning tool overrides tab ...................................................................92
Insert tab ..............................................................................................93
Holder drawing tab ..............................................................................99
Orientation tab .................................................................................. 107
Program point tab ............................................................................. 107
Tool Mapping............................................................................................ 108
Instructions for changing Tool number or Cutter comp ........................... 109
Spindles and tool holders.......................................................................... 109
Overview of spindles and toolholders .............................................. 110
Spindles and tool holders dialog....................................................... 110
Displaying spindles or tool holders during simulation..................... 111
Setting the length of tool extending past the holder ......................... 111
Detecting gouging with tool holders and spindles ........................... 111
Spindle properties dialog .................................................................. 111
Toolholder properties dialog............................................................. 111
Creating or modifying spindles ........................................................ 112
Creating or modifying toolholders ................................................... 113
Tool holder selection ........................................................................ 113
Tool life management overview ............................................................... 114
Restrictions for tool life management....................................................... 114
Tool Life dialog ........................................................................................ 115
Removing tool life restrictions on a tool .................................................. 116
Turret location........................................................................................... 116
117
iv Contents
Creating NC code
135
143
Contents v
161
167
vi Contents
230
Contents vii
267
viii Contents
Contents ix
Extending FeatureCAM
427
432
x Contents
458
Turn/milling (TURN/MILL)
477
Contents xi
520
xii Contents
530
Contents xiii
572
Support information
575
Index
xiv Contents
585
Import/Export
Importing files
To import CAD files:
1. Open a new or existing part file. You must have a part open to
import geometry.
2. Select File > Import from the menu.
The Import function is not available unless you already have a part file
open. A standard Browse dialog for Windows appears. You can also set a
few parameters in the Import Options dialog such as replacing existing
profiles with newly imported profiles with the same name. You can also
set how fine to smooth the curves and to keep a *.iges log file.
You can set the file type and folders you want to import from or simply
browse until you locate the file you want to import.
After importing the file, the Import Results window opens.
FeatureCAM can import these formats. If the description listed has (3D)
following it, you need FeatureMILL3D or the Solid Import Module to
import it.
Type
Description
Latest
Version
*.dwg
(see page
17)
2008
*.dxf (see
page 17)
2008
Import/Export 15
*.iges
(see page
29)
*.geo
*.xmt and
*.xmb
(see page
19)
19.1
*.sat and
*.sab (see
page 19)
18
*.sldprt
(see page
20)
2008
*.sldasm
(see page
20)
2008
*.mod
and
*.model
(see page
26)
4.2.x
*.ipt and
*.iam (see
page 20)
2008
*.prt,
*.prt<nu
mber>,
*.asm and
*.asm<nu
mber>
(see page
27)
*.catpart
(see page
27)
R18
*.par (see
page 28)
V19
16 Import/Export
5.3
*.prt (see
page 25)
NX5
*.stp or
*.step
(see page
27)
AP
203/AP21
4
POLYLINE
POLYLINE
with smooth
vertices
POLYGON
MESH
LINE3D
POINT
point
SPLINE (DXF
only)
curve
UCS
UCS
SEQEND
LAYER
layer
VERTEX
COLOR
Import/Export 17
CIRCLE
ARC
INSERT DXF
BLOCK
BODY
SHEET
3DSOLID
DIMENSION
See Simplyfying 3D AutoCAD data for 2D import (see page 18) for
further details.
18 Import/Export
When exploding solids you often get duplicate lines and circles. Any
edge that was shared between two different faces will be duplicated. This
repeated geometry causes trouble if you try to chain the geometry by
double-clicking. To work around this, you can:
Chain manually, by picking each piece individually
Use AutoCAD to explode specific faces of the model (not the
entire model), and then do chaining normally with double-click or
piece-to- piece
Remove duplicate pieces in EZFM and then do chaining normally
To see if you have imported geometry:
1. Select a line or circle.
2. Look at the object's name listed in the status bar. Imported lines
have names that begin with _ln and imported circles have names
that begin with _circ.
3. Select the object again.
4. See if the same name is listed in the status bar.
5. If a duplicate name appears and selected geometry is the same,
delete the second occurrence of the geometry.
If your AutoCAD model contains layers, those layers will be retained
upon import.
Import/Export 19
CAD systems that use the Parasolid kernel can create files of type *.xmt.
These files contain the solid models created by systems including
SolidWorks, SolidEdge and Unigraphics. FeatureCAM can import
ASSEMBLIES and PARTS that are made up of BODIES.
FeatureCAM can import files of version 18.0 or earlier of the Parasolid
library. Later versions may be supported since then, so please visit
FeatureCAM.com for further information.
SolidWorks is a registered tradename of Solidworks Inc.
Parasolid, SolidEdge and Unigraphics are registered tradenames of
Siemens AG.
20 Import/Export
Import/Export 21
After recognizing and suppressing the holes the model appears as shown
below. Note that the holes are filled in. The circles that are visible are
actually the top of the hole features that were recognized.
By looking at the Part view, you can see that eight holes were created
automatically.
22 Import/Export
Import/Export 23
24 Import/Export
Import/Export 25
Point
Not translated
Line
Curve
Circle
Curve
Curve
Curve
Curve
Composite curve
Curve
NURBS curve
Curve
Surface
NURBS surface
Surface
Skin
Exact solid
Polyhedral solid
26 Import/Export
Import/Export 27
Importing STL
STL (Standard Tessellation Language) is a file format native to
stereolithography CAD software. A standard format STL file can be
imported directly into FeatureCAM with no special license or optional
reader (STL import is part of the 2D milling product). These files must
have a *.stl extension. The result is an STL 'blob' which is all the
triangles as a single pickable unit, that is, not separate solids, or separate
faces. The blob can then be machined using 3D techniques for rapid
prototyping (surface manufacturing - in the 3D product), or can be used
as a stock model (in all products).
FeatureCAM supports both binary and ASCII STL.
Importing DMT
DMT (Delcam's Machining Triangles) is a file format generated by
Delcam (http://www.delcam.com)'s CAD software including
PowerMILL, PowerSHAPE, and CopyCAD. The file has the extension of
*.dmt and can be imported directly into FeatureCAM. The DMT file
represents 3D models as triangles, similar to an STL (see page 28) file.
Any function or operation that can be applied to an STL file can also be
applied to a DMT file.
28 Import/Export
Import/Export 29
For other systems try and ensure that 3D surfaces are exported as
trimmed NURBS.
If you are working with Pro/Engineer from Parametric Technology
Corporation set the following IGES import options:
Physically dependent - OFF
Logically dependent - ON
Both physically and logically dependent - ON
See Import/Export Options for more details on these parameters
Import/export options are divided into two tabs:
The General tab (see page 32) contains mainly IGES import options.
The Digitized Data (see page 28) tab contains information on importing
digitized curves and surfaces via DXF.
FeatureMILL can read the following IGES entities. If the 3D column is
checked, then FeatureMILL3D or the Solid Modeling option is required
to read these entities.
Entity IGES Description
FM Object Type
3D
100
Circular Arc
102
Composite Curve
Curve
104
Conic Arc
Curve
106
Copious Data
Line
108
Plane
Not supported
110
Line
112
Parametric Spline
Curve
Curve
114
Parametric Spline
Surface
Surface
116
Point
Point
118
Ruled Surface
Surface
120
Surface of Revolution
Surface
122
Tabulated Cylinder
Surface
126
Rational B Spline
Curve
Curve
128
Rational B Spline
Surface
Surface
30 Import/Export
141
Boundary
Curve
142
Curve on Parametric
Surface
Curve
143
Bounded Surface
Surface
144
Trimmed Surface
Surface
186
Brep
304
Not supported
408
Subfigure Instance
Geometry, curves, or
surfaces
410
View
Not supported
502
Vertex
Point
504
Edge
Curve
508
Loop
Curve
510
Face
514
Shell
All other IGES entities are ignored. Look in the status bar and the log file
for feedback about the IGES file import. After importing a *.iges file you
will be told either The IGES file has been imported successfully or
The file example.iges is corrupted and cannot be imported. A log file
is created which details the IGES import process. The name of this file is
specified in the Import Settings dialog which is displayed with the
Import Settings option of the File menu.
Import/Export 31
Gaps in your data make chaining your geometry into curves more
difficult. With small gaps you may have to adjust the Chaining
tolerance set in Chaining in the Options menu. This tolerance
represents the distance between endpoints that will automatically be
bridged by the chaining algorithm. By increasing this tolerance you may
be able to automatically close the gaps between endpoints during
chaining. You can change this tolerance in the Chaining dialog. With
some data you may find that you must manually insert line segments or
arcs to close the gaps in the data. After closing these gaps, you should
find that the data will chain more easily.
32 Import/Export
Import/Export 33
Import/Export Options
Import/export options are divided into two tabs:
The General tab (see page 32) contains mainly IGES import options.
The Digitized Data (see page 28) tab contains information on importing
digitized curves and surfaces via DXF.
34 Import/Export
Import/Export 35
6. Under Output to, select ANSYS as the Settings For field as shown
below.
7. Click OK.
8. Use Save As to export the part to a *.iges file.
36 Import/Export
Exporting files
Exporting DXF and DWG files
The DXF and DWG files exported are version 11 files. DXF files are
exported in the ASCII form, the binary form is not exported.
FeatureMILL Object
DXF Entity
Point
POINT
Circle
CIRCLE
Arc
Line
LINE
Layer
LAYER
UCS
UCS
Import/Export 37
Surface
Curve
3D feature
Point
116 = Point
Line
110 = Line
Arc/Circle
Layer
Dimensions, & other attributes
not exported
38 Import/Export
Import/Export Options
Import/export options are divided into two tabs:
The General tab (see page 32) contains mainly IGES import options.
The Digitized Data (see page 28) tab contains information on importing
digitized curves and surfaces via DXF.
Import/Export 39
Generating/simulating
toolpaths
Simulating parts
FeatureCAM provides several types of simulation:
Centerline simulation. Lines are drawn that represent the center of
the tip of the tool. Rapid moves (G0) are shown in green, and lines
and arcs (G1, G2, G3) are shown in black. These colors can be
changed if desired. This simulation method is usually the fastest.
2D Simulation. For turning, this style shows a cross section of the
part. For milling this style shows a flat (from the top) view of the
part, with each tool being shown in a different color.
3D Solid Simulation (sometimes called Visicut). This style shows a
three-dimensional shaded rendering of the initial stock and
simulates material removal in 3D. You can optionally display the
holder. Any gouge caused by holder interference or the tool hitting
the part during a rapid move is displayed in pink. For turning
simulation a 3/4 cut-away view is optionally available to view ID
cuts.
3D RapidCut. Shows a very fast simulation of a 3-axis milling job.
Can also be used for 2.5-axis milling, but is best for 3-axis milling.
Full Machine Simulation (see page 536). Allows the user to show
the motion of the entire machine tool.
With all simulation methods, video-style controls are used to pause, stop
and step through the toolpath, providing the user with fine control over
the process.
40 Generating/simulating toolpaths
Generating/simulating toolpaths 41
42 Generating/simulating toolpaths
or
Region of interest
The Region of Interest
button in the Simulation toolbar lets you
limit the portion of the part that is rendered during a 3D solid
simulation or 3D Rapidcut
simulation. There are two main reasons
to do this:
The rest of the part is not simulated and so it is faster to simulate
your region.
If you are using RapidCut, the region is simulated at a finer
resolution.
There are three different types of region:
Generating/simulating toolpaths 43
Stock: This is the default type of simulation where the entire stock is
rendered during simulation:
Feature: Select the name of the feature from the drop-down list and a
region around the feature will be selected as the region.
XYZ Location: The region is defined by either a box you drag or by two
points whose coordinates you can enter.
The sides of the box are aligned with the X and Y axes.
44 Generating/simulating toolpaths
Part Compare
Part compare is a feature of Rapidcut simulation that lets you compare
the results of a toolpath simulation with the actual part model. Regions
that are properly cut are displayed in green. Regions where extra material
remains are shown in light or dark blue. Gouged regions are shown in
yellow or red. Click here (see page 46) for an example.
To run part compare:
1. Set the desired Part compare parameters (see page 54) tolerance.
2. Run a rapidcut simulation.
3. Select View > Simulation > Show part compare from the
menu.
To view the actual part model that the simulation is compared with, select
View > Simulation > Show target part from the menu.
If you adjust the view after a part compare has been performed, a
new rapidcut simulation is performed automatically, but you must
run another part comparison.
Part compare also works with the region of interest (see page 43).
Generating/simulating toolpaths 45
Examining the trough more closely, you can see that the bottom of the
trough is greatly undercut. This is indicated by the dark blue color. The
light blue regions indicate a slightly undercut region.
46 Generating/simulating toolpaths
Simulation options
The behavior of the Centerline, 2D and 3D simulations is controlled by
the settings in the Simulation Options dialog, available in the
Options menu. You can open this dialog while a simulation is running
and refine or coarsen the simulation on-the-fly. If you open Simulation
Options during a simulation, the simulation pauses until you close the
dialog. You will get an error message if you run the 3D simulation in a
display showing fewer than 256 colors. The simulation will still run, but
won't look as good.
General simulation options
2D/3D shaded simulation options
Centerline simulation options
Part compare options (see page 54)
Wire simulation options
For Centerline simulation this option will display each tool in a different
color during the simulation.
Show holder
Show holder toggles the display of the tool holder during Centerline
and 3D solid simulation.
Generating/simulating toolpaths 47
48 Generating/simulating toolpaths
Translucent part
Select this check box to change the stock of a 3D solid simulation to be
slightly transparent.
Generating/simulating toolpaths 49
Translucent tool
Select this check box to change the tool of a 3D solid simulation to be
slightly transparent.
Pause on gouge
Pause on gouge toggles the pausing of the 3D simulation if a gouge is
detected with the part or tool holder. See Detecting gouges (see page 58)
for more information.
Show pause on gouge dialog
This option turns on the display of a dialog to warn you that a gouge has
taken place. If this option is deselected, then the simulation just pauses
without displaying a dialog when a gouge is detected.
Tool cutting tolerance
This tolerance affects the fineness of the 3D simulation. If this is set high,
the simulation will appear more faceted. The lower this tolerance is set,
the smoother the simulation will appear.
Tool visual tolerance
This tolerance affects the appearance of the tool. By increasing this
tolerance, the tool appears chunkier. By decreasing the tolerance the tool
will look rounder and smoother, but the simulation will take up more
memory and may be slower.
Rotate view when indexing
This setting applies to 4th or 5th axis indexed parts and turn/mill parts.
With Rotate view when indexing selected, the simulation will rotate
the part for an A-axis or B- axis indexing move in milling or for a C-axis
rotation in turn/mill. While these rotations provide for a more accurate
simulation, they can slow down the simulation especially with
simultaneous X- and C-axis moves in turn/mill. To speed up the
simulation, deselect this setting and the part will stay fixed and the tool
will move around the part.
3/4 view with lathe ID work (see page 49) must be deselected for
Rotate view when indexing to work with turn/mill parts.
50 Generating/simulating toolpaths
View independent
This attribute is normally selected. In this state, you can pause a 3D
simulation and change the view at any time. This simulation method uses
a solid model and should be used for all 3D simulations except animated
simulations of ballend tools. For simulating ballend tools, we recommend
that you deselect View independent. It will not allow you to rotate the
model, but the simulation will run considerably faster. Remember this is
for ballend tools only.
Save result files during rapid cut
This option must be turned on to view intermediate shaded simulations
(see page 68) in rapid cut mode. This option is useful if you want to have
quick access to images of the part at the conclusion of each operation.
This option requires a lot of memory and slows down the simulation
process, so we recommend that you use it only when you want to study
the results of each operation carefully.
Steps % of Normal
Steps % of Normal is a value between 0 and 200 that changes the
animation step size for 2D Simulation. Set it to less than 100 to decrease
the step size and to more than 100 to increase it.
5-axis simultaneous wrap tol
This tolerance controls the linearization of the 3D simulation. If this is set
larger, the simulation of 5-axis simultaneous features will be faster, but
may not be entirely accurate as the tooltip of the machine will tend to
travel in arcs instead of straight lines. (See Linearization (see page 297).)
If this tolerance is set smaller, the simulation of 5-axis simultaneous
features will be more accurate, yet the simulation will be slower.
This control is only visible if the 5-axis simultaneous product is available
(licensed or in evaluation mode).
Generating/simulating toolpaths 51
52 Generating/simulating toolpaths
Generating/simulating toolpaths 53
54 Generating/simulating toolpaths
Regions that have extra material greater or equal to the Show rest
material parameter are shown in blue. The more rest material there is,
the darker the shade of blue.
Regions with gouges greater than or equal to the Show gouge
parameter are shown in yellow. Larger gouges are shown in red.
Regions with rest material less than the Show rest material parameter
or gouges less than the Show gouge number are shown in green. These
areas are considered correctly cut.
If either the Show rest material value or the Show gouge value
is set too small, then the part comparison will be very noisy and
difficult to interpret.
Target part tessellation tolerance (see page 55)
See also Rapidcut simulation and Generating/simulating toolpaths.
Generating/simulating toolpaths 55
Simulating 3D toolpaths
Due to the large number of moves in the toolpaths for a typical 3D part,
animating the entire toolpath using 3D solid simulation is often timeconsuming. Instead, consider one of the following techniques:
Mix 3D solid and rapidcut simulation (see page 57).
Use centerline simulation and pause the simulation periodically and
erase the displayed toolpaths to clear the screen.
Use rapidcut and use the Next operation
see the results of each operation.
button to quickly
Use rapidcut and slow down the speed control so that you see some
intermediate results.
Use a region of interest (see page 43) in combination with either
3D solid simulation or rapidcut.
See also Simulation types and Using simulation video-style controls (see
page 42).
56 Generating/simulating toolpaths
or Rapidcut
Generating/simulating toolpaths 57
By using this technique, you can use rapidcut to fast forward to a point
and then use 3D simulation to more carefully study a particular set of
toolpaths.
See also Using simulation video-style controls (see page 42).
Detecting gouges
Using 3D simulation, you can visually detect gouges with the tool (during
rapid moves), the tool holder or the spindle. Any gouge is displayed in
pink. If you want the simulation to pause when it detects a gouge, set the
Pause on gouge simulation option. If this option is set, the simulation
will automatically pause if a gouge is detected. Click the Play button in
the simulation toolbar to continue the simulation. See Simulation options
for additional options.
The behavior of the Centerline, 2D and 3D simulations is controlled by
the settings in the Simulation Options dialog, available in the
Options menu. You can open this dialog while a simulation is running
and refine or coarsen the simulation on-the-fly. If you open Simulation
Options during a simulation, the simulation pauses until you close the
dialog. You will get an error message if you run the 3D simulation in a
display showing fewer than 256 colors. The simulation will still run, but
won't look as good.
General simulation options
2D/3D shaded simulation options
Centerline simulation options
Part compare options (see page 54)
Wire simulation options
58 Generating/simulating toolpaths
Generating/simulating toolpaths 59
Manufacturing errors
Manufacturing errors occur when FeatureMILL is unable to complete the
tool path generation for a part. When an error occurs, the user is unable to
run any simulation, post to NC code or save NC code. Errors appear
between lines of asterisks (*) in the operation sheet listed after the
operation in which the error occurred. Errors are also displayed in the Op
List tab with a red exclamation point icon in the left margin. Warnings
are also tagged using an exclamation point on a yellow triangle icon.
If an error is detected during toolpath generation, the Code generation
failed dialog is displayed.
If you click Yes in this dialog, the first error in the operations list will be
highlighted. If you click No, the errors will still appear in the operations
list, but you must explicitly ask to step through the errors by clicking
Next Error.
If an error occurs during toolpath generation, three error buttons appear in
a separate toolbar in the left-hand corner of the window to enable you to
read and fix the errors. The buttons perform the following functions:
Selects the next error in the operations list.
Selects the previous error in the operations list.
Provides options for fixing the error that is selected.
If you click Hint while an error is selected in the Manufacturing
Operations Sheet, a series of dialogs appears to help you fix the error.
See also Error hints dialog (see page 576).
60 Generating/simulating toolpaths
Tool load
3D toolpath simulation can be used to estimate and graph horsepower
requirements. These estimates can be used to fine-tune your program for
maximum performance. By clicking the Show tool load
button on
the simulation toolbar, the Tool Load dialog is displayed when a 3D
simulation is performed. This dialog graphs the horsepower requirements
of the part program and displays the current simulation time and
instantaneous horsepower.
Generating/simulating toolpaths 61
If you have run a feed optimization, the Tool Load graph shows the
current loads in black and the previous (unoptimized) feedrates in white.
62 Generating/simulating toolpaths
Part documentation
Manufacturing reports
Reports
After you generate a toolpath for a particular part, you can get feedback
through the Manufacturing Feedback window or printouts by
clicking the Details tab located at the bottom of the Results window.
At the top of the Details tab, there are two options.
Operation List displays a detailed report on each manufacturing
operation. Click here for Detailed explanation (see page 64).
Shows the Manufacturing Operations Sheet. This option
corresponds to the Operations option of the Show Reports submenu
of the View menu.
Tool List displays a report on the automatically selected tools. See
Tooling groups (see page 83) for specific parameters for each tool
type.
To view the NC code for your part click the NC Code tab. This posts the
part program and shows the M & G-codes. It is not a report in the normal
sense, but is often reviewed as a report by those who understand NC
code. You can also display the NC code by clicking the NC Code
icon in the Steps toolbox.
If you hold the Shift key down and then click the NC Code tab, the
underlying ACL code is displayed in the Manufacturing
Feedback window.
Part documentation 63
You can not click the NC tab unless you have a dongle installed. Clicking
one of the report buttons shows you the documentation, but it doesn't save
it to disk. Use Save NC (see page 138)from the File menu to save the
documentation.
The Turrets tab (see page 523) is used for synchronized turning.
See also Changing the fonts for the reports in the Manufacturing
Feedback window (see page 65).
Operation List
The Operation List sheet lists information for each manufacturing step
on cut type, cut depth and center point, tool details, speed/override,
feed/override, and estimated manufacturing time. It is displayed when
you click the Op List tab at the bottom of the Results window.
Part name
Part name shows the file name of the part. If you have not saved your
part, the default part name is FM1.
Setup name
Computed at
Stock
Stock material
Step no
Cut type
Feature
Pass
Tool slot no.
Tool diameter
Cut depth
Cut step
Speed
Feed
Feed is the feed of the tool that performs the currently selected operation.
The feed can be in IPR or IPM units depending on the unit set on the
operation
Est. HP and Power
Priority
64 Part documentation
Op List tab
Clicking on the Op List tab in the Manufacturing Feedback window
brings up a table of operations.
Each row displays the operation, the feature that the operation came from
and the tool that will be used to cut the feature.
If there is a or a icon in the left hand margin, you have an error or
warning (see page 60) for this operation.
This tab has three main functions:
Simulation control (see page 66)
Operation ordering
Operation editing (see page 69)
Part documentation 65
button.
66 Part documentation
button.
4. Click a Z level from the menu and the toolpaths from that level will
be displayed.
Part documentation 67
button.
You must turn on the 2D/3D shaded simulation option Save result
files during rapid cut (see page 51) for this procedure to work for
rapid cut simulations.
68 Part documentation
Mill or Drill tab for the operation. Here you can modify
manufacturing attributes.
Feature
Tool
Feed
Speed
Retract
Part documentation 69
You can also right-click a row of the table and a menu of feature
tabs is displayed. Select the tab name to go directly to that tab. See
also Overriding the tool, feed or speed for multiple operations at
once (see page 70).
Printing
You can print the tooling lists, operations sheets, NC programs, and
drawing for a part using Print from the File menu. You can also preview
these documents with Print Preview. Some options may be grayed out
in the dialog if you haven't generated toolpaths and thereby created the
lists and some of the graphics options. The files are all ASCII text files
that print like a text document.
1. Select what you want to print in the Print Range section of the
dialog. See FeatureCAM file types for more information.
2. If there is a toolpath displayed and you want to print it, click Print
tool path.
3. If you want to print so that the units of your part are honored, click
Print to scale. This means that a 1 inch line segment will
measure 1 inch on the paper. If your part is larger than your
physical sheet of paper only a portion of your part will be printed.
If Print to scale is deselected, your drawing will be scaled to fit
the paper.
4. Set your Print Quality. The specific options depend on your
printer.
5. Set the Number of copies to print.
70 Part documentation
6. Click OK.
Setup opens the standard Windows printer configuration window.
Part documentation 71
Tooling
FeatureMILL has extensive tooling databases and automatically selects
tools for each manufacturing operation.
Overview of tooling (see page 73)
Previewing the automatically selected tool (see page 73)
Tooling database (see page 75)
How to import tooling (see page 78)
How to export tooling (see page 79)
How to explicitly set a tool for an operation (see page 80)
Assigning tool numbers (see page 108)
Spindles and toolholders (see page 109)
Tool life management (see page 114)
72 Tooling
Overview of tooling
For each manufacturing operation in created for the features of a part, a
tool must be selected from the internal tooling database. This database is
broken into separate tool cribs to represent individual collections of tools
that your organization might have. The figure below shows the structure
of the tooling database.
FeatureMILL comes with two different built-in tool cribs. The Basic crib
is the default crib that contains standardly available tools that most shops
will own. The Tools crib is a large, crib containing thousands of tools.
This crib is most often used as a source to copy from into custom tool
cribs or into the basic tool crib. Only one tool crib is available at a time
and all tools are selected for a part from only the current tool crib. Tool
cribs contain individual tools and they are classified into tool groups such
as drills, end mills, and boring bars. You cannot create new tool groups,
but you can create new tools to reflect the specific tools that your shop
owns.
Each feature type has rules for tool selection. By double-clicking a
feature and clicking the Tools tab, you can see the specific tool that has
been selected to perform the operation. A feature's Tools tab is also a
convenient place to override the tooling choice if you prefer another tool.
Tooling 73
Tool numbering
FeatureCAM automatically selects tools from the active tool crib. These
tools are assigned a tool number (also referred to as a tool slot or tool
pocket) for an automatic tool changer. The numbering is assigned
according to the following rules.
1. Use the number assigned in the Tool Mapping (see page 108)
dialog.
Note that this numbering is in effect for the current part only.
2. If no number has been assigned via tool mapping, then the number
assigned to the tool in the crib (the Tool number field for milling
tools or the Tool slot for turning tools), is used as the tool
number. If two tools have the same permanent number in the crib,
the first tool used is assigned the preset number and the other tool
is given a new number.
3. If no number has been assigned via tool mapping or in the crib,
FeatureCAM assigns a tool number.
See also:
Milling tool overrides tab
Tool Mapping (see page 108)
Turning tool overrides tab (see page 92)
74 Tooling
Tooling database
The tooling database defines the set of tools from which FeatureMILL
selects tools to perform manufacturing operations. These tool sets are
called cribs. FeatureMILL comes with two standard tool cribs, the Tools
tool crib and the Basic tool crib. The Tools tool crib is a comprehensive
tool crib that contains more tools than your shop probably owns. The
Basic tool crib contains a smaller set of tools such as HSS endmills and
standardly available drills. By default FeatureMILL is set to use the Basic
tool crib. You should modify the cribs to reflect the tools your shop has.
You might also want to construct some cribs of commonly-used tools that
you use over and over again. This can simplify setting up for making the
part.
The currently active tool crib is displayed in the status bar. To change
which tool crib you are currently using, click the crib name in the status
bar. A menu of cribs is displayed that you can select from.
To create or modify a tool crib, you must have a part file open. Then
access the Tool Manager dialog by selecting Tool Manager (see page
76) from the Manufacturing menu.
Tooling 75
The database must be set up properly before it can be used. Follow these
steps:
1. Establish a location on your network for the database and copy a
blank database from the FeatureCAM CD-ROM to that location.
2. Fill the database with default tooling and feed/speed information.
Do this by running INITDB on any computer that has access to the
database and point INITDB to the database.
3. When installing FeatureCAM on user computers, instruct them to
reference the shared network database during the installation
process. Or, if FeatureCAM is already installed on the user system,
then instruct the FeatureCAM user to use the File options dialog
to switch from a local database to a shared network database
Tool Manager
Use the Tool Manager to view, modify or add tools to a tool crib. Tools
are separated into groups. The Tool group drop-down list box contains
the groups supported by FeatureMILL.
The Tool Manager only shows one type of tool at a time. The dialog is
arranged so it's convenient to move tools from one crib to another. In
general you want to have the Tools tool crib listed as the From crib and
the Basic tool crib listed as the To crib.
The fields of the Tool Manager dialog are explained below.
Tool manager list options
Tool Groups (see page 83) list for tool cribs are separated into related
groups, according to the type of manufacturing operation that class of
tools typically performs.
From crib list
Available tools list
To crib
New tool
New crib
Delete crib deletes the current tool crib. See How to delete a tool crib
(see page 78) for more information.
Select all
Add
76 Tooling
The Import button brings up the Tool Import dialog. This allows you to
import tools from other FeatureCAM users.
The Export button brings up the Tool Export dialog. This allows you
to export tools so that you can share them with other FeatureCAM users.
There are two different file types that are supported, *.xml and *.tdb. We
recommend that you use the *.xml format as it supports exporting form
tools and custom drawn holders.
Remove
Current tools
OK
Cancel
Tool grades
Properties: Select a tool in the Available Tools or Current Tools
list and click Properties to see more details of the tool.
Default tool registers
Tooling Speed and Feed overrides
Tooling 77
78 Tooling
5. Select an option for handling new tools with the same name as
existing tools:
Select Overwrite if you want the new tool to be copied over
the old one.
Select Add 2nd Copy to add the new tool under a different
name.
Select Skip Tool, to ignore any new tools with the same name
as old tooling.
6. Click Import.
7. Click Close.
See also How to export tooling (see page 79)
Tooling 79
80 Tooling
2. Create the bore feature and override the tool to be the same insert
drill.
If you view the tools in the Tool mapping (see page 108) dialog, you see
that there are two drills listed in the same tool slot, but they have different
Length offset registers.
Form tools
The FeatureCAM tool cribs contain thousands of industry-standard tools
in a wide variety of types. Custom-shaped form tools are not included in
the default tool cribs, but you can create these tools and use them to cut
features. The pictures below show examples of form tools.
Using these tools does not change the toolpaths generated for features,
but the 3D simulation does simulate the proper shape of form tools. Form
tools are never automatically selected, but they can be manually selected
by the user.
Form tools have unique shapes, but their type must be endmill, twistdrill
or sidemill. If you want to use the form tool to perform a milling
operation it must be an endmill form tool. Drilling operations can be
performed with endmill form tools or twistdrill form tools. OD/ID
grooves can only be performed with sidemill form tools.
Creating a form tool (see page 81)
Displaying a profile of an existing tool (see page 82)
Using a form tool or insert drill for drilling operations (see page 82)
Tooling 81
82 Tooling
Milling tools
Tooling groups
Tool Groups lists for tool cribs are separated into related groups,
according to the type of manufacturing operation that class of tools
typically performs. The following tool-group divisions are defined for
FeatureMILL. The following figures illustrate the parameters that define
all of the tooling groups.
Boring bars for milling (see page 85)
Chamfer mills (see page 85)
Counter bores (see page 86)
Tooling 83
84 Tooling
Chamfer mills
Chamfer mills are used for chamfer features or for chamfering large
diameter holes.
Tooling 85
Counter bores
Counter bore tools are used for the counterbore operations of counter
bored holes. See also Hole: Tool Selection.
Countersink
Countersink tools are used for counter sink operations on holes.
See also Hole: Tool Selection.
- Shank Diameter
- Body Diameter
- Overall Length
- Angle
- Flat Diameter
86 Tooling
Endmill tools
Endmill tools are used to represent flat endmills, ball endmills, bull-nose
mills and tapered endmills. The basic parameters on shown below.
Tooling 87
Face mills
Face mills are used for facing features.
Reams
Reams are used for reaming operations on holes. See also Hole: Tool
Selection.
Rounding mills
Rounding mills are used for round features.
88 Tooling
Side mills
Side mills are used for OD and ID grooves. The Slitting saw parameter
is only used as documentation on the tool.
Spot drills
Spot drills are used for spot drilling starter holes. Note that center drills
(see page 90) are preferred for spot drill operations. See also Hole: Tool
Selection.
Tooling 89
Center drills
Center drills are used to drill starter holes. They are preferred over spot
drills for spot drilling operations. Spot drill tools (see page 89) can also
be used for spot drill operations. See also Hole: Tool Selection.
Taps
Taps are used to tap holes. For inch tools, you specify the threads per inch
(TPI), and for metric tools, you specify the pitch of the threads.
Spiral-style taps have twisted flutes while Gun-style taps have straight
flutes. Bottom taps have a flat bottom, while plug taps come to a point.
If a bottom tap is required for a blind hole, a warning is issued in the
operations sheet. Regardless of the type of tool used for tapping, the hole
must allow enough clearance for the tap. If the hole violates this rule, an
error message is generated when you enter the hole dimensions. See
Hole: Threading, boring, and reaming for more information on tapping
depth and Hole: Tool Selection for information on tool selection
preferences.
The Limit parameter is ignored for tool selection. It is used only to
document the tool.
Drill diameter
90 Tooling
Tap types
Tapered taps
Common tool parameters (see page 84).
Thread mills
Thread mills are used for OD and ID thread milling operations.
For single point tools, set Max Pitch equal to Cutter Length.
Common tool parameters (see page 84).
Twist drills
Twist drills are used for drilling operations.
For insert drills, select the Insert drill check box and enter the Insert
Depth instead of the Angle. If an insert drill is initially chosen for a
drilling operation, the spot drill operation is omitted. See Hole: Drill to
depth for more information on drill depths. See also Hole: Tool Selection.
See also Using a form tool or insert drill for drilling operations (see page
82).
Common tool parameters (see page 84)
Tooling 91
Turning tools
Turning tool overrides tab
Use the default tool registers if you want to permanently assign tool
registers for this tool every time it is used. If the tool number is 0, then
this indicates that no default value is assigned to this tool and that
FeatureCAM automatically assigns a tool number when the tool is used.
If you want to change these values only for a particular part, use the Tool
Mapping dialog (see page 108).
Tool number is the current tool slot number for that tool. Tools can
occupy the same tool slot (see page 80).
Diameter offset register number is the diameter cutter comp. offset
register for that tool.
Length offset register number is the tool length offset register. Most
lathe controllers have a single register that contains the length and
diameter offset values. In this case, the Length offset register
number is the important field to set in FeatureCAM.
Tool ID is the tool ID register for the tool. This is a seldom used field
that is used by Bridgeport lathes and occasionally for Cincinnati
Machines lathes.
Coolant is the type of coolant to use for the tool.
Operations is the type of operation to use the tool for. This option is
used to limit the tool to be used for only specific operations.
Max depth of cut is the maximum cut depth that is allowed for this
tool.
92 Tooling
Insert tab
The Insert tab describes the characteristics of the tool's insert. The
specific values contained in this tab are dependent on the type of tool. See
the tool type (listed in the title of the dialog) below for more information.
Lathe - turn tool properties:
Inscribed circle diameter (see page 94)
Insert shape (see page 96)
Name (see page 98)
New material button (see page 98)
Tip angle (see page 94)
Tip radius (see page 95)
Lathe - bore tool properties:
Inscribed circle diameter (see page 94)
Insert shape (see page 96)
Measure (see page 98)
Name (see page 98)
New material button (see page 98)
Tip angle (see page 94)
Tip radius (see page 95)
Lathe - groove tool properties:
Cut-grip grooving tool (see page 83)
Insert shape (see page 96)
Name (see page 98)
New material button (see page 98)
Tip angle (see page 94)
Tip radius (see page 95)
Tooling 93
Tip angle
The included angle of the insert.
94 Tooling
Graphic explanation
Tip radius
The radius of the cutting tip of the insert.
For threading tools, 3D simulation simulates the tool with a tip
radius of 0.0. This is just for visualization purposes only. The NC
code or tool selection is not affected in any way.
Graphic explanation
Tooling 95
Insert shape
The valid insert shapes are listed. For the custom diamond shape, the tip
angle (see page 94) is entered by the user.
Holder tab
The Holder tab describes the characteristics of the tools holder and how
the insert is oriented relative to the holder. The specific values contained
in this tab are dependent on the type of tool. See the tool type (listed in
the title of the dialog) below for more information.
Lathe: turn tool properties
End angle (see page 100)
End clearance (see page 100)
End cut (see page 101)
Length (C) (see page 102)
Shaft Height (A) (see page 103)
Side angle (see page 100)
Side clearance (see page 101)
Side cut (see page 105)
Lathe: bore tool properties
End angle (see page 100)
End clearance (see page 100)
End cut (see page 101)
Length (C) (see page 102)
Min diameter (see page 102)
Shaft Height (A) (see page 103)
96 Tooling
Tooling 97
Measure
The unit of measure of the insert. Select the Inch check box to specify
the insert in inches. Deselect the Inch check box to specify the insert in
millimeters.
Name
The name of the insert. The name must be unique among all the tools in
the crib.
New material button
Click this button to create a new material name. To create a new material
from the Tools Properties dialog:
1. Click the New material button. The Turning Tools Material
dialog displays.
2. Click the New button.
3. Enter the new material name and click OK.
4. Click OK in the Turning Tools Material dialog.
You still have to define feed/speed tables for your new material. See
Adding a new material (see page 119) or Feeds and speeds (see page 118)
for more information.
Width
The width along the Z axis of a grooving/cutoff tool.
98 Tooling
Graphic explanation
Max TPI
The maximum threads per inch that the tool can cut.
Min TPI
The minimum threads per inch that the tool can cut.
Tooling 99
End angle
The angle, off of vertical, of the end of the insert.
Graphic explanation
End clearance
The distance from the end edge of the insert to the holder.
Graphic explanation
Side angle
The angle of the side of the insert.
100 Tooling
Graphic explanation
Side clearance
The distance from the side edge of the insert to the holder.
Graphic explanation
End cut
A classification of a tool that indicates that the tool will cut in a direction
parallel with the length of the holder.
Tooling 101
Min diameter
The Min diameter is the smallest diameter that accommodates an ID
tool.
Graphic explanation
Length (C)
The length of the holder.
Graphic explanation for boring tools
102 Tooling
Tooling 103
104 Tooling
Side cut
A classification of a tool that indicates that the tool cuts in a direction
perpendicular with the length of the holder.
Cut depth
The maximum depth of cut for grooving tools.
Holder Type
Threading and groove/cutoff tools have additional subtypes listed under
the Holder Type parameter.
For threads possible holder types are:
OD Threads - Enter this value for outer diameter threading tools
ID Threads - Enter this value for inner diameter threading tools
For grooves possible holder types are:
OD Groove - Enter this value for outer diameter grooving tools
ID Groove - Enter this value for inner diameter grooving tools
Face Groove - Enter this value for face grooving tools
Cutting - Enter this value for cutoff tools
Tooling 105
These two diameters are the minimum and maximum diameters between
which the tool can plunge.
The tool inside edge of the groove must be between the Min plunge
diameter and Max plunge diameter if the groove is being cut in the
positive direction. The outside edge must be between these two diameters
if the groove is being cut in the negative direction.
Creating holder curves
1. If you want to display the insert and current holder shape for a
particular tool, see Displaying holder and insert geometry (see page
107) in the graphics window. This enables you to have a reference
to draw on top of.
2. Regardless of the eventual orientation of the holder in the machine,
draw the holder curve in the XZ plane with the length of the tool
holder in the +Z direction and the leading edge of the insert at the
origin. The curve you draw must be a closed curve. Graphic
explanation
3. Name the curve appropriately so that you can remember is later
when you associate the curve with a user defined (see page 106)
holder.
Associating curves with user-defined holders
Remember that you must create the curve first. See Creating holder
curves (see page 106) for more information.
1. Bring up the Tools Properties dialog for the desired tool. Click
here for specific instructions.
106 Tooling
Orientation tab
On the Orientation tab, select the orientation of the holder in the
machine and the handedness of the tool. To set the options on this tab:
1. Select an orientation by clicking the button at the end of the tool
that indicates the desired orientation. Nothing is implied by the
shape of the inserts in the icons. The actual insert of the tool can be
any shape.
2. Select the Handedness of the tool from either Right Hand or
Left Hand.
Tooling 107
Tool Mapping
Tool Mapping is where you change the tool slot assigned to the selected
tool. You can change the Cutter comp. offset register for any tool
here too. Access this dialog by selecting Manufacturing > Tool
Mapping from the menu.
The dialog has a table at the top. Each row of the table represents a tool.
Click the name of a tool to modify its values in the following fields below
the table.
Tool number
Diameter offset register number
Length offset register number
Tool ID
The Tool Mapping dialog has these options:
Set
Clear in crib
Set All
Reset All
Same
You can perform the following operations in the Tool Mapping dialog:
Dragging and dropping tools
Toggling operations for a tool
Increasing tool slots listed
Changing offset registers per operation
108 Tooling
Instructions (see page 109) for changing the Tool number or Cutter
comp. offset register for a tool.
See also How to use an insert drill to drill and bore in the same program
(see page 80) and tool life management (see page 114).
Tooling 109
110 Tooling
Tooling 111
Tool Groups - This button displays a list of tooling types that use this
holder.
Use curve to describe holder shape - If you want to make a custom
holder shape, select this option and select a curve in the drop-down menu
that describes the shape. This curve must be in the XZ plane with one
endpoint at the origin.
Paste copy into graphics window - Click the Paste button to copy
into the graphics window a set of lines and arcs for the current holder
shape. This can be useful as a reference if you are going to draw a custom
holder shape.
Tip diameter - This is the outer diameter of the holder at the tip for
collets. For convenience, you can set the Tip diameter for endmill
holders to Based on tool dia so that the holder is scaled to fit a tool.
Tool Diameter - For collets this can be specified as a minimum and
maximum value, to accurately reflect actual collets, or it can be set to Fit
any tool so that the diameter is adjusted to fit any tool with a diameter
less than the Tip Diameter.
Dimensions - The other dimensions of the holders are shown below.
See also Spindles and toolholders (see page 109) and Creating or
modifying tool holders (see page 113).
112 Tooling
Tooling 113
Selection details
Certain operations are associated with collets and others with the endmill
holders. See Creating (see page 112)or modifying spindles for how to
change this association.
Once the holder type is determined, tool selection is based solely on
matching the diameter of the tool with the tool diameter parameter of the
holder. For endmill holders, the holder with the smallest tool diameter
that is greater than or equal to the tool's actual diameter is preferred. For
collects, the tool's diameter must be within min. and max. tool diameter
of the collet. For both the endmill and collet holders, if a match cannot be
made from the existing tool holders, an existing holder is scaled by
adjusting the tool diameter and tip diameter.
Holders are associated with tools in the holders tab of the Tool
Properties dialog.
114 Tooling
3. For milled parts, tool life management is only active for the
creation of a single program. Therefore it is active for single setup
parts, or 4-axis or 5-axis indexed parts. For 4-axis and 5-axis parts,
if you have Setup dominant selected, you must also select
Generate single program to enable tool life management. See
the Index tab of the Stock dialog for more information on
indexing. If you have a multiple setup milling part without
indexing, you must deselect all but one setup in the Part View to
enable tool life management for this setup.
4. It is not active for turning, turn/mill or wire EDM parts.
5. Tool life only applies to the use of a tool during the running of a
single program. Tool life information is not stored permanently in
the tooling databases.
Tooling 115
Turret location
The Turret location is now kept in the *.cnc file, since there may be
multiple turret locations with the advent of multi-turret turning.
To change the location(s):
1. Select Manufacturing > Post Process from the menu.
2. In the Post Options dialog, click the Turn/Mill tab.
3. Click the Edit button and XBUILD opens. Select CNC-Info >
Turrets... from the menu.
See also Tools page for turning.
116 Tooling
You can also explicitly set the feed rate or spindle speed for an individual
operation, but these changes only affect a single feature in a single part
file.
6. For milling, select the desired tool grade and tool finish.
7. For certain materials there are actually two tables, each associated
with a hardness value. If there are two tables, the Hardness 2
button will be available. Click Hardness 2 to see the other table.
Feeds and speeds are interpolated for hardness values in between
the two hardness values associated with the two tables.
8. Click OK when you have finished viewing the table.
See also Undefined tool finishes.
COPPER 10.0
0.25 3
1 1 1 0.1
2 2 2 0.2
3 3 3 0.3
COPPER 20.0
0.25 3
New Material
11 11 11 0.11
12 12 12 0.12
13 13 13 0.13
COPPER 30.0
0.25 3
21 21 21 0.183
22 22 22 0.173
23 23 23 0.163
COPPER 40.0
0.25 3
31 31 31 0.184
32 32 32 0.174
33 33 33 0.164
STEEL 20.0
0.25 4
41 41 41 0.185
42 42 42 0.175
43 43 43 0.165
44 45 46 0.155
9. Click Close.
The file created is tab delimited text. You can edit the file in a
spreadsheet if desired. This file can now be imported into FeatureCAM.
See How to import feed/speed tables (see page 121) for more
information.
Show/hide material
FeatureCAM comes with a long list of materials. Some of these materials
might not be applicable for your shop. You can delete materials from the
database, but when you upgrade to a new version these deleted materials
reappear. The solution is to hide an unwanted material. When the
materials database is updated, hidden materials will not reappear.
To hide or show a material:
1. Select Manufacturing > Materials > Show/hide from the
menu.
2. Select any material you would like to show.
3. Deselect any material you would like to hide.
4. There are also buttons located to the right of the material list that
can be used to select all or deselect all of the material names.
Local
File type
coordinate
No
No
Code created
*.fm
*.mf with
multiple
fixture
Yes
No
No
Yes
*.mf with
global
fixture
*.fm
*.mf with
multiple
fixture
*.mf with
global
fixture
*.fm
Yes
Yes
*.mf with
multiple
fixture
*.mf with
global
fixture
*.fm
*.mf with
multiple
fixture
*.mf with
global
fixture
Feed optimization
Feed optimization is an optional process that evens out the tool load by
adjusting a program's feedrates. This optimization is performed so that
the horsepower required for the cuts approximates a target horsepower. In
the graph shown below, the initial feedrates are shown in white. The
optimized feedrates are shown in black. Notice how the black curve
removes the spikes in the tool load.
When cutting this feature in aluminum with the default stepover and
feed/speed table, the horsepower is estimated at 2.0 for the roughing pass
and 0.3 for the finishing pass. A 0.5" tool is selected. Let's assume that
you would like to keep the horsepower requirements for this cut to less
than 2.5. When a tool load is run on this example, the maximum
horsepower actually required is shown to be 5.9. In order to stay under
the stated horsepower requirement, the feed rate for the roughing pass
must be reduced by 50%. Without feedrate optimization, your only choice
for lower the horsepower requirements are to adjust the width or depth of
cut for the entire operation or change the feedrate for the entire operation.
When you examine the actual toolpaths of this boss there are light cuts, as
shown in the narrow cut on the left and heavy cuts, as shown in the wide
cuts on the right.
Feedrate optimization looks at the tool load for each move and adjusts the
feedrate to even out the load. Instead of reducing the overall feedrate for
the roughing pass, let's keep the feedrate for the roughing feature the
same and use feedrate optimization to adjust the feedrates of the
individual moves of the toolpath. The table below shows that feedrate
optimization allowed us to reduce the machining time by 47% while
maintaining a more constant cutter load.
Before Feedrate
Optimization
After Feedrate
Optimization
Roughing
2:57
1:21
Finishing
0:30
0:27
Total
3:27
1:49
Time
Savings
47%
Max
2.4
Horsepower
2.4
Target horsepower
Set this milling attribute to the desired horsepower for the operation. This
n (see page 130)umber is then used in feed optimization to even out the
tool loads. This attribute is automatically set to the estimated horsepower
for 2D roughing passes performed with flat end tools. For 3D roughing
passes performed with flat end tools, this attribute is also set to the
estimated horsepower as long as the Z increment (see page 424) attribute
is set. For all other operations, this attribute has no default value.
If the Target horsepower is not set for an operation, then its feedrates
are not (see page 130) modified by feed optimization. This means that if
you do not explicitly set the target horsepower for individual operations,
feed optimization will only affect 2D roughing operations and 3D
roughing operations with flat end mills and the Z increment parameter
set.
For 2.5D finish milling operations, we recommend that you use
Peripheral feeds instead.
Creating NC code
Post options
Post options for milling
The available CNC files are described here. Click the Browse button to
select the post processor.
Edit will start XBUILD for the current CNC file.
Post Options in the Options menu controls the type of CNC machine
that FeatureMILL targets for NC output.
icon.
Save Options
In FeatureCAM, you can save a number of previous versions of your part
as you work. To activate this feature:
1. Select File > Save Options from the menu.
2. Select Create backup copies.
3. Enter the Number of Copies to Keep.
Now when you save your work, the previous version(s) will be saved to
disk under a name that begins with 'Backup'. The latest version of your
work will always be saved using the name of your FeatureCAM part.
Save computed toolpath
For certain parts, generating toolpaths can be time-consuming and you
may want to save them for the next time you open a part. The setting of
Save computed toolpath controls the default behavior for saving
toolpaths. Select from Never save, Always save, or Ask me to be
prompted each time you save a part. Note that this is different than saving
the NC text file that the NC machine reads. Instead you are saving the
FeatureCAM internal toolpath representation.
Compressed file
If you select Compress file, the size of the FeatureCAM files are
reduced on disk. Note that compressed files cannot be read into earlier
versions of FeatureCAM.
Save preview picture in file
Select Save preview picture in file to store an image of the part in the
file. If the part is stored, then this image is displayed in the Open file
dialog.
Milling macros
Macros can be generated in the NC code for multiple Z levels of a milled
feature. To generate these macros, your post processor must support
them, and you must turn this function on for the post.
1. Open the Post Options dialog by selecting Post Process in the
Options menu.
2. Select your post processor.
3. Select the Enable Macros checkbox.
4. Click OK.
5. Select Default Attributes from the Options menu.
6. Set the Minimize tool changes check box.
You could set Minimize tool changes in the Ordering dialog
instead. Using the Default Attributes setting includes macros for
any parts you create.
Minimize tool changes groups operations together that use the same
tool. This saves time for you by eliminating or reducing needless tool
changes. You must select this check box if you want to generate hole
macros in the NC code.
1. Turn off Minimize rapid distance.
This attribute only affects milling setups and is the only ordering option
that will change the order of features specified in the part view.
Minimize Rapid Distance moves to the next closest feature that uses
the same tool as the last operation. This check box must be deselected if
you want to generate hole macros in the NC code.
1. Click OK.
Now when you generate NC code, you will get macros for the milled
features that are milled at multiple Z depths.
Indexing
Indexing uses the 4th axis to rotate the part between machining operations
so that the machining takes place on different planes of the part.
Overview of indexing (see page 144)
How to create an indexed program (see page 144)
4th axis indexing - How the clearance plane is calculated (see page 149)
Overview of indexing
Indexing uses the 4th axis to rotate the part to access each feature. In
FeatureCAM each face of the part can be assigned to a separate setup (see
page 147) or features can be placed radially (see page 146) around the
center of rotation by using only one setup.
Parts whose features can be accessed by rotating around a single axis are
candidates for 4th axis wrapping.
See also 4th axis indexing - How the clearance plane is calculated (see
page 149).
You must have a CNC control that supports a 4th axis, and a rotary
table or native 4th axis that can be controlled by the CNC machine
in order to use indexing.
step.
5. Decide what world coordinate axis you will rotate about. The Xaxis is recommended since the majority of the post processors
support only X-axis indexing. (For the rest of this description we
have assumed that you have selected the X axis.) For the X-axis,
click Index around the X-axis. For the Y-axis, click Index
around the Y-axis.
6. Position the stock appropriately.
7. Specify the tool change position (see page 148).
8. If you want to create setups on each face:
a. Create the setups for indexing (see page 147).
b. Switch to each setup and create your features.
9. If you want to use a single setup, create each feature and follow
this procedure (see page 146) on the location page to orient each
feature.
10.Generate the tool paths.
11.Click Post Process in the Manufacturing menu and select a
post from the 4thxs directory.
12.Click the NC tab in the Manufacturing Results window.
4th-axis rotation
In this example, the part is indexed around the X-axis.
The X-axes of each setup are parallel to the X-axis of the Stock
Coordinate System.
In the case of indexing around the X axis, the X coordinate will move the
feature along the X axis and the Y coordinate will translate the feature in
the perpendicular direction.
In the case of indexing around the Y axis, the Y coordinate will move the
feature along the Y axis and the X coordinate will translate the feature in
the perpendicular direction.
See also 4th-axis indexing - positioning the stock and 4th axis overview.
Indexing can be performed around the X or Y axis of the stock axis. The
post processor you use must have the same indexing axis as your part. For
each setup the corresponding axis must be parallel to the indexing axis.
For example, if you are indexing around the world coordinate X axis, the
X axes of each setup must be parallel to the stock axis. See Overview of
setups for more information on setups.
When using indexing, the part documentation is combined for all setups.
This means that you will have just one operations list, one tool list and
one NC part program for all setups.
When positioning features in the Location dialog box, use the XYZ or
polar types of positioning.
See also 4th axis indexing with a single setup - positioning features (see
page 146).
Restrictions of indexing
You must use a post from the 4thxs directory. Normal posts do not
support indexing.
The post CNC files have the indexing axis hard-coded. Most are
setup to rotate about the X axis. The axis of rotation in your
program must match the rotation axis of the post.
If you are using multiple setups and are rotating about the world X
axis the X axes of the setups must be parallel to the world X axis.
If you are using multiple setups and are rotating about the world Y
axis the Y axes of the setups must be parallel to the world Y axis.
Wrapping (3D)
4th-axis wrapping
4th-axis wrapping allows you to wrap a 2.5D feature around either the X
or Y axis. You must have a machine tool with 4th-axis capabilities to take
advantage of this feature.
Overview of 4th axis wrapping (see page 151)
Basic 4th axis wrapping requirements (see page 153)
How to create a NC program using 4th axis wrapping (see page 153)
Creating a 4th axis wrapped feature from a 3D model (see page 154)
Curve unwrapping (see page 155)
Cut side perpendicular (see page 157)
Restrictions of 4th axis wrapping (see page 159)
See also Indexing (see page 143)
The features are not displayed as wrapped, but when you generate
toolpaths for a wrapped setup, the toolpaths are wrapped.
See also:
Basic 4th-axis wrapping requirements (see page 153)
How to create a NC program using 4th-axis wrapping (see page 153)
Creating a 4th-axis wrapped feature from a 3D model (see page 154)
Wrap tolerance
Arcs that are wrapped must be converted to small 3D line segments. The
Wrap tolerance is used to determine the acceptable distance between
the line segments and the initial arc. The figure on the left shows a lower
tolerance for a wrapped circular groove. The right-hand figure shows a
large tolerance. In this case the circle is approximated by a square.
This attribute is also used to control the polar interpolation on face cuts
for turn/milling. If FeatureCAM is performing the polar interpolation, any
linear move or off center arc move on the face of the part must be
interpolated by linear moves and rotations about the C axis. Wrap
tolerance is used to control the fineness of this linear interpolation. The
figure on the left shows a straight face cut with loose wrap tolerance. The
right-hand figure shows the same cut with a tighter tolerance.
Curve unwrap
If you are working with a curve that has been wrapped around an axis and
you want to unwrap the curve into a planar curve, use Curve unwrap.
Wrapped features in FeatureCAM require a planar curve, so this function
is helpful if you want to generate toolpaths from data that is already
wrapped.
To complete this dialog:
1. Name the curve in Curve name field.
2. Select the curve in the drop-down list box or click
the source curve with the mouse.
and select
3. Select the axis that the curve is wrapped around. This setting will
default to your current wrapping axis that you specified in the stock
wizard.
4. The Tolerance will control the accuracy of the unwrapped curve.
All unwrapped curves are piece-wise linear, so the smaller the
tolerance, the more points your curve will have.
5. The Radial offset should normally be set to 0 since the curve is
unwrapped in place. If you have extracted the curve at the bottom
of the feature, then you will want to set the Radial offset to the
depth of the feature to offset the curve to the top.
6. Project to UCS plane should be selected if you are creating a
2D feature. The only time it should be deselected is if you want a
3D curve to result.
7. We recommend that you select Smooth/reduce to try and reduce
the number of points in your curve.
Cylindrical cams
You must have 4th-axis wrapping (see page 150) to cut cylindrical
cams.
Cylindrical, or barrel, cams are specified as you would a normal cam. See
Cams for more information on reciprocating cams. For simple cams, the
rise and fall are radial distance. On cylindrical cams the rise and fall
displacements are along the wrapping axis.
For example, if you create a barrel cam that is wrapped around the X axis
with the following parameters:
1. Bring up the Cam dialog from the Create menu or the Curve
wizard.
2. Select Cylindrical cam.
3. Specify the Radius as the the radius of your cylindrical stock. See
Overview of 4th-axis wrapping (see page 151) for more
information.
4. Specify either Wrap X Axis or Wrap Y Axis. Make sure that this
setting matches the wrapping axis you specified in your setup.
5. Enter the Segment parameters.
6. Click OK.
7. Use this curve to create a groove.
You now have a feature that you can use for 4th-axis wrapping.
If instead, you wish to have walls that are perpendicular to the index axis,
as shown below, you must use the Cut sides perpendicular to Index
axis attribute.
If you require perpendicular sides, you must have a lathe or mill with X-,
C- and Y-axis motion. To program your feature to have perpendicular
sides you must select Wrap feature around X-axis and also select
Cut sides perpendicular to index axis. Features cut with this option
have sides that are perpendicular to the index axis. There are a number of
restrictions (see page 158) for this type of feature.
If you preview the toolpaths and are getting wild moves at the
feature edges, select a smaller tool. Often the automatically
selected tool is too large. Most problems using Cut sides
perpendicular to index axis are related to using a tool that is
too large. Make sure the tool is small enough before making the
changes discussed below.
If the finishing pass for the walls of the feature does not
immediately follow the roughing pass, you may need to adjust the
plunge point for the finishing pass to ensure that it plunges near the
center of the feature. You want to avoid plunging near the outside
walls where the Y displacement is the greatest. If the initial move
of the finish pass gouge, adjust the plunge point for the finish pass.
See also 4th axis overview (see page 143).
4-axis simultaneous
A 4-axis simultaneous surface milling feature requires your machine to
have four degrees of freedom. For FeatureCAM, the four degrees of
freedom are restricted to moving in X, Y and Z, and a rotation about the
stock indexing axis (A, B, or C in the case of turn/mill). You may define
4-axis features in a turn/mill document with a tool that 'cuts from the OD'.
You may also use 4-axis features in a 4-axis indexed milling environment
in a milling document (see the Indexing tab of the Stock properties).
In an appropriate document type, with an appropriate post (*.cnc file),
some surface milling operations have a 4-axis tab. The 4-axis tab lets you
control or specify the tool orientation. The default value is Vertical
which is used for standard 3-axis milling. However, it can also be a
continuously changing orientation for 4-axis simultaneous machining.
With 4-axis simultaneous, FeatureCAM will try to machine the feature's
surfaces while tilting the tool axis in the way specified by the user.
FeatureCAM's 4-axis product is identical to its 5-axis (see page 465)
product (there are no new terms, dialogs, or concepts to understand) with
one important exception: during toolpath calculations, all tool axes are
projected onto the appropriate plane. For instance, if the current
document is an index-around-X type, then at a particular toolpath point,
the tool axis will be projected onto the STOCK YZ plane. This results in
the toolpath point at (XYZ), and a tool axis of (0JK) so that (0JK) can be
converted to an 'A' angle in the posting process.
Multiple fixture
documents (2.5D &
3D)
If you want to cut different parts on your machine at once, use the
Multiple Fixture Part. With multiple fixture parts, you can mix
different setups from FeatureCAM parts. FeatureCAM can then create a
single program for cutting all the parts and it can minimize tool changes
across all parts.
Example of multiple fixture part (on page 162)
Creating a multiple fixture part (see page 162)
Editing a multiple fixture design (see page 163)
Saving and opening multiple fixture parts (see page 166)
Configuration
1. The XYZ part origin is read from the file and setup you selected.
You can also override it if you wish.
2. X and Y repeats define a rectangular array of the selected part
setup. Use these numbers to determine how many copies of the part
to mill at the same time.
3. X and Y spacing is the spacing between part origins. Depending on
your post, these spacing numbers might not have any effect on the
part as produced at the machine. That is controlled by the Fixture
ID and how the Fixture ID is used to locate other parts relative to
each other.
4. Click Next to open the Layout (see page 163) dialog.
Layout
This is where the multiple part file setup diverges. You can build each
part in its own piece of stock material, or build them from one larger
block of stock material.
Individual blocks (see page 164) are simpler to design, but perhaps
less efficient.
Single block (see page 164) may minimize waste, but is more
difficult to layout and fixture.
Individual blocks
1. Select Individual Block and click Next. FeatureMILL constructs
the layout in the Graphics window and displays the Preview
dialog.
2. Depending on your screen layout, drag the Preview box out of the
display as much as needed so you can preview your parts.
3. If you are happy with the layout, click Finish.
4. Otherwise, click Back until you reach the dialog with the settings
you want to modify.
5. Change those parameters and click Next until you return to the
Preview dialog.
6. Repeat this process until the part layout is correct, then click
Finish.
7. You can repeat the whole Add process to place more setups or
parts in the whole layout as needed to complete the task.
Single block
When you select Single block, the dialog changes. The Nested
(see page 164) option is described elsewhere.
Click Next to open the Stock (see page 165) dialog.
Nested
Depending on your part geometry, you might be able to make better use
of a given stock size by nesting your parts. Nesting involves flipping the
part around so that it can nest in the blank spots between other parts and
can minimize waste in cutting some parts.
Selecting Nested in the Layout dialog changes the picture and adds
some more parameter fields.
X/Y shift is set for the inverted row. The important concept is that you
don't set space directly between neighboring shapes. That parameter was
handled earlier when you specified how many repeated columns and rows
to use. For shift spacing, you are setting the distance between the two
rows' top edges (Y shift) and the columns' right edge offset (X shift). You
probably will need to adjust your X and Y spacing in addition to the X
and Y shifts to find the optimum spacing. Don't overlook negative values
either.
Stock
1. The part origin is read from the file. You can override it if you
wish.
2. Notice that the block is automatically sized based on the part size
and the spacing you specified. If your stock has a different size,
enter those dimensions here. Clicking Auto calculates the
minimum block the parts will fit in as described in the
Configuration dialog.
3. Click Next to open the Preview dialog. FeatureMILL constructs
the layout in the Graphics window and displays the Preview
dialog.
4. Depending on your screen layout, drag the Preview box out of the
display as much as needed so you can preview your parts. If the
layout is acceptable, click Finish.
5. Otherwise, click Back until you reach the dialog with the settings
you want to modify.
6. Change those parameters and click Next until you return to the
Preview dialog.
7. Repeat this process until the part layout is correct, then click
Finish.
8. You can repeat the whole Add process to place more setups or
parts in the whole layout as needed to complete the task at hand.
For more information, refer to Completing the multiple fixture (see
page 166) part.
Parts list
1. To open a part file for use in a Multiple Fixture part, use Parts
List in the Multiple Fixtures dialog.
2. Then Browse for the parts you want to include, one by one.
3. Perform the Add process.
Besides the browse and select functions, Parts List is also where you
update a Multiple Fixture document if the source files have changed:
1. Select the source file.
2. Click Reload.
3D surface modeling
(3D)
Surface wizard
You can build surfaces from the Surface toolbar, the wizard or by
selecting Construct > Surfaces in the menu. With the Surface
wizard:
1. Select the category of surfaces:
From curves
Predefined surfaces
From one surface
From multiple surfaces
2. Pick a construction method from that category.
3. Click Next. The Surface Construction dialog appears.
4. Look through the construction methods and check that they will
construct the kind of surface you want.
5. If the methods don't match what you are trying to do, click Back
and use a different method. The same surface can often be made in
different ways.
6. When you have the construction method you want, fill in the fields
with the correct information. Surfaces use curves, other surfaces,
points, surface normals, and other kinds of user-specified
information to create your part model.
7. Click Finish to add the surface design to the part model.
Surface definition
To build and use surfaces in FeatureMILL, you need to understand how
FeatureMILL defines a surface. A surface is defined by a rectangular set
of points and a description of how the surface behaves at each point on
the surface which determines the smoothness of the surface. The set of
points determines the shape, or geometry, of the surface.
The rectangular nature of the control point mesh means that a surface has
four boundary curves. In some cases, surfaces are constructed where one
or two (opposite) boundary curves are degenerate or form a single point
such as the poles of a sphere. In other cases where surfaces wrap around,
such as a cylinder, two opposite boundaries can be the same curve and are
called seams. With seams and degeneracies, a surface may appear to have
only three, or two, or even no boundaries (a sphere), but the four
boundaries are always defined. With these four boundaries, you can break
a surface into rows and columns so surfaces have a table-like structure.
Surface editing
There are a number of ways to edit surfaces. FeatureMILL supports
filleting, merging, intersecting and direct modification of the surface. You
can also derive a surface from any 2.5D feature.
Revolution
A surface of revolution is created by spinning a curve about a specified
axis. The revolution is any amount from -360 to 360 . These are similar
to a swept surface, and can be used to create other primitive shapes not
provided such as a torus or a cone. These surfaces are exact.
While you can use a 3D curve as the curve to spin around an axis, there is
a higher chance of creating a self-intersecting surface. Where possible, it's
best to use a 2D curve for input to this surface.
To create a surface of revolution, you need a curve and either the X
or Y axis for rotation, or a custom line for the axis.
Follow these steps to create a surface of revolution:
1. To start, either:
Click the Surfaces
icon in the Steps toolbox. In the
Surface Wizard, select From curves and Surface of
Revolution.
In the Advanced toolbar, click the Surface Wizard
button. In the Surface Wizard, select From curves and
Surface of Revolution.
If the source curve had extended all the way to the rotation axis, the
housing could be completed in one step. A drawback to this method is
that the central boundary would be degenerate (a point) and may not
provide good machining results.
Sweep
A sweep creates a surface by replicating the shape of the curve at multiple
positions along a path. The path is not necessarily a straight line. A sweep
moves one curve along another and is useful for making many shapes. By
creating complex curves for both the axis and the cross-section, complex
fillets and blends can be directly achieved in a single surface.
Swept surfaces are exact unless the path or axis curve is a spline curve,
not a curve built from lines, and arcs and chained together. Along a spline
curve axis, the shape may deform.
There are two kinds of sweeps: a regular sweep and a translational sweep.
Translational sweeps maintain the same relationship between the curve
and axis normals at all points throughout the sweep. Otherwise, the sweep
curve stays in its drawn position at all points on the axis.
The swept curve needs to be hooked to the axis curve at the start point of
the curve. This figure shows an example of a cross-section curve that is
properly defined. A UCS was created at the start point of the axis curve.
The cross section curve was then defined relative to this UCS. Note that
the setup axes were not changed. The UCS is used as a design coordinate
system only.
Sweep example
The speaker housing uses a swept surface to define the top, back, and
bottom sides in one surface. The source curves are a large diameter circle
segment (1000 inches) and a center line through the three sides (at
maximum diameter of the segment). The Translational sweep switch
was turned off for this surface to keep the bow in the same orientation
relative to the axis throughout the sweep. The slightly bowed bottom is
flattened later as a Modify surface operation.
Ruled
A Ruled surface creates a linear surface between two curves. The curves
can be open or closed, planar or non-planar. For closed curves, the
starting points of the curves should line up or the surface may twist in odd
ways.
You must have at least two curves before you can create a ruled
surface pull-out.
Follow these steps to build a ruled surface:
1. To start, either:
Click the Surfaces
icon in the Steps toolbox. In the
Surface Wizard, select From curves and Ruled Surface.
In the Advanced toolbar, click the Surface Wizard
button. In the Surface Wizard, select From curves and
Ruled Surface.
In the Curves and Surfaces toolbar, click the Ruled
Surface
button in the Surface from curve menu.
2. Enter a Surface name for future reference.
3. Pick the curve on one bounding edge of the surface, curve 1.
4. Continue picking curves either with the Pick button and mouse or
from the drop-down list. If you use the list, use the Add item
from list button to add the curve to the list.
5. Use the Move item up , Move item down , Reverse
buttons to set the
selected curve , and Delete item
sequence and direction of the curves in the ruled surface.
6. Optionally select Reparameterize curves.
7. Click Preview to see how the current settings affect the surface.
Make adjustments as necessary until the surface is how you want it.
8. Click Finish or OK.
More about ruled surfaces (see page 180)
An example of a ruled surface (see page 180)
Surface design hints (see page 168)
Then they are selected as the two curves for the ruled surface which
passes under the other surfaces of the model to the extent of the part so
there is a complete surface for use in the mold.
Twists in surfaces or solids with closed cross sections
When creating ruled surfaces of lofted surfaces or solids with closed cross
sections, you want to make sure that the start points of the curves line up
with the way you would like to create the lines of your shape. The figure
on the left shows a ruled surface created from cross sections with
misaligned start points. After using Curve start/reverse to change the start
point of the square center curve, the twist is removed, as shown on the
right.
Coons
Coons defines a surface between four bounding curves. For planar curves,
Cap surface (see page 189) is probably a better option, although the
curves must be joined into a loop first. For a grid of curves, Coons
surfaces do not produce smooth results since each surface is not
influenced by its neighbors. Joining curves into cross-sections and using
Lofted (see page 186) surfaces will produce better results in that situation.
When using the three curve Coons option, the ordering of the curves
makes a difference in the appearance of the surface. Try different
sequences until the result is correct.
Chained curves behave differently in a Coons surface than spline curves.
If your surface doesn't look quite right in the Preview, select the
Reparameterize curves check box and try the Preview again.
Reparameterize curves analyzes the curves and may adjust the control
points of the curves to yield a better surface result. Reparameterize affects
both chained and spline curves, but the effect is stronger on chained
curves.
Coons surfaces are not as common in practice as they are in mathematical
discussion. Coons surfaces are approximate (see page 168).
Coons example
You might use a Coons surface to create a trough shape that necks down
as shown below. This is easy to draw as two bounding curves on the stock
surface, and two arcing end curves. You don't have as much control over
the behavior of the surface between curves as if you had used a lofted
surface to create a similar shape.
Mesh
Surface from curve mesh creates a surface from a grid of curves.
Overview (see page 184)
How to create a surface from a curve mesh (see page 185)
Restrictions of surface from curve mesh (see page 186)
See also Coons (see page 182).
the curve mesh constructor will create the surface shown here:
The mesh of curves may only partially intersect. This allows the surface
to be built up incrementally. The figure below shows an example of such
a surface.
The surface is made up of Coons patches. If the input curves are smooth,
the surface will be smooth (equal tangent plane planes along the curves).
The input curves must intersect at crossing points, but explicit curve
points are not necessary at the crossings. The curves are reversed
automatically. Triangular patches are supported when a pair of row or
column curves meet at their ends.
How to create a surface from a curve mesh
The curves of your mesh must already exist in position in the
drawing before you can create a surface.
1. To start, either:
Click the Surfaces
icon in the Steps toolbox. In the
Surface Wizard, select From curves and Curve Mesh.
In the Advanced toolbar, click the Surface Wizard
button. In the Surface Wizard, select From curves and
Curve Mesh.
In the Curves and Surfaces toolbar, click the Curve Mesh
button in the Surface from curve menu.
2. Enter a Surface name for future reference.
3. Pick the Row curves with the mouse and Pick button, or choose
them in the list and click Plus.
4. If you pick them out of sequence, change the sequence with the Up
and Down arrow buttons.
5. Pick the Column curves with the mouse and Pick button, or
choose them in the list and click Plus.
6. If you pick them out of sequence, change the sequence with the Up
and Down arrow buttons.
7. Enter an acceptable Tolerance. This tolerance is used in
approximating some of the curves.
8. Click Preview to view the surface.
9. Select Zero twists if you want the surface to be flatter.
10.Click Preview to see how the current settings affect the surface.
11.Click Finish or OK to create the surface.
Loft
Lofting has its heritage from shipbuilders as they laid out ship hulls. They
passed imaginary lines between multiple sequential cross-sections. A
lofted surface creates a smooth surface from cross-sectional curve data.
The curves can be non-planar as well.
The curves for the lofted surface must already exist in position in
the drawing before you can create a lofted surface.
Follow these steps to create a lofted surface:
1. To start, either:
Click the Surfaces
icon in the Steps toolbox. In the
Surface Wizard, select From curves and Lofted Surface.
In the Advanced toolbar, click the Surface Wizard
button. In the Surface Wizard, select From curves and
Lofted Surface.
In the Curves and Surfaces toolbar, click the Lofted
Surface
button in the Surface from curve menu.
2. Enter a Surface name for future reference.
3. Pick the curves with the mouse and Pick button, or choose them in
the list and click the Plus button.
4. If you pick them out of sequence, change the sequence with the Up
and Down arrow buttons.
5. Specify an acceptable Tolerance. Tolerance means that the
resulting surface may deviate from the exact offset by no more than
value you enter.
6. Click Preview to view the surface.
7. Select Interpolated or Spline. Use Preview to see the
difference.
8. Optionally select Uneven spacing. Use Preview to see the
difference.
Cap
A cap surface takes a closed planar curve and makes a trimmed surface.
It's a shortcut to build a flat surface trimmed with a custom-fit edge and
for solid models. It is useful for making a planar trimmed surface to fill
the area inside a curve.
Supporting multiple curves in the cap surface allows you to nest your
curves inside other curves. Depending on the direction of the curve, you
can then include cutouts and surfaces within cutouts all in one operation.
In the example below, the gray portion of the bullseye pattern contains
surfaces, while the reversed clear rings have no surfaces of surfaces. Use
Preview with this feature to get the curves directions right before you
close the dialog.
A cap surface may be either exact (see page 168) or approximate (see
page 168) depending on your settings.
Cap surface creates a surface to cover an 'open end' of another surface or
surfaces. The surface(s) to be capped should form a closed surface by
itself, or when considered as a group. While you can cap open surfaces, a
straight line is drawn between the open points of the surface, and can
generate inappropriate surfaces in cases where the endpoints cause the
closing line to cross the surface boundary.
Cap example
The blow-dryer has a cap surface on the handle, but the handle is an open
curve. So you have to close the curve and create a new curve from the
handle curve and the geometry you used to close the curve. Snapping a
line between the endpoints creates the needed geometry. Chain it all into
a curve and build the Cap surface.
Surface primitives
Sphere
Sphere constructs a spherical surface around a center point and of the
specified radius, or by using an existing circle as the 'equator' of the
sphere you want to construct. Spheres are exact surfaces, but contain
seams and degenerate curves at their poles.
Follow these steps to make a sphere surface:
1. Depending on the construction method you use, you may need a
circle of the correct diameter at the right location in the drawing to
create a sphere.
2. Use the Surface wizard or select Sphere from the Surface
toolbar pull-out.
3. Name the surface for future reference.
4. Pick one of the following construction methods:
5. Center and Radius method:
a. Enter the coordinates for the center point, or click Pick to pick
the point with the mouse.
b. Enter the Radius of the circle.
6. Circle method:
Select the circle (optional) from the drop-down list that represents
the circle's maximum diameter. Or click Pick and pick the circle
with the mouse.
7. Click Finish or OK to create the surface.
More about spheres (see page 193)
An example of a sphere surface (see page 193)
Surface design hints (see page 168)
More about spheres
Sphere constructs a spherical surface around a center point and of the
specified radius.
Spheres are exact surfaces, but contain seams and degenerate points at
their poles.
Sphere example
The blow-dryer could be redesigned to use a spherical motor housing. So
if the design called for 2.25 inch diameter sphere instead, you could
create such a surface by drawing the 2.25 inch diameter circle at depth in
the block. Now use that circle to construct a sphere, which you could trim
with the ruled parting surface.
Cylinder
Cylinder creates a tube specified as a radius around a center line of the
appropriate length. You can specify the length of the cylinder either by
begin and end points or by specifying a center point, a direction, length
and radius. It has no caps on the ends so you may need to use a Cap
surface to complete your design. Cylinders are exact surfaces and contain
a seam where two edge boundaries meet. Be careful not to trim across the
seam. Editing along the seam is fine.
Follow these steps to build a cylinder:
1. A cylinder requires no curves or geometry for input.
2. Use the Surface wizard or select Cylinder from the Surface
toolbar pull-out.
3. Name the surface for future reference.
4. Pick one of the following construction methods:
5. Two points
a. Enter the coordinates for the Center point, or click Pick and
pick the point with the mouse.
b. Enter the coordinates for the end point, or click Pick and pick
the point with the mouse.
c. Enter the Radius of the cylinder.
6. Direction, length
a. Enter the Length of the cylinder.
b. Enter the Center point coordinates of the cylinder.
c. Enter the Direction coordinates.
d. Enter the Radius of the cylinder.
7. Click Finish or OK to create the surface.
More about cylinders (see page 195)
An example of a cylinder surface (see page 196)
Surface design hints (see page 168)
More about cylinders
Cylinders are exact surfaces but contain a seam where two edge
boundaries meet. Be careful not to trim across the seam. Editing along the
seam is fine.
Cylinder example
The vent tube of the blow-dryer can be modeled as a cylinder. Pick end
and center points with the mouse and Pick buttons, or enter explicit
coordinates. Remember to set the points 2 inches in Z in the stock to
create the cylinder at the right depth. Now set the radius to 1 inch. The
cylinder can be trimmed to the rest of the model with the ruled surface.
Flat surface
Flat creates a rectangle between two diagonally opposed corner points.
Follow these steps to create a flat surface:
1. Flat surfaces require no pre-existing curves or geometry.
2. Use the Surface wizard or select Flat surface from the
Surface toolbar pull-out.
3. Name the surface for future reference.
4. Enter the coordinates for a corner point, or click the Pick point
button and pick the point with the mouse.
5. Enter the coordinates for the diagonally opposite corner point, or
click the Pick point
button and pick the point with the mouse.
6. Enter an (optional) Elevation offset for the surface. You can also
pick the Z coordinate of any point using the Pick point
button.
7. Click Finish or OK to create the surface.
More about flat surfaces (see page 197)
An example of a flat surface (see page 197)
Surface design hints (see page 168)
Reverse surface
Surface reverse is an exact operation. Follow these steps to reverse a
surface:
1. You must have an existing surface to use Surface reverse.
2. Use the Surface wizard or select Surface reverse from the
Surface toolbar pull-out.
3. Set whether to create new surface or modify an existing surface.
4. Name the surface for future reference if it's a new surface.
5. Click Pick and select the source surface, or select the surface from
the drop-down list box.
6. Select whether you want to:
reverse normals
transpose row/column
reverse trim loops
7. Click Finish or OK to create the new surface or edit the existing
surface, whichever matches your settings.
Sheets (see page 230) can also be reversed using the Surface reverse
operator. They cannot be selected with the mouse, but instead should be
picked from the drop-down list box in step 5 above.
More about surface reverse (see page 200)
Surface editing hints (see page 169)
More about surface reverse
Because of the rectangular definition of surfaces, you have three options
in the surface reverse process.
You can keep the same surface, but reverse the direction of the
calculated normals, thereby turning the surface inside out. This is
perhaps the most common function as it affects isoline milling (see
page 358).
You can reverse the layout of the surface by swapping all the row
and column layout with each other.
You can also reverse the trim loops of the surface. This process
takes a trimmed surface and changes the trim operation so that
what was trimmed away before is now the retained surface and the
discarded surface is the surface you selected for the surface reverse
operation.
Surface offset
This function offsets the surface along its surface normals. You may need
to reverse the surface normals to get the offset you desire. Surface offset
is an approximate (see page 168) operation.
You must have an existing surface to use Surface normal offset.
1. Open the Surface wizard and set it to perform a Surface
normal offset or select Surface normal offset from the
Surface toolbar.
2. Set whether you want to modify the existing surface or create a
new surface from the process.
3. If you are creating a new surface, name the surface for future
reference.
4. Click Pick and select the source surface, or select the surface from
the drop-down list box.
5. Set the Distance you want to offset the surface.
Extend
Extend adds a linear extension to the selected surface similar to extruding
the boundary curve of the surface however far you set. The direction of
the extend is the tangent direction at the boundary. Remember that the
surface is defined with rows and columns as you select which boundary
to extend.
Follow these steps to extend a surface:
1. Extend requires an existing surface to work with.
2. Use the Surface wizard or select Extend surface from the
Surface toolbar pull-out.
3. Set whether you want to modify the existing surface or create a
new surface from the process.
4. If you are creating a new surface, name the surface for future
reference.
5. Click Pick and select the source surface, or select the surface from
the drop-down list box.
6. Select the edge to extend either with the radio buttons, or click
Pick and select the edge with the mouse.
7. Set the distance for how far to linearly extend the surface.
8. Click Finish or OK to create the new surface.
More about extending surfaces (see page 202)
An example of an extended surface (see page 202)
More about extending surfaces
Surface extends create extra surface to fill gaps or to be trimmed away
cleanly by a nearby surface. For example, open fillets often have to be
extended slightly before they will cleanly trim the surfaces they fillet (and
so they can be cleanly trimmed by another surface).
Extend is an exact operation.
Extend example
Consider the fillet in the soap dish model. If the top surface were
undersized for some reason, or the fillet radius didn't reach to the top
surface, an extend operation could resolve the problem. In this case,
select the Extend surface option from the Surface toolbar.
Unless you are sure of your process, it's safer to create a new surface
instead of modify an existing surface. Select the Create new surface
radio button and name it. Working through column and row options and
previewing the results, the intended surface is achieved using First
Column and an extension of 0.1 inch.
Trim surface
Trimming cuts away a portion of a surface. The portion that is removed is
determined by a trimming curve that lies on the surface. Trimming is
useful for creating solid models or for simply removing an unwanted
portion of a surface.
Overview (see page 204)
How to trim a surface with a curve (see page 205)
Trimming restrictions (see page 206)
Surface editing hints (see page 169)
Comparison with Surface/surface trimming (see page 219)
See also Surface/surface intersection, Surface/surface trimming (see page
216), and Fillets (see page 210).
This orange surface is the top portion of a soap bottle mold. It must be
trimmed by the red curve to reflect the correct shape.
This blue surface shows the result of trimming the orange surface with
the red curve.
See trimming restrictions (see page 206) for the rules for trimming
surfaces.
Trimming a surface with a curve
1. To trim a surface, you must have a surface and a curve that bounds
the area to be trimmed in the part model. The curve must cut across
the surface boundary at two points for an open trim, or be
contained completely within the surface.
2. Use the Surface wizard and set the first radio button to From
one surface and the second button to Trim. Or use the From
one surface pull-out and select Trim.
3. Set whether to Create a new surface or Modify the existing
surface.
4. Name the new surface for future reference.
5. Click Pick and select the source surface, or select the surface from
the drop-down list box. The location that you select will determine
the portion of the surface that is kept.
6. Click Pick and select the trimming curve, or select the curve from
the drop-down list box.
7. Use Preview to verify the surface. If it's not right, reset some of
the options and verify it again with Preview. You may need to
toggle the Side kept switch to trim the desired part of the surface.
8. Click Finish or OK to create the new surface.
Trimming restrictions
Trimming curves have two main restrictions:
1. The curve must lie on the surface. Convenient ways of getting a
curve on a surface are:
If the surface is a flat surface, model the curve in the plane of
the curve.
Project a curve onto the surface.
Intersect two surfaces to get a curve.
2. The curve must divide the surface in two distinct regions. If not,
you will get the error Cant trim, curve does not end on a
boundary. Think of the surface as a piece of paper and the
trimming curve as a path for a pair of scissors. After the cutting
operation, you should be left with two pieces of paper. The
trimming curve must do one of the following:
Form a loop in the interior of the surface
Cut across two surface boundaries
Cut across the same boundary twice
Trimming examples (on page 207)
Additional trimming restrictions (see page 206)
Additional trimming restrictions
Do not include portions of the boundary when constructing curves
for trimming. Trimming curves may cross or end on boundaries.
Avoid cutting through the degenerate boundary a surface such as
the pole of a sphere or surface of revolution.
Avoid cutting along a seam of a surface (across is fine). A seam
exists, for example, at the left/right boundary of a cylinder. You
can detect seams with the Curve Extraction dialog, and then
canceling out after you know where the seam is. Avoid cutting a
seam rotating the object because many objects with seams are
symmetrical.
Trimming examples
Untrim surface
Untrim removes one or all trimming loops from a trimmed surface and
consequently adds area back to a surface.
Overview (see page 207)
How to untrim a surface (see page 208)
See also Overview of trimmed surface (see page 204) and Surface editing
hints (see page 169).
Overview of untrimming surfaces
A trimmed surface is a surface with an embedded curve that removes a
portion of the surface. See Overview of trimmed surfaces (see page 204)
for more information.
When you untrim a surface you are removing the trimming curve from
the surface and therefore adding the material back to the surface. The
trimmed surface in the first image becomes the surface in the second
image after you remove its circular trimming loop.
If you import a part model, it is often useful to untrim portions of the part
that you would like to machine with 2.5D features. For example, in this
simple part, surfaces are used to represent the geometry of the hole.
Removing the entire outer trimming loop is undesirable since the notches
at the top of the surfaces would also be removed. Instead, only the semicircular edges from both surfaces need to be removed as shown here:
Split surface
Split breaks an existing surface into two new surfaces along a row or
column division.
Follow these steps to split a surface:
1. You must have a surface in the model to use Split.
2. Use the Surface wizard or select Split surface from the
Surface toolbar pull-out.
3. Name the first surface for future reference.
4. Name the second surface for future reference.
5. Click Pick and select the source surface, or select the surface from
the drop-down list box.
6. Select whether to split the surface along the rows or columns.
7. Click Pick or enter the XYZ coordinates of the point to split the
surface along.
8. Use the Preview feature to verify the surfaces. Change some
settings, such as the row/column option, or pick the split point
more carefully.
9. Click Finish or OK to create the new surfaces.
This figure shows the same fillet with the surfaces automatically trimmed
against the two fillet boundaries.
Just like the case of an arc between two lines, there is more than one
possible fillet between two surfaces. This figure shows the same two flat
surfaces with a fillet on another corner.
12.Define the Arc step of the fillet. If you select Variable, the
spacing of the fillet cross sections will be calculated automatically
based on the Tolerance. More cross sections will be placed in
curved regions of the fillet as in this figure:
13.If you deselect the Variable button, you must set an Arc Step.
The spacing will then be constant between cross sections as in this
figure:
14.Set the Begin radius. Having two settings for radius lets you
create a fillet that grows or shrinks along the path of the fillet as
needed. For a closed fillet, the Begin and End radius need to be
the same.
15.Set the End radius of the fillet as applicable.
16.Click Finish or OK to create the filleted surface.
Surface editing hints (see page 169)
Fillet restrictions
The fillet constructor works with two surfaces only.
The surfaces must intersect.
If trimming, the top and bottom boundary curves of the fillet must
form a valid trimmed surface in the respective surfaces. See
Trimming restrictions (see page 206) for the rules of valid
trimming curves.
Merging surfaces
Merge combines surfaces together into a new surface. Follow these steps
to merge surfaces:
1. You must have at least two surfaces in the model to use Merge.
2. Use the Surface wizard or select Merge surface from the
Surface toolbar pull-out.
3. Name the surface for future reference
4. Click Pick and select surface 1, or select the surface from the
drop-down list box.
5. Click Pick and select surface 2, or select the surface from the
drop-down list box.
6. Select the row/column option on surface 1 you want to merge into
surface 2.
7. Select the row/column option on surface 2 you want to merge into
surface 1.
8. Set whether the Merge should blend the two surfaces, which loses
some of the original surfaces that are merged. Setting exact
maintains all of the original surface in the final merge.
9. Use Preview to see what the merged surface will look like. If you
don't have the results you want, you may need to change the edges
you want to merge. The Flip surface check box for surface 2
might also help create the right surface.
10.Click Finish or OK to create the new surface.
More about merging surfaces (see page 216)
Surface editing hints (see page 169)
Surface/surface trimming
Surface/surface trimming calculates the intersection of one surface
against one or more surfaces and trims the surfaces with this curve.
Overview (see page 216)
How to trim surfaces against each other (see page 218)
Restrictions (see page 219)
Comparison with Trim a surface with a curve (see page 219)
See also Trim a surface with a curve (see page 203) and Surface surface
intersection.
Overview of surface/surface trimming
Surface/surface trimming has two types of surfaces, trimming surfaces
and trimmed surfaces. The trimming surface is the surface that does the
cutting. Think of it as a pair of scissors or a knife. The trimmed surfaces
are the surfaces that are cut. Think of them as the paper. You can have
only one trimming surface, but you may have more than one trimmed
surfaces.
the blue curve in this figure is the intersection curve between the two
surfaces.
These surfaces are the result of using the vertical surface as the trimming
surface to cut the horizontal surface. If you select the Trim this surface
also check box, the trimming surface will also be trimmed using the
intersection curve as in this figure:
See Trimming restrictions (see page 206) for all the restrictions for
trimmed surfaces.
If you have multiple trimmed surfaces, the intersection curve must
form a valid trimmed surface for each of the trimmed surfaces.
If you have selected the Trim this surface also check box, then
the intersection curve must form a valid trimmed surface with
respect to the trimming surface.
Comparision of Surface/surface trimming and Trim a surface
with a curve
Surface/surface trimming is more accurate and is the preferred
method of trimming surfaces against each other.
Surface/surface trimming should be used if the intersection curve of
the two surfaces is a valid trimming curve for the surface to be trimmed.
Instead:
1. Calculate the intersection curve of the blue surface vs the
orange surface.
2. Calculate the intersection curve of the red surface vs the red
surface.
3. Join the two curves.
4. Trim the orange surface with the joined curve.
Modify surface
Modify works with the surface by manipulating links and surface curves.
Follow these steps to use Modify surface:
1. You must have a surface in the part model to use Modify surface.
2. Click Pick and select the surface, or select the surface from the
drop-down list box.
3. Set whether to show the isolines or not with the Show surface
option.
4. Select the type of operation you want to perform on the surface.
Choices are:
Change point (see page 222)
Change link to line (see page 222)
Change link to arc (see page 223)
Add surface curve (see page 223)
Delete surface curve (see page 223)
5. Click Finish or OK to complete the surface edit.
More about modifying surfaces (see page 224)
An example of a modified surface (see page 224)
Surface editing hints (see page 169)
Change point
Change point lets you change any intersection point on the surface to any
other point. Use the Pick button and the mouse to select the point. Then
enter the point's new coordinates. The surface is redefined to maintain the
overall smoothness of the surface so the shape is still tangent continuous.
This edit breaks the link between the surface and the method originally
used to construct it. You can't open the surface's Properties dialog now
and modify it based on the parameters that originally defined it as those
parameters no longer apply directly to this surface.
Change link to line
Change link to line takes any selected segment and changes it to a straight
line between the two points that bound the segment. The surface is
recalculated to properly incorporate this change in its definition.
This edit breaks the link between the surface and the method originally
used to construct it. You can't open the surface's Properties dialog now
and modify it based on the parameters that originally defined it as those
parameters no longer apply directly to this surface.
Change link to arc
Change link to arc changes a selected segment to an arc that follows the
original segment path. This does not obviously change the shape of the
surface but you can use it to control surface behavior between defining
curves, for example.
This edit breaks the link between the surface and the method originally
used to construct it. You can't open the surface's Properties dialog now
and modify it based on the parameters that originally defined it as those
parameters no longer apply directly to this surface.
Add surface curve
Add surface curve adds another surface curve to the surface you
selected with the mouse or defined by coordinates. This is often a
preliminary step for a subsequent modify operation based on the new
surface curve if there wasn't a surface curve or link where you needed
one.
This edit breaks the link between the surface and the method originally
used to construct it. You can't open the surface's Properties dialog now
and modify it based on the parameters that originally defined it as those
parameters no longer apply directly to this surface.
Delete surface curve
Delete surface curve removes a surface curve from the surface. This
can drastically affect the shape of the surface. You cannot delete any
boundary.
This edit breaks the link between the surface and the method originally
used to construct it. You can't open the surface's Properties dialog now
and modify it based on the parameters that originally defined it as those
parameters no longer apply directly to this surface.
Corner blend
Blend surfaces are surfaces that create smooth transitions between two,
three or four surfaces.
Overview of blend surfaces (see page 226)
How to create blend surfaces (see page 227)
Restrictions on blend surfaces (see page 228)
See also Fillet (see page 210), Surface/surface trimming (see page 216),
Curve from surface intersection, Curve from surface isoline, and Curve
projected onto a surface.
Three-surface blends
This figure shows a three-surface blend example. This blend is used to
create what is known as a 'suitcase fillet'. This means that you want to
create the intersection of three fillets like the corner of a suitcase. If you
create the fillets with FeatureMILL3D, the curves can usually be
automatically detected.
Four-surface blends
This figure shows a four-surface blend example. It is another suitcase
fillet. In this case one surface is not a fillet.
The curve for this surface must be specified. Four-surface blends can also
be used to join four distinct surfaces as in this figure.
3D solid modeling
(Solid Modeling)
A sheet is a group of surfaces that are created using the solid modeling
tools, but that do not create a solid. Sheets have restrictions on how they
can be used since they do not enclose a 3D volume. FeatureCAM
automatically names them with a "sheet" prefix like "sheet902". When
you create a sheet, a dialog is displayed indicating that a non-solid
result was created from the design operation.
Note that the list of design features is only available for solids that are
created in FeatureCAM. If you import a solid, only the resulting solid
model is imported. You can access the faces of the solid, but you have no
history of how the model was constructed.
See also Unattached design features (see page 233).
icon in the
2. Select the solid that you want to verify from the list.
3. Select the Color bad faces option.
4. Click Verify.
Any self-intersecting faces are shown in the color that is set for
Verify : self intersecting in the Default Colors dialog.
Any other bad faces are shown in the color that is set for Verify
solid bad face in the Default Colors dialog.
Transforming a solid
1. Select the solid (see page 234).
2. Click the Transform
For cut extrude solids, you must ensure that the cut will divide the solid
into two distinct pieces like in this figure.
When working with open curves, an additional check box called Flip
Side to Cut is displayed. After previewing your result, you can select
this check box if you want to keep the solid on the other side of the
extrude.
Continue with curve as-is - no change is made to the curve and a sheet is
created.
7. If you displayed this dialog from the Solid toolbar, you can click
Apply to preview the feature as a solid. If the cut is on the wrong
side of the curve, click Flip Side to Cut and click Apply again to
verify.
8. Click OK or Finish.
Overview of stitching
Stitching converts well-trimmed surface models with shared edges and
shared boundaries into solid models. Once the surfaces have been stitched
together into a solid, you can perform any solid modeling operation on
the solid. The surfaces must not overlap or have gaps between
them. The surfaces on the left will not stitch because they overlap. The
right-hand figure will stitch because the overlap has been trimmed away.
Troubleshooting stitching
1. Make sure that no duplicate surfaces are displayed.
2. Make sure that the surfaces do not overlap. In this case, you must
trim the surfaces before stitching.
3. If you have more than one base solid created, select the name of the
solid.
4. Click OK or Finish.
Remember that all features are subtracted from the solid, even bosses.
To create a blended fillet, fillet the adjacent edges in a single fillet. The
blend will automatically be calculated based on the radii or the fillets.
To create a mitered fillet, fillet the adjacent edges in different fillets. The
fillets are intersected and trimmed against each other.
This solid is then cut with a flat surface resulting in half of the solid being
cut away.
You can also cut a solid with a collection of surfaces that have common
edges. The surfaces are stitched together and the solid is then cut with the
resulting surfaces.
5. If you wish to create a solid for both sides, check the Keep both
sides check-box.
6. Click the Preview to preview the cut. The result will be shown in
thick blue lines. If you want to cut on the other side of the
surface(s), click the surface name and click the Reverse
selected surface
button.
7. Click Finish or OK.
Combine solids allows you to combine solids in three different ways. See
Solid operations (see page 252) for more information.
Solid operations
A Difference B is A minus the portion of B that is inside of A.
A Union B is A plus the portion of B that is outside of A.
A Intersection B is the volume that is common to both A and B.
Initial solids
Cube Union
Cylinder
Cube
Intersection
cylinder
Or
Cylinder Union
Cube
Or
Cylinder
Intersection
Cube
If you are using a hidden line view or shaded view, results of the shell
design feature will not be visible, but if you cut the solid, you can see the
void.
You can optionally select faces of the solid not to offset. The faces that
are offset create openings into the void.
Silhouette curves
Silhouette curves represent the widest part of a solid and serve as useful
parting curves for molds. These curves can also be used to split the faces
of a solid.
The left-hand figure shows a solid model. Initially, the side of the part is a
single surface. As a first step in creating two mold halves, we would like
to split the side face at its widest part. The right-hand figure shows the
silhouette curve for the solid.
In the silhouette curves dialog, you can also use the calculated silhouette
curves to split the faces of the solid. The figures below show that the side
face is now split into two separate pieces along the silhouette curve.
See Select core/cavity for more information on splitting solids into two
halves.
This curve can then be used to create parting surfaces (see page 263).
5. If you want to join the resulting curves that touch into a single
piece, click Join Resulting Curves.
6. Silhouette curves can often be made up of many small pieces. To
reduce the number of these pieces, check Smooth/Reduce. The
number after the Smooth/Reduce label is the tolerance for data
smoothing. The smaller the number, the tighter the curve will
approximate the original silhouette. This option can smooth out
sharp corners in your curve, so use it with caution.
7. If you want to split the faces of the solid at silhouette curves, check
the Split Faces at Silhouettes check-box.
8. The Tolerance affects how tightly the silhouette curve
approximates the actual silhouette. Reduce this number if the
silhouette misses regions of your part.
9. Click OK or Finish.
Select core/cavity
Select core/cavity uses surface orientation to extract surfaces for the core
or cavity portion of a mold.
Overview of select core/cavity (see page 258)
Selecting core or cavity faces from a solid (see page 259)
Creating a solid form core or cavity faces of a solid (see page 260)
Top
All surfaces (or portions of surfaces if the Automatic Split option is
enabled) that are visible from the top.
Bottom
All surfaces (or portions of surfaces if the Automatic Split option is
enabled) that are visible from the top.
Other
All surfaces that do not fall into either the top or bottom category. These
surfaces are usually referred to as the core.
4. If you want the faces that are on the top, click the Top radio
button.
5. If you want the faces that are on the bottom, click the Bottom
radio button.
6. If you want the core surfaces, the surfaces that are neither on the
top nor on the bottom, click the Other button.
7. If you want to include the vertical surfaces, click the Include
vertical surfaces radio button.
8. If there are surfaces you would like to explicitly exclude, click the
Pick surface
button and select the surfaces or select the name
of the surface in the drop-down list and click the Add
button.
9. If you would like to split the surfaces at the silhouette curve, check
Auto split and leave the Parting surface field set to
**Automatic.
10.If you would like to split the surfaces at a parting line check Auto
split and set the Parting surface field to the name of the parting
surface.
11.Click OK or Finish.
12.The appropriate surfaces are now selected so that you can easily
create 3D surface milling features.
Split face
The split face operator takes a curve or list of curves, projects them onto
the selected face and splits the face into multiple faces using the projected
curves as the boundaries.
To create a solid lofted design feature:
1. Select Split face from the Solid wizard or the Solid toolbar.
2. Select a face name in the Face drop down list or click the Pick
surface
button and select the face in the graphics window.
3. Select the curve name in the Curve drop down list and click the
button, or click the Pick Curve
button and select the
Add
curves in the graphics window.
4. Repeat step 3 if you want to use more than one curve to split the
face.
5. Click the Preview button to confirm that the surface is correct.
6. Click OK or Finish.
Deleting faces
If you have a solid that you designed in FeatureCAM, you can easily
delete a design feature (see page 234). If you delete an extrude feature,
that cut a slot in a part, the slot is removed and the material is filled back
in that region. If you have a solid model that you imported or stitched, it
is difficult to remove a design feature since you do not have the design
features that were used to create the part, so you must use delete faces to
remove the feature and heal the model back together.
The example shown below was an imported surface model that was
stitched into a solid. The left-hand figure is the original solid and the
right-hand figure shows the same model with the faces that represent the
three holes deleted.
Most of the regions that you will want to remove are the equivalent of
2.5D features in your solid. This includes extruded holes, pockets or
bosses. It is important that you select all surfaces that represent the
feature in the solid. For example for a blind hole, the walls and bottom
must be removed. If you only select the walls to be removed, the bottom
would be left floating in space and cannot be healed back into the model.
To delete faces from your solid:
1. Select Delete face from the Solid wizard or the Solid toolbar.
2. If you want to create a new solid with the faces removed, click
Create New Solid and enter the name of the new solid.
3. If you want to modify an existing solid, click Modify Existing
Solid.
4. Select the faces by either:
a. Selecting the surface name and clicking the "+" button.
b. Picking the surfaces in the graphics window and clicking the
"+" button.
c. Clicking the Pick Surface button and picking the surfaces in
the graphics window.
5. If you want the gaps left by the deleted surfaces to be filled in,
check Heal Remaining Faces.
6. Click the Preview button.
7. If you get an error message, it is probably because you left out
some of the surfaces that need to be removed. Add the other
surfaces and try Preview again.
8. Click Finish.
Explode solid
This constructor copies the faces of a solid into surfaces.
To explode a solid:
1. Select Explode from the Solid wizard or the Solid toolbar.
2. Select the name of a solid from the Solid drop-down list or click
the Pick s (see page 234)olid button and select the solid in the
graphics window.
3. If you only want to copy the selected faces, click the Selected
Faces only check-box.
4. Click OK or Finish.
Parting surface
This function, takes a curve and creates a parting surface.
The Parting surface constructor does not part the model. Use Cut solid
with parting surface or Select core/cavity for that functionality. The curve
can be a 2D or 3D curve. The curve can be obtained any many ways
including Silhouette Curves (see page 255) , Surface Edges, Curve
projected onto a surface The Z axis of the UCS indicates the parting
direction of the mold. For 3D curves the curve is divided at any corners.
To create a parting surface:
1. Select Parting surface from the Solid wizard or the Solid
toolbar.
Draft a Face
Many of the solid design features allow you to include a draft angle, but
they require that all faces be drafted the same amount. Draft a face
allows you to set a draft angle on one or more faces individually.
If the surface connected to the bottom edge of the face is selected as the
fixed reference, the bottom of the face stays fixed and the top edge of the
face is moved out.
To draft a face:
1. Select Draft a face from the Solid wizard or the Solid toolbar.
2. Enter the draft angle in degrees.
3. Select the faces to draft by:
a. Selecting the surface name and clicking the Add
button.
3D surface
manufacturing (3D)
3D Milling methods
You have a number of options for milling a 3D feature. The object is to
select a method that is efficient for your feature's shape and that also
gives an acceptable finish.
Roughing
Semi-finishing and finishing strategies
Finishing models with few surfaces
Finishing walls of pocket or boss shapes with a 3D floor
button.
Corner (see page 373) remachining creates a multiple trace corner toolpath with
Across or Along options.
The 3D Surface Milling Properties dialog uses a tree view. The tabs
displayed in the dialog change depending on which level in the tree view
you select.
- Feature
- Operation information
- Operation
The top level of the tree view is the Feature level. The tabs available at
this level are:
Dimensions (see page 276) - specify the part and check surfaces
Location - reposition the feature reletive to the surface
Process (see page 277) - create, delete and reorder the operations of the
feature
Machining Side (see page 279) - control which side of surfaces to
machine
Misc (see page 281) - a variety of feature-level attributes
The next level is the Operation information level. The tabs available at
this level are:
Strategy (see page 283) - rough/finish classification, edge protection
and re-machining
Edges - choose how the tool behaves at the limits of the part surfaces as
seen from the top view.
The Edges tab is not available for Z-level roughing or Swarf
finishing operations.
Stock - choose the clipping curves for the material to be removed
Slopes (see page 304) - slope angle limits for restricting toolpaths
The Slopes tab is not available for Z-level roughing, Plunge
roughing, Isoline finishing, Flowline finishing, Horizontal +
Vertical and Swarf strategies.
Surface Control (see page 307) - exclude feature surfaces for specific
operations
The third level is the Operation level. The tabs available are:
Tools (see page 309) - view selected tool or change to a different one
F/S (see page 309) - view automatically calculated feed or speed or
change feed or speeds
Milling (see page 314) - operation level attributes
Leads (see page 310) - control leads and ramps
- Feature
- Operation Information
- Operation
The top level of the tree view is the Feature level. The tabs available at
this level are:
Dimensions (see page 276) - specify the part and check surfaces
Process (see page 277) - create, delete and reorder the operations of the
feature
Machining Side (see page 279) - control which side of surfaces to
machine
Misc. (see page 281) - a variety of feature-level attributes
The next level is the Operation Info. level. The tabs available at this level
are:
Strategy (see page 283) - rough/finish classification, edge protection and
re-machining
Boundaries - boundary curves (formerly known as stock curves) for all
operations
Slopes (see page 304) - slope angle limits for restricting toolpaths
Surface Control (see page 307) - exclude feature surfaces for specific
operations
The third level is the Operation level. The tabs available are:
Tools (see page 309) - view selected tool or change to a different one
F/S (see page 309) - view automatically calculated feed or speed or
change feed or speeds
Milling (see page 314) - operation level attributes
Leads (see page 310) - control leads and ramps
Part surfaces
Use this dialog to pick surfaces you want to include in your 3D part
feature.
1. Select the surface(s) in the list box or click Pick and select a
surface with the mouse. To pick additional surfaces, click Pick
again before selecting each additional surface.
2. Click OK to return to the 3D Feature Properties dialog.
3. Click OK and Apply to return to the 3D Feature Properties
dialog and apply your surface selection to the feature.
You need to consider the following when specifying part surfaces:
You cannot manufacture undercut surfaces using 3-axis machining,
so it is a good idea to use only surfaces in the feature that can be
cut from the setup.
Some surfaces may be cut from multiple setups to manufacture all
parts of the surface. In such situations, a Stock Curve is helpful
in limiting the machining area to just those spots that need it.
Check surfaces
Use this dialog to select surfaces you want to use to limit machining in a
3D feature. Check surfaces are surfaces that denote area that will not be
milled away. You should select surfaces that are more horizontal than
vertical. The check surface acts as a boundary up to which milling occurs.
With vertical check surfaces the milling will stop there, but may resume
on the other side of the check surface if the surface to be milled extends
beyond the check surface.
1. Select the surface(s) in the list box or click Pick and select a
surface with the mouse. To pick additional surfaces, click Pick
again before selecting each additional surface.
2. Click OK to return to the 3D Feature Properties dialog.
3. Click OK and Apply to return to the 3D Feature Properties
dialog and apply your surface selection to the feature.
Process tab
The Process tab shows the operations that are included for milling.
These feature are selected in the operations list. You can turn off
operations by unchecking them. This allows you to customize operations
and then turn them off to reduce screen clutter when working on
subsequent operations.
The buttons on the right have these functions:
New
operation (see
page 277)
Move
operation up (on
page 279)
Delete (see
"Delete
operation" on
page 279)
Move operation
down (on page
279)
See also 3D Milling methods and surface manufacturing (see page 267).
Cutting strategy for new features
This page allows you to select the cutting strategy you want to use for
your feature. You can only specify one strategy in the New Feature
wizard. The strategy choices are grouped by finishing, roughing and
specialized strategies. The strategy choices are:
Finishing Strategies
Parallel (see page 323) - toolpaths that are parallel to the X or Y
axes.
Z level finish (see page 350) - toolpaths that are parallel to the XY
plane.
Isoline milling (see page 358) - toolpaths that follow the rows or
columns of individual surfaces.
2D spiral (see page 328) - Toolpaths that move in a spiral toward
or away from the center of the part. Stepover is constant from the
top view.
3D spiral (see page 335) - Toolpaths that move in a spiral toward
or away from the center of the part. Stepover is constant in 3D.
Radial milling (see page 339) - toolpaths that move out radially
from the center of the feature.
Flowline milling (see page 361) - toolpaths that follow the rows or
columns of a flowline surface which are then projected onto the
part.
Between 2 curves (see page 364) - toolpaths that are created
between two specified curves.
Roughing Strategies
Z level rough (see page 339) - toolpaths that are parallel to the XY
plane.
Plunge roughing (see page 368) - toolpaths which remove large
amounts of material from a component through a series of vertical
plunging movements.
Parallel (see page 323) - toolpaths that are parallel to the X or Y
axes.
Specialized Strategies
Horizontal + Vertical (see page 367) - machine steep and shallow
regions using different techniques.
Corner Remachining (see page 373) - A remachining technique
used to clean up corners that occur between non-tangential
surfaces.
Pencil milling (see page 365) - a single clean-up pass for corners.
4-Axis (see page 369) Rotary - used in turnmill to machine round
surfaces with an X tool.
Swarf (see page 380) - toolpaths are cut using the side of the tool.
The tool is in constant contact with the surface.
5-Axis Trim (see page 387) - toolpaths that are along the edges of
surfaces. There is the option to cut on the inside or outside edge of
the surface.
For more details on these options, see operations overview (see page
270).
To complete this page:
1. Select the desired strategy.
2. Click the Next button.
3. If you are creating a new feature, the New feature part
surfaces dialog is displayed.
4. If you are adding a new operation to an existing feature, the New
feature strategy (see page 283) dialog is displayed.
Delete operation
Delete operation discards an operation from the feature. You can disable
an operation instead by unchecking the operation. The check box, when
set, includes that operation in the feature.
Move operation up
Move operation up changes the order of operations in the milling feature
by moving the selected operation up one place in the feature.
Move operation down
Move operation down changes the order of operations in the feature by
moving the selected operation down one place in the feature.
1. Select the name of the surface in the list. If you do not know the
button and select
name of the surface, click the Pick surface
the surface in the graphics window. The name of the surface is then
highlighted in the list.
2. Click the Switch Machining Side
button.
For open surfaces with a floor, the normals will be flipped to create a
pocket shape and the insides will be milled. For open surfaces with a top,
they will be treated as a boss shape and the outsides of the surfaces will
be milled.
Misc tab
Each manufacturing attribute on the Misc tab is described in detail
below.
Plunge clearance (see page 281)
Base Priority (see page 281)
Feed override % (see page 282)
Maximum spindle RPM (see page 282)
Min corner radius and deburr radius
Plunge feed override % (see page 282)
Spindle RPM override % (see page 282)
Spline tolerance (see page 282)
Tool % of arc radius (see page 282)
Z rapid plane (see page 283)
See also Surface manufacturing (see page 267)
Plunge clearance
Plunge clearance is the distance above a feature at which the tool starts to
feed. In the case of deep hole drilling, the drill will retract to this distance
between pecks. Compare with Z Rapid Plane (see page 283).
Priority attributes (3D)
If you want to ensure that an individual feature is cut before anything
else, you can set its Priority attribute in the Misc. tab. All features have
a Priority manufacturing attribute. By default, the value is 10. To make
sure that a feature is manufactured first, set its priority to a lower value.
To make a feature last, set its priority to a higher value. For example, if
you set the Priority of a pocket to 8, its roughing pass is the first
operation performed, its finish pass is second, and the rest of the
operations are ordered according to the scheme described above.
While you can specify the exact order of every feature by priority,
you shouldn't do so casually because you lose the automatic
optimization sequences built into FeatureMILL. It's harder to
maintain or change the part too.
Feed override %
Feed override % is a scaling factor for the feed rates generated by the
system. A value less than 100 reduces the calculated feed rates. A value
more than 100 increases the rates.
Max. spindle RPM
Max. spindle RPM is the maximum spindle speed (in RPM) that
FeatureMILL will calculate.
Plunge feed override %
Plunge feed override % gives the scaling value for the feed rate used
during the initial plunge into the material for milling operations.
Spindle RPM override % (3D)
Spindle RPM override % scales the system-generated speed rates for a
particular operation, enter the percentage change as the Spindle RPM
override % attribute. A value of 100 leaves the speed rate unchanged. A
value of less than 100 will reduce the speed rate, and a value of greater
than 100 increases the speed.
Spline tolerance
Spline tolerance approximates the profile with arcs and lines if a
profile is defined as a spline. The smaller the value of the parameter, the
smoother the profile.
Tool % of arc radius
Tool % of arc radius controls the size of the tool that FeatureMILL
automatically selects.
In earlier program versions this attribute was called Default tool
%.
If Tool % of arc radius is set to 100 then a tool equal to the smallest
corner radius is selected for a feature such as a pocket. With Tool % of
arc radius set to 100 the tool dwells in the corners as it changes
direction. This can sometimes nick the part. To avoid this problem, set
Tool % of arc radius to a slightly smaller number, such as 98.
Z rapid plane
Z rapid plane is the minimum safe distance in Z above your part. This
attribute can be set as a default, or it can be set on a feature.
Before performing a rapid move away from a feature, the tool is retracted
to the Z rapid plane setting for that feature. The rapid move to the next
feature will change in Z height, that is, will change Z coordinates, if the
next feature has a different Z rapid plane setting. So that when it arrives at
the next feature it will be at the Z rapid plane for that next feature.
This value is relative to the top of your stock in the current user
coordinate system. Compare with Plunge clearance (see page 281).
Strategy tab
This page allows you to fine tune your cutting strategy.
To complete this page:
1. For Z level, you may click Rough for a roughing pass, or Finish
for a finishing pass.
2. The following options are available for certain types of operations
a. For 2D spiral milling, select Spiral in to spiral from the edge in
toward the center. Select Spiral out to spiral away from the
center. See Horizontal + vertical strategy (see page 367) if using
that specialized technique.
b. For 3D spiral milling, see step 3 below.
c. For parallel milling, select X parallel to cut parallel to the X
axis, Y parallel to cut parallel to the Y axis. Also specify an
Angle (measured in degrees in the counter clock-wise direction)
to rotate the toolpaths off of the principal axis. You may also
choose to add a perpendicular, remachining pass by selecting
Add Perp. Remach. Pass. As an example, this setting will
add a Y parallel pass to a X parallel operation. To use this
option you also must specify the Steep Slope Angle. The
perpendicular pass will only be applied to regions that exceed
this slope limit. See H (see page 367)orizontal + vertical
strategy if using that specialized technique.
If you have a vertical surface and you want to cut to the bottom, check the
Cut to bottom of vertical walls check-box.
Stock tab
This page controls the boundaries of the toolpaths.
Use part surface dimensions - creates toolpaths on the surfaces
regardless of the location of the stock. If you are using a spiral toolpath,
this option automatically calculates the silhouette curve of the feature and
uses this curve as the shape of the spiral. This generally has the best shape
for spiral toolpaths.
5-Axis tab
For a turn/mill document with a B-axis enabled post (.cnc file) or a 5-axis
positioned document, some surface milling operations will have a 5-Axis
tab. The set of operations is restricted to parallel, z-level finish, isoline,
3D spiral, flowline finish, 5-axis trim, and swarf.
This tab lets you set three different things: Tool Axis, Tilt Axis for
Gouge Avoidance, and Tool Axis Limits. The first two sections of
the dialog can be confusing because they both control the tilt of the tool
axis. The first section, Tool Axis, can be thought of as a first level of
tool tilting, controlled in a manual way. And then you can add extra
tilting in order to avoid gouges with the tool holder by using Tilt Axis
for Gouge Avoidance.
You can use these two sections of the dialog box independently, one
without the other, meaning that you can use the second section
without having specified any tilting in the first section.
The Tool Axis will let you define the tool orientation. The default value
is Vertical which is used for standard 3-axis machining. However, it can
also be a continuously changing orientation for so-called 5-axis
simultaneous machining.
Vertical (Z) - The tool remains aligned with the Z-axis of the
active setup. This is the default value and is the value used for
standard 3-axis machining.
Use Lead and Lean - The tool is at a fixed angle relative to the
direction of the toolpath.
Lead Angle - the tool angle in the feed rate direction.
Lean Angle - the tool angle perpendicular to the feed rate
direction.
For more information, see Lead/Lean (see page 291).
Other Toward Point - The tool tip always tries to point towards the
fixed point. The angle of the tool is constantly changing. For
more information see Continuously Changing Orientation (see
page 293).
From Point - The tool tip always tries to point away from the
fixed point. The angle of the tool is constantly changing. For
more information see Continuously Changing Orientation (see
page 293).
Towards Line - The tool tip always tries to point towards the
fixed line. The angle of the tool is constantly changing. For
more information see Continuously Changing Orientation (see
page 293).
From Line - The tool tip always tries to point away from the
fixed line. The angle of the tool is constantly changing. For
more information see Continuously Changing Orientation (see
page 293).
Automatic - The swarf operation will have an automatic option
(instead of the above Other option). The automatic option will tilt
the tool to keep the side of the tool in contact with the surface(s)
being cut.
The Retract to Cylinder (see page 303) check-box - defines the safe
area of the operation to be an infinitely long cylinder.
Tool Axis Limits (see page 298) - enable you to define limits on the
direction of the tool axis whilst cutting a multi-axis toolpath.
Tool Axis Tilt For Gouge Avoidance (see page 295) - Allows you to
tilt the tool in order to avoid gouging the model with the holder in a user
defined way.
Lead/Lean
The tool is at a fixed angle relative to the direction of the toolpath. You
can specify two different angles - Lead and Lean. If you specify a Lead
and a Lean angle the Lead Angle is applied first in the direction of the
move, and then the Lean Angle from this rotated position towards a
vector perpendicular to the move.
Lead Angle - defines a rotation of the tool axis in the direction of travel.
It is measured from the perpendicular to the direction of travel; 0 is
vertical. Typically this is used to avoid cutting at the center of a ball
nosed tool on flattish areas. The diagram below has a lead of 30 degrees.
Lean Angle - defines a rotation of the tool axis at right angles to the
direction of travel; 0 is vertical. The diagram below has a lean of 30
degrees. Typically this is used to avoid collisions (such as a step). Or this
can be used when machining up to a step to allow you to use a smaller
tool.
From Point - The tip of the tool will move significantly whilst the head
of the machine tool remains relatively still. This option orientates the tip
of the tool away from a point.
Towards Line - The head of the machine tool will move significantly
whilst the tip of the tool remains relatively still. This option orientates the
tip of the tool towards a line.
From Line - The tip of the tool will move significantly whilst the head
of the machine tool remains relatively still. This option orientates the tip
of the tool away from a line.
In general, the tool axis, when viewed as an infinite line, will not pass
through the given entity (i.e., will not pass through the point when using
X-parallel, towards point). This is because the tool paths are laid out on
what we call the frame and the tool axes are computed in the frame. For
example, for an X-parallel with a .05" stepover, lines (toolpaths) are
computed on the front (or top) of the stock spaced at .05". The tool axes
are calculated for each of these lines/toolpath points and then the
projection (to the part surfaces) maintains that tool axis vector all the way
to the point of contact that will become the toolpath point. Some options
such as tool axis limits and automatic collision avoidance alter the final
tool axis as well.
Tool Axis Tilt
This area of the dialog automatically tilts the tool axis, in a user defined
way, to avoid collisions between the shank/holder of the tool assembly
and the model.
Tilt Axis for Gouge Avoidance - specifies how the tool will move to
avoid any collisions.
The default of No tilting - means that the holder and shank are not gouge
checked.
Lean - if a collision is detected, the tool axis will move from the
original axis in the Lean direction until the collision is avoided.
Lead - if a collision is detected, the tool axis will move from the
original axis in the Lead direction until the collision is avoided.
To Point - if a collision is detected, the tool axis will move from
the original axis, in the direction of the Point, until the collision is
avoided, to become a Toward Point Tool Axis.
From Point - if a collision is detected, the tool axis will move
from the original axis, in the direction of the Point, until the
collision is avoided, to become a From Point Tool Axis.
To Line - if a collision is detected, the tool axis will move from
the original axis, in the direction of the Line, until the collision is
avoided, to become a Toward Line Tool Axis.
From Line - if a collision is detected, the tool axis will move from
the original axis, in the direction of the Line, until the collision is
avoided, to become a From Line Tool Axis.
Towards the Surface Normal - if a collision is detected, the
tool axis will move from the original axis and move towards the
Surface Normal direction until the collision is avoided.
This simple example uses a X-parallel toolpath over a step to show the
effect of Collision Avoidance. If you create a simple parallel toolpath
over this, you will get collisions of the shank as it climbs or descends the
step:
One way around this is to increase the length of the tool. Another way is
to change the toolpath strategy. The third way is to use Collision
Avoidance. In this case, the initial Tool Axis is Vertical. Select a Tilt
Axis for Gouge Avoidance of Lead.
Create a new parallel toolpath. You can see that the toolpath now tilts on
the steep portions to avoid the tool holder colliding:
However, the toolpath is still 3-axis on the flat portions where the tool
holder doesn't collide:
In summary, the tool tries to respect the original Tool Axis Definition
for as much of the toolpath as possible. Only when this isn't possible does
the tool axis change, in the direction specified in the Tool Tilt Axis
field, until the tool assembly no longer collides.
Linearization
5-Axis machine tools do not guarantee (and frequently don't use) a
straight line move from one point to another in multi-axis. This means
that you cannot necessarily guess where the tool might move to between
two points. The machine tool will move all of its axes at once - it doesn't
just move in X and then rotate the head. It will do both together so that
both movements are carried out at the same time. This is not a big issue
if the points are close together. However, if the points are far apart, the
machine tool (which may be rotating the tool tip between two points) can
cause gouges when the part is cut on the actual machine.
Consider moving between two points. Although the move looks like a
straight line, it won't necessarily be a line on the machine tool.
Head - Head
Both rotary axes move the head.
The machine tool X limits are equivalent to the angle above the XY
plane. The machine tool measures the angular range relative to the Z axis
and FeatureCAM measures it relative to the XY plane. So, the angle
required for the limit is the complementary angle to the one given for the
machine tool. This is described in more detail in Table - Table. The X
limit of 60 translates to Elevation Angle limits of 30 to 90 .
Azimuth Angle - defines the angular limits of the machine tool in the
XY plane. 0 is along the X axis; 90 is along the Y axis. Can range from 0
to 360.
Elevation Angle - defines the angular limits of the machine tool above
the XY plane. 0 is in the XY Plane; 90 is along the Z axis, -90 is along
the -Z axis. Can range from -90 to 90.
That is, the elevation angle limits the angle in the XZ plane. Angle 0 is
the X tool, 90 is the Z tool, so a minimum elevation 0 to max elevation 90
cuts the complete right half of a sphere (flowline) given no
min_azimuth/max_azimuth. (Think of it as latitudes and longitudes that
are reachable. The longitude (circles parallel to XZ plane for millturn) is
controlled by elevation angles).
The latitude (think of a tool axis in the XY plane for millturn) is
controlled by azimuth angles. I.e. -90 to 90 would cut the entire top half
of a sphere if given no elevation limits... (X axis is 0 azimuth angle).
However, the allowable range is 0 to 360, so setting minimum to 270 and
maximum to 90 is acceptable (the limit is set going clockwise around
positive Z axis from minimum to maximum).
The example below shows you how to transpose the angular limits on the
machine tool to the Azimuth and Elevation limits on the Limits tab on
the Tool Axis Direction dialog. These examples all use a sphere with
an Isoline or Flowline Projection toolpath. If no tool axis limits are
imposed, you will see the following toolpath:
Retract to cylinder
On the 5-axis tab, there is a Retract to Cylinder check box. This will
affect the approaches, plunges, and retracts of a 5-axis simultaneous
operation. With Retract to Cylinder selected, the safe area of the
operation will be defined as an infinitely long cylinder. The radius of this
cylinder is calculated as the maximum distance of the stock's bounding
box from the cylinder's axis plus the Z rapid plane distance. For instance,
with a round stock (along the Z), the blue square is calculated as the
bounding box of the stock. An additional Z-rapid (1.0 " in this example)
is added to this radius to define the safe area as the black 'cylinder'. All
retracts and rapids will essentially go to or from this radius. All plunges
will begin a distance of plunge clearance (0.1 " in this example) away
from the stock's bounding cylinder (at the black dot).
Notice that retracting to cylinder is not desirable in this case. (The tool
axis is fairly close to the vertical (Z-axis) tool. In this case, the tool must
begin at a very large Z value in order to start on the 'safe area cylinder'
(the black circle above). Here is the same tool position, but no longer in
the top view. 'Retracting to cylinder' will result in large Z-values in the Gcode (+30 ") in this case.
machined.
If the wrong side is selected, click the Switch Machining Side
button or go to the Machining Side tab to change this. The arrow that is
tangent to the surface indicates the starting corner and direction of the
first isoline toolpath.
The Start Curve column indicates whether you are going to start milling
at the First row, Last row, First Column or Last Column. If you
want to change start curve of the isoline paths, click the Set Isoline
Row Column
button until the arrow in the graphics window is
aligned with the correct row or column of the surface. The Cut
Direction column of the table indicates the direction of the toolpaths.
button to toggle the direction along the row
Click the Cut direction
or column.
Flowline Guide Surface
If you select a flowline guide surface (see page 361), the isolines of
another surface are projected onto all the surfaces of the feature.
See also Surface manufacturing (see page 267).
F/S tab
The F/S tab lets you view and edit feed and speed settings for the
operation selected in the tree view.
Speed
The Speed section is for setting how fast the tool spins. The default units
are RPM (revolutions per minute). Optionally select Use SFM (surface
feet per minute) to change the units. FeatureCAM uses the
Recommended speed value by default. You can optionally enter a
different value and the override option is automatically selected. If want
to revert back to the recommended value, deselect override.
Feed
The Feed section is for setting how fast the tool moves through the
stock. The default units are IPM (inches per minute). Optionally select
Use IPR (inches per revolution) to change the units.
You can set the Use IPR attribute globally on the Misc. tab of
Machining Attributes.
FeatureCAM uses the Recommended feed value by default. You can
optionally enter a different value and the override option is
automatically selected. If want to revert back to the recommended value,
deselect override.
Coolant
The Coolant section is for setting the type of coolant to use for the
selected operation. The default coolant is Flood. You can select a
different coolant from the list and the override option is automatically
selected. To revert back to the default coolant, deselect override.
You can change the default Coolant type on the Misc. tab of
Machining Attributes.
Reset All clears any overrides you made to the feeds and speeds and
returns the settings to the default value for tool attributes listed on that
page.
See also Feeds and speeds (see page 117).
See also Surface manufacturing (see page 267).
The moves between toolpaths are controlled by the Stepover type (see
page 315).
See also Overview of surface manufacturing (see page 268), surface
milling feature dimensions tab (see page 276), 3D Milling methods,
strategy tab (see page 277), Feed and speed tab (see page 309), milling
tab (see page 314)
3D Milling methods
You have a number of options for milling a 3D feature. The object is to
select a method that is efficient for your feature's shape and that also
gives an acceptable finish.
Projection milling methods
Z level rough (see page 339)
Z level finishing (see page 350)
Isoline milling (see page 358)
Pencil milling (see page 365)
Remachining (see page 375)
Recommended Machining Strategies
Roughing
Semi-finishing and finishing strategies
Finishing models with few surfaces
Finishing walls of pocket or boss shapes with a 3D floor
Stepover type
The Stepover type controls the type of transition move that is inserted
between toolpaths. The choices are:
Direct: The tool moves straight over to the next position. The tool
can move in all 3 axes. This figure shows a direct stepover move
on a flat surface feature.
Arc: For Z-roughing only, the tool attempts to connect to the next
position with an arc. (If that is not possible, an arc and several
tangential lines are used). For Z-roughing, only Direct and Arc
apply.
Stair step: The tool moves up in Z and then over in X and Y. This
figure shows a stair step transition move on a spherical surface.
This figure shows the same surface feature using a direct stepover.
Loop: The tool makes an arc move out of one toolpath and an arc
move into the next toolpath. These transitions are actually
programmed from linear moves and may move all three axes. This
figure shows a loop move on a flat surface feature.
3D milling strategies
Types of surface milling operations
Parallel (see page 323) - creates a raster
pattern within a boundary and projects it
onto the model.
Corner (see page 373) remachining creates a multiple trace corner toolpath with
Across or Along options.
Radial milling (see page 339) - toolpaths that move out radially
from the center of the feature.
Flowline milling (see page 361) - toolpaths that follow the rows or
columns of a flowline surface which are then projected onto the
part.
Between 2 curves (see page 364) - toolpaths that are created
between two specified curves.
Roughing Strategies
Z level rough (see page 339) - toolpaths that are parallel to the XY
plane.
Plunge roughing (see page 368) - toolpaths which remove large
amounts of material from a component through a series of vertical
plunging movements.
Parallel (see page 323) - toolpaths that are parallel to the X or Y
axes.
Specialized Strategies
Horizontal + Vertical (see page 367) - machine steep and shallow
regions using different techniques.
Corner Remachining (see page 373) - A remachining technique
used to clean up corners that occur between non-tangential
surfaces.
Pencil milling (see page 365) - a single clean-up pass for corners.
4-Axis (see page 369) Rotary - used in turnmill to machine round
surfaces with an X tool.
Swarf (see page 380) - toolpaths are cut using the side of the tool.
The tool is in constant contact with the surface.
5-Axis Trim (see page 387) - toolpaths that are along the edges of
surfaces. There is the option to cut on the inside or outside edge of
the surface.
For more details on these options, see operations overview (see page
270).
To complete this page:
1. Select the desired strategy.
2. Click the Next button.
3. If you are creating a new feature, the New feature part
surfaces dialog is displayed.
Parallel milling
Overview of projection milling methods
Projection milling techniques are a robust and easily understood method
of generating 3D toolpaths. They work by taking a pattern of curves and
projecting points from these curves onto the surfaces of the part.
Advantages
Robust
Handles overlapping surfaces well.
Good for multiple surface manufacturing.
Allows specifying planar stepover distances or scallop heights for
finishing.
Surface normals are not considered for the manufacturing
computation
Disadvantages
Poor handling of nearly vertical surfaces
Does not handle vertical surfaces since they are invisible from
above.
See Restrictions of projection milling techniques (see page 325) for
more details.
Parallel toolpaths
Parallel toolpaths are parallel to the X axis or Y axis of the current setup.
To slant the toolpaths relative to the axis, set the Parallel angle (see page
324) attribute on the Strategy tab.
This method mills only the area above and down to the surface(s) in the
feature. If part of the stock does not have a feature surface in it, that area
wont be milled away, except perhaps incidentally to the manufacturing
of another surface feature.
For information about 3D Manufacturing attributes, refer to 3D Milling
tab and Manufacturing attributes (see page 314).
Parallel angle
Parallel angle is available only in X and Y parallel roughing and sets
what angle the roughing passes occur in reference to the X or Y axis. This
value can be anywhere from -360 to 360 degrees. A positive value rotates
counter-clockwise from the Z axis, and a negative value rotates clockwise
from the axis. Examples of using Parallel angle are:
1. Setting the angle to 90 on an X-parallel operation causes it to
effectively become a Y-parallel operation.
2. Setting the angle to 180 causes the toolpaths to be cut from the
opposite side of the part. For example, an X-parallel operation with
the angle set to 0 starts at the minimum Y coordinate. With the
angle set to 180, the toolpaths start at the maximum Y coordinate.
One raster pass over the entire model. A second pass, perpendicular to the
first, that only machines the areas of the model that are steeper than the
Angle.
2D Spiral milling
2D Spiral toolpaths
2D Spiral toolpaths mill a feature in a continuous spiral either towards the
feature center or away from the feature center. Spiral is only a general
description of the actual path as not all feature shapes lend themselves to
a truly spiral pattern. The pattern is obtained by taking the stock
boundary, the feature boundary or the curve specified in the Stock tab
(see page 288) and offsetting this curve toward the center of the part. The
steps between the passes is calculated in 2D. For spiral toolpaths that use
a 3D stepover use the 3D spiral technique (see page 335). To use the
stock boundary, click Use stock dimensions on the Stock tab. This
results in a square shape to the toolpaths.
If you want to use a different curve as your toolpath shape, Click Select
curves for boundaries on the Stock tab. The options for using a curve are
different for spiral milling (see page 329) and other techniques (see page
333).
3D pocket
The 3D pocket projects the boundary curve onto the surface and spirals
inside of this closed curve as shown in this figure.
3D side
The 3D side setting projects the boundary curve onto the surface and then
cuts on one side or the other as shown in this figure.
Wall only
The Wall only setting traces along the curve, for example:
Spiral boss feature with curve allowance. Notice the gap between the
bosses and the toolpaths.
Stock overcut % (3D)
Stock curve overcut % applies to three types of surface milling
features, spiral toolpaths designated as a boss on the stock page, features
cut with projection milling technique that do not have an explicit
boundary curve and select Z level rough passes. In the boss case this
attribute applies only to how the toolpaths behave around the stock
boundary. For other 3D surface milling features use the cut allowance
feature described on the stock page (see page 288). The stock overcut
% only applies if Use stock dimensions is selected on the feature's
Stock tab (see page 288).
Stock overcut specifies what percentage of the tool approaches or
passes beyond the stock boundary.
It can have a value between -100 and 100 with the following meanings:
0 puts the centerline of the tool on the stock curve.
For Z level rough, this attribute applies to all features except pocket
features without stock curves. This attribute controls the outer extend of
boss features and the amount that pocket feature cuts beyond its
boundary. The default value is 100% which puts the edge of the tool on
the boundary. A number greater than 100 extends the toolpaths beyond
the boundary. A number less than 100 essentially offsets the outer
boundary and clips the toolpaths against this closer boundary.
Boundaries for technique other than spiral
You are given a choice of:
3D pocket - The toolpaths are restricted to the regions inside of the
curves specified as the boundaries.
Island curves can also be specified for 3D pockets. The toolpaths are
generated outside of the island curves, but inside the boundary curves.
The island curves must be inside of the boundaries and must not touch the
boundaries.
Boundary curves may extend beyond the stock or beyond the surfaces of
the feature. Regardless of the curves that are specified, toolpaths do not
extend beyond the surfaces of a feature.
Curve allowance (see page 332) - The distance to stay away from the
boundary or island curves. This must be a positive number and is an
absolute distance.
How to create a 3D boss from font curves
1. Create the surface or surfaces you want to use as the floor of your
feature.
2. Create your text.
3. Use Extract font curve and extract the outer boundaries of the text.
4. Use Extract font curve again and extract the islands.
5. Create a spiral out 3D boss operation (see page 269) for the floor
surfaces using the outer boundary curves as the boundaries.
6. Set the curve allowance to the tool radius.
7. Create another spiral out 3D pocket operation for the floor surfaces
using the island surfaces as the boundaries.
8. Again, set the curve allowance for this operation to the tool radius.
3D spiral
This finishing technique is best suited to machining areas, which require a
constant stepover and works well on near-vertical faces.
Spiral toolpaths mill a feature in a series of offsets towards the feature
center. The initial pattern is specified by taking the stock boundary, the
feature boundary or the curve (see page 288) specified in the Stock
tab. To use the stock boundary, click Use stock dimensions on the
Stock tab. This results in an initial square shape to the toolpaths. The
next and subsequent toolpaths are obtained by offsetting the initial shape
in 3D (along the surfaces being cut). This differs from 2D spiral
operations (see page 328) which offset the initial shape in 2D and then
project this shape onto the surfaces. Also, there is no spiral-out with a 3D
spiral operation.
Select Use part surface Dimensions in order to use the silhouette of
the part surfaces as the initial boundary shape as shown in the simple
figure on the left. The figure on the right shows the toolpaths that would
result if Use stock dimensions was used instead.
The Spiral option on the milling attributes page eliminates the stepover
between the offsets, and morph the pattern into a continuous spiral. With
the Spiral option checked, you get the result shown below. You can see
that this minimizes the number of tool retracts and converts the original
closed contours into one long spiral.
With the Spiral option deselected you get the following result. Notice
that there is a retract between each contour.
Boundary curves can also be used to control the shape of the spiral. All of
these options are accessed by clicking the Curve options button on the
Stock tab. By specifying a boundary curve, this shape is used as the
initial contour of the spiral.
The boundary curve is clipped against part surfaces as shown in the figure
below. If the curve is entirely outside of the stock, the silhouette of the
surfaces is used as the boundary curve.
The Total Offset option of the Boundary curve dialog (see page
329) is disabled for 3D spiral milling.
Curve Allowance is the same as described for 2D spiral milling
(see page 329).
Radial toolpaths
Radial toolpaths are created from the center of the part toward the
boundary. This figure shows a radial toolpath example.
Z-level roughing
The Z-level roughing method slices the feature at various depths and
mills the corresponding 2.5D contours as a pocket or boss shape at each
depth.
Overview (see page 340)
The images below illustrate the differences in the slicing. The second
picture shows the slices without Flat surface support. The bottom picture
shows the additional slices that are added with the level option invoked.
Looking at a different angle you can see that three complete levels are
machined.
Area- machines flat areas only (rather than the whole level).
Looking at a different angle you can see that only the flat areas are
machined in the first level.
With Reorder selected, paths are created that machine vertical regions as
shown below.
Toolpath corner %
Effective only during Z-level rough, a non-zero Toolpath corner %
replaces sharp corners with rounded corners. Defines the maximum
deviation from the sharp corner. The maximum this can be set to is 40%
of stepover. This means that if you have a 10mm stepover the maximum
deviation from the sharp to the rounded corner is 4mm.
Looking in at a corner in even more detail you can see the trochoidal
paths more easily:
Reorder
The Reorder attribute tells FeatureCAM to re-sequence the toolpaths to
minimize retractions while trying to avoid full width cuts. Use Reorder
when you have a part where several separate regions are cut. If you want
the toolpaths to move directly across a surface without worrying about
retractions, deselect Reorder.
Z-level finishing
The Z-level finishing method slices the feature at various depths and then
mills each slice. This technique works well for steep sloped walls.
Overview (see page 350)
Z-level interleave (see page 351)
Troubleshooting (see page 356)
See also Surface manufacturing (see page 267), Recommended
machining strategies, 3D Milling tab and Manufacturing attributes (see
page 314) and 3D leads/step tab (see page 310).
Roughing
Semi-finishing and finishing strategies
Finishing models with few surfaces
Finishing walls of pocket or boss shapes with a 3D floor
If you check Closed spirals on the Strategy tab and check the Spiral
Milling attribute, continuous spiral toolpaths are generated.
If you deselect Closed spirals on the Strategy tab and select bidirectional as the cut direction (see page 404), zig-zag toolpaths are
created.
If you deselect Closed spirals on the Strategy tab and select Uni- d
(see page 404)irectional as the cut direction, you can create toolpaths
that cut in a single direction.
In addition to the style of cut on the shallow regions, you can also change
the toolpaths with the Remove shallow slices Strategy attribute. The
figure below shows an example of Z finish toolpaths.
With Remove shallow slices checked, the slices in the flatter regions
are removed. This results in the removal of some possibly unnecessary
slices, but shallow regions tend to be larger and the shallow toolpaths
tend to vary more in the Z direction.
Corner correction
Corner correction defines the type of corner correction that you want to
apply to all internal corners of a Z-level finish toolpath. The types are
available from a pull-down list and three options are available:
None - no sharpening or arc fitting is carried out.
Arc Fitted - arcs are created and rounded in all internal corners.
The yellow toolpath shows the Arc Fitted toolpath and the green
toolpath shows the Normal toolpath.
Arc fitting is of particular importance when high speed machining, as it
eliminates sudden changes in tool direction.
Corner Radius %
This defines the radius used if you select a Type of Arc Fitted. The
radius is defined as a proportion of the tool diameter. For a Z finish pass
the default value is 5%. So, if you have a tool of diameter 10mm (radius
5mm) then the arc radius is 0.5mm. The Corner Radius% can have a
value between 0 and 100.
Spiral Z level
The standard Z level finishing toolpaths creates paths with a constant Z
height as shown below. The tool either retracts or feeds along the surface
between Z levels.
With the Spiral milling attribute checked, the toolpaths change into a
continuous spiral. The toolpaths no longer have a constant Z height.
Isoline milling
Isoline manufacturing follows the isolines of the surface being
manufactured. It is a good technique for finishing surfaces.
Overview (see page 359)
Restrictions (see page 360)
Advantages
Uniform finish with scallop height control. The toolpaths are
spaced based on the distance along the surface.
Nearly-vertical walls handled well. Since this is not a projection
technique, nearly vertical walls are cut correctly.
Disadvantages
Toolpaths generated on a surface by surface basis.
Flowline
The Flowline technique projects the isolines from one surface onto the
surfaces of the feature. The isolines are projected in the direction of the
surface normal. In the example below, the isolines of a flat surface are
projected onto the part. By using a side mill cutter, flowline machining
can be used to machine undercut regions.
.
2. The normal of the flowline guide surface must point toward the
surfaces of the part. When you click the surface control tab, two
arrows are displayed on the flowline guide surface. In the figure
below, the normal correctly points toward the part surfaces. If the
normal needs to be reversed, click the Switch machining side
button .
The arrows also indicate the starting point of the surface isolines and their
direction. In the picture above, the toolpaths that is projected starts in the
lower left and follows the rows of the surface. Use the Set isoline
button to change the starting point of the pattern and use the
row/col
Cut direction button to change the direction of the cuts.
Machining under cut regions
Undercut regions can be cut with either a Isoline (see page 358) operation
or a Flowline (see page 361) operation.
Across curves:
Equation
2: Across
Curves
You can limit the pattern by selecting Tool Center to generate the
pattern based on the center of the tool. Select Contact point to generate
the toolpath based on last point of contact between the tool and the
surface.
In the Milling tab, you can set Edge tolerance which is the trimming
tolerance used to reduce the noise of resulting toolpath near the start and
end curves. The Stepover attribute is by default blank and the value is
automatically determined based on the tool radius and tolerance.
However, if you want to override the automatically generated stepover,
you can set "stepover" to a particular value. If the automatically generated
stepover is too large, you can restrict it by specifying a Max stepover.
Pencil milling
Pencil milling is used to clean up corners or fillets of a part.
Overview (see page 365)
How to create a pencil mill operation (see page 366)
Troubleshooting (see page 367)
See also Surface manufacturing (see page 267), Recommended
Machining Strategies, 3D Milling tab and Manufacturing attributes (see
page 314) and 3D leads/step tab (see page 310).
Roughing
Semi-finishing and finishing strategies
Finishing models with few surfaces
Finishing walls of pocket or boss shapes with a 3D floor
The first step is to determine the regions that contain the corners as shown
on the left. Depending on the number of surfaces in the model, this step
may take a little time. After the regions are detected, a single toolpath is
created that cleans out the corners regardless of the number of surfaces
contained in the region.
3. Select Pencil milling and finish as the operation and click OK.
4. Click the Leads/steps tab (see page 310) and set the options for the
moves between toolpaths.
5. Click OK.
6. Generate toolpaths. If you receive an error, see Trouble shooting
pencil milling (see page 367).
Plunge roughing
Overview of plunge roughing (see page 368)
Restrictions of plunge roughing (see page 369)
Overview of plunge roughing
Plunge roughing provides an alternative form of roughing. With this
technique, roughing is performed with a series of overlapping holes. The
advantage of this technique is parts can be roughed quickly since the
force of the operation is directly up the spindle.
This figure shows a sphere that is being plunge roughed with a flat end
tool.
The pattern of the drilling operations are parallel to the X or Y axes just
like parallel milling (see page 323). Neighboring rows of the pattern can
be offset horizontally (see page 285) to better cover the part.
To limit the cutting area along the index axis, set Index Start Coord
and Index End Coord. For a turn/mill document these parameters
control the extend of the toolpaths along the Z axis. For a 4-axis milling
document, they are values along the index axis.
Stepover controls the distance between circular cuts for circle milling or
the distance the tool travels in a full revolution along the index axis for
spiral milling.
A stepover angle is presented for the Line type. This angle controls the
distance between the linear cuts.
Along
This style of remachining creates a corner toolpath which follows the
trace lines.
Across
Across remachining creates corner toolpaths that zig-zag across the trace
lines.
Multi-pencil
Creates a corner toolpath which follows 'along' the trace lines. This is
basically a different ordering of the Along tool path.
The slope boundaries (see page 304) tab is available, so that a
horizontal-only corner operation is possible.
Detection Limit - only corners below the angle specified are found.
The tool used for the corner remachining must be smaller than the
Previous tool diameter.
Overview of remachining
Remachining is used to automatically mill regions that were not cut by
previous operations. Remachining can be performed with or with a
parallel (see page 323), Z finish (see page 350) or 3D spiral toolpath (see
page 335). There is also a separate type of toolpath that is strictly for
remachining called corner remachining (see page 373).
Overview (see page 376)
How to create a remachining operation (see page 378)
Remachining settings (see page 378)
Limitations (see page 379)
Troubleshooting (see page 379)
See also Surface manufacturing (see page 267), Recommended
Machining Strategies, 3D Milling tab and Manufacturing attributes (see
page 314), Pencil milling (see page 365) and 3D leads/step tab (see page
310).
Roughing
Semi-finishing and finishing strategies
Finishing models with few surfaces
Finishing walls of pocket or boss shapes with a 3D floor
Swarf milling
Swarf machining
Swarf cutting calculates toolpaths which cut with the side of the tool and
only works on developable surfaces as the tool needs to be in contact with
the surface for the whole cutting depth.
For a tool to swarf cut, it has to be able to have contact with the surface at
all points along the cutting edge of the tool. For non-developable surface,
FeatureCAM always leaves material on or produce fragmented toolpaths
(rather than gouge). This means that you need to look at parts carefully
before trying to swarf cut them. It may be that rotating the part (cutting
from the side rather than the top of an aerofoil blade) may produce the
desired result. Swarf machining makes every attempt to machine the
selected surfaces but you may have to consider running more commands
including ones with different options for swarf milling to obtain the best
machining results.
It is possible to identify approximately whether a surface is developable
and ruled by shading and also displaying its wire frame geometry within
FeatureCAM. You can then orientate the view to be roughly down the
expected tool axis vector. If the surface top edge and the surface bottom
edge appear to be parallel at all points on both edges and no shaded
elements are visible then the surface is roughly developable and ruled.
Use the Surface Control tab to determine whether you swarf cut on the
inside,
Axial Offset - offsets the lowest position of the toolpath along the
tool axis.
Swarf milling works best with ruled surfaces where the parameterization
of the surfaces is well-behaved.
Troubleshooting Swarf
Swarf is a very powerful technique. Unfortunately, in a five-axis
simultaneous situation, there are, perhaps, many different correct answers
to the swarf problem. FeatureCAM attempts to pick an intelligent answer,
but sometimes picks a different answer than what you had in mind. For
instance, a single plane can be swarfed in the U direction or the V
direction. In the picture below, the feature consists of the two magenta
surfaces and the red surface. The swarf correctly cuts the desired edge of
the magenta surfaces, and then (mathematically, correctly) cuts an
undesired edge of the red surface. There are several things you can try :
Break the feature into many features (at the limit, you might have
one swarf feature per surface). In this case, you may end up with
three features.
In cases like the above, the floor of the swarf must not be
touched. This is very difficult to do especially with a flat-end
tool. The floor may be included as a check surface, but then most
likely, you will not get the complete toolpath. In this situation, you
can get close by using multiple cuts and a fairly small Zincrement. You may also use a slightly negative check allowance.
Increase the Degouge tolerance. The regular tolerance controls
the accuracy of the tessellation. That is, curved surfaces are first
flattened out to triangles, and it's the triangles that are machined.
The Degouge tolerance, on the other hand, tells FeatureCAM
that, in order to get a better, smoother toolpath, it's ok to gouge the
triangles by up to that much.
5-Axis Trim
This technique allows you to profile (or trim) around the outside of a set
of surfaces. This technique only works on surface models (not triangle
models). On the strategy page of the trim operation, you may choose
whether to profile on the Inside Edge of the surface set:
3D machining attributes
3D Milling tab and Manufacturing attributes
When you click the Milling tab for a feature's operation, you see the
attributes available for 3D milling. These attributes control how the
manufacturing takes place. You can override any attribute you wish for
the kind of manufacturing you desire. The check boxes (see page 388)
and attributes (see page 399) are discussed separately.
See also Surface manufacturing (see page 267).
Switch settings
Check boxes
Not all check boxes are available for all operation types.
One raster pass over the entire model. A second pass, perpendicular to the
first, that only machines the areas of the model that are steeper than the
Angle.
Arc/line approx.
Select this check box to create an arc line approximation for toolpaths
that are contained in the XY, YZ and XZ planes. This allows 3D
programs to be smaller and to result in smoother surface finishes for
certain types of parts.
Arc/line approximation applies to the following 3D techniques
X-parallel and Y-parallel roughing or finishing with Parallel
Angle set to 0
Z-level roughing and finishing
Isoline finishing where the toolpaths line in a plane
Scallop height checkbox
This check-box is available on the Milling page of certain finish
operations. For projection milling methods, it toggles the way that you
specify how far the tool moves over between passes. With Scallop
height unchecked, you specify the stepover (see page 418). With it
checked, you specify the scallop height (see page 392).
For Z-level finish operations it toggles how you specify how the tools
moves down in Z. With Scallop height unchecked, you specify the Zincrement (see page 424). With it checked, you specify the scallop height
(see page 392).
With scallop height checked, spacing of the toolpaths are calculated along
the surfaces to provide a uniform surface finish. These figures show
surfaces cut without using scallop height:
This figure shows the same surfaces cut with scallop height:
Scallop height
Absolute scallop height between passes for isoline milling, projection
milling finishing passes and Z-level finishing. This distance is measured
along the surface and represents the maximum cusp height between
neighboring passes as shown here.
This attribute only applies if the scallop height checkbox (see page 391)
is selected.
Flat surface support
With Flat surface support as Off, the Z levels are calculated at a constant
Z increment. With Flat surface support as Level or Area, extra levels are
inserted above each flat surface in the model. This ensures that the finish
allowance is accurately left on all flat surfaces.
There are three options available for flat surface support:
Level - machines whole flat Z levels.
Area - machines flat areas only (rather than the whole level).
Off - flat areas are not considered.
The images below illustrate the differences in the slicing. The second
picture shows the slices without Flat surface support. The bottom picture
shows the additional slices that are added with the level option invoked.
Looking at a different angle you can see that three complete levels are
machined.
Area- machines flat areas only (rather than the whole level).
Looking at a different angle you can see that only the flat areas are
machined in the first level.
Reorder
The Reorder attribute tells FeatureCAM to re-sequence the toolpaths to
minimize retractions while trying to avoid full width cuts. Use Reorder
when you have a part where several separate regions are cut. If you want
the toolpaths to move directly across a surface without worrying about
retractions, deselect Reorder.
For Z-level operations (rough or finish), the Reorder attribute enables
zone machining, where the toolpaths descends in the Z (or -Z) direction if
that is more efficient than cutting the entire part in complete Z levels. The
phone handset example below shows that the toolpaths cut the top of the
part in complete Z levels and then cut one side and the other.
Spiral Z level
The standard Z level finishing toolpaths creates paths with a constant Z
height as shown below. The tool either retracts or feeds along the surface
between Z levels.
With the Spiral milling attribute checked, the toolpaths change into a
continuous spiral. The toolpaths no longer have a constant Z height.
Looking in at a corner in even more detail you can see the trochoidal
paths more easily:
Attributes
3D attributes
Attributes specific to 3D milling are described here. For information on
other attributes shared with 2.5D milling, refer to Manufacturing attribute
descriptions.
Add perp. pass (see page 325)
Angular start and end (see page 415)
Z start
Arc/line approx.
Select this check box to create an arc line approximation for toolpaths
that are contained in the XY, YZ and XZ planes. This allows 3D
programs to be smaller and to result in smoother surface finishes for
certain types of parts.
Arc/line approximation applies to the following 3D techniques
X-parallel and Y-parallel roughing or finishing with Parallel
Angle set to 0
Z-level roughing and finishing
Isoline finishing where the toolpaths line in a plane
Axial offset
For swarf finishing, this attribute offsets the lowest position of the
toolpath along the tool axis. Positive numbers offset the toolpath towards
the tool holder, negative numbers away.
A swarf with a positive offset:
Axial tolerance
This is only relevant to swarf finishing.
For a relatively rare number of geometries, the tool axis can waver
slightly as it positions accurately on the surfaces to be machined. This can
be due to small but significant changes in the geometry as the tool moves
from one position to another. To allow a degree of latitude for the
command, this tolerance can be set to a value larger than the machining
tolerance to allow the tool axis to be stabilized as it moves across this
geometrically varying region. As a result excess material may be left on
the surface involved but the load on the tool may be reduced.
No axial tolerance set:
Check allowance
Check allowance sets the distance that the tools will approach, but not
pass closer than for a check surface. If Check allowance is set to a
specific value, that value is used for both rough and finish passes. If it is
left blank then if behaves differently for roughing and finishing. If left
blank for a roughing pass then check allowance is set to finish allowance
+ leave allowance. If left blank for a finishing pass then check allowance
is set to leave allowance.
Corner Radius %
This defines the radius used if you select a Type of Arc Fitted. The
radius is defined as a proportion of the tool diameter. For a Z finish pass
the default value is 5%. So, if you have a tool of diameter 10mm (radius
5mm) then the arc radius is 0.5mm. The Corner Radius% can have a
value between 0 and 100.
Corner radius %
Slices in Z-level (both rough and finish) can be arc fitted to avoid sharp
changes in direction. For Z roughing, only the toolpath closest to the part
is rounded. Corner radius % defines the radius that is inserted in to the
toolpaths.
The radius of internal corners is defined as a proportion of the tool
diameter. The default value is 5% for a finish pass and 0% for a roughing
pass. So if you have a tool of diameter 10 mm then the arc radius is 0.5
mm. The Corner radius % can have a value between 0 and 100.
Arc fitting is of particular importance when high speed machining as it
eliminates sudden changes in tool direction.
Cut direction
This dialog provides controls for the direction the tool will cut. Different
options are available for certain toolpath techniques.
Style Options
Unidirectional - Toolpaths will only go in one direction. For Zlevel toolpaths, the conventional/climb mill parameters control the
direction. For other toolpaths, the decreasing/increasing controls
the direction.
Bidirectional - If active, the decreasing or increasing parameters
control the initial cuts direction.
This value can therefore be used to control the location and amount of
material left on non-swarfable surfaces. For example, if material on a
surface can mostly be machined by swarf machining, but there is a region
where 3 mm of material could be left, then you can either:
choose a Radial offset of 3 mm to leave 3 mm of material on the
whole of the surface; or
set a Radial offset of 0 mm and a Degouge tolerance of 3
mm. In this case, the surface will be completely machined where
possible, but some material of up to 3 mm will be left on a part of
the surface.
Degouge tolerance remains in effect even if Gouge check is
not selected.
Edges for surface milling
This page gives you options to set how the toolpaths are generated near
surface edges.
Cut to bottom: Roll over top edge and cut to bottom of
stock/part limits
Does not set any boundary. In this case, FeatureCAM will only use the
boundary specified by the curve options in the Stock tab (see page 288).
Cut top edge: Just roll over the top edge
Sets a pocket-like curve boundary to the silhouette of the part offset by a
tool radius. The tool will roll over the edges by a tool radius as shown
below. In PowerMILL this is known as a silhouette boundary. Edge
boundary all is using a silhouette boundary of the part, but it uses the top
(highest) Z values where the silhouettes are at a vertical surface.
If you have a vertical surface and you want to cut to the bottom, check the
Cut to bottom of vertical walls check-box.
There are two types of curves used by the Don't roll option. One type is
a curve on the surfaces of the feature. This is called a part boundary and
the points are the contact points where the tool will stop at the edge of the
feature. These curves do not depend on the tool. The second type of curve
is a tool center (offset) curve. A tool center curve is a part boundary curve
that has been offset by the tool edge radius. The Show combined
boundary button on the Stock page gives a preview of all the part
boundary and tool center curves.
Boundary tolerance: controls the accuracy of the part boundaries. The
default value is automatically computed. Smaller values give better
results but take longer to compute. To reset to the default value, set the
value to 0, click OK and Apply on the Edge page.
Use separate wall tolerance: The part boundaries use a tolerance to
check for vertical surfaces (walls). By default it uses the boundary
tolerance (above). Selecting this option lets you enter a separate tolerance
value for vertical walls. You may need to use this setting if you use the
Cut to bottom of vertical walls option on the Edges page. If you
preview the part boundaries and they are not consistently at the bottom of
vertical walls, select Use separate wall tolerance and enter a larger
tolerance than the boundary tolerance above.
Edge tolerance: specifies the tolerance between the part boundaries
and the surfaces. The default value of 0 means this tolerance is set
automatically based on the boundary tolerance above. If the tool center
curve is rolling over the edges of the feature you may need to set a larger
edge tolerance (relative to the boundary tolerance).
Milling tolerance: Note that the tolerance setting on the Milling tab of
the surface milling operation is used for the tolerance of the tool center
curves. You may need to use a smaller milling tolerance to get smooth
tool center curves.
Advanced part boundary examples
The Show combined boundary preview shows both the part
boundary (blue) and the tool center (red) curves;
In the following example, the part boundary (red) is smooth, but the tool
offset (blue) is rough. Decrease the Milling tolerance for a smoother
tool offset:
In the following example, the part boundary (red) is not consistent along a
vertical wall. First try reducing the Boundary tolerance. If that does
not solve the problem, try using a separate (larger) Wall tolerance.
Using the Rollover option, the tool offset (red) (and toolpath) rolls over
the part boundary (blue):
Fan at ends
This is relevant to swarf finishing.
As the toolpath moves from one surface to another there can be a change
in ruling direction. This is called 'fanning'. When Fan at end on
planes is selected, fanning will happen only in the end region of a plane.
When Fan at ends is not selected, fanning is allowed to happen
anywhere 'across' the plane.
In the example, when Fan at ends is selected, the tool axis will change
primarily in regions labelled
constant in the region labelled
in region
and
Minimum fanning
In a swarf toolpath, as the toolpath moves from one surface to another
there can be a change in the ruling direction. Since the tool aligns itself
with the ruling direction, you have to specify the distance over which the
tool can change from one ruling direction to the next. The fanning
distance is measured as the smallest movement on either surface edge (or
the distance the closest part of the tool is to the opposite part of the
surface before fanning starts). The actual fanning distance may be larger
than the Minimum fanning value specified, to prevent the toolpath
from gouging.
and
: ruling direction
: fanning distance
Min Z increment
Is used with scallop-height Z-level finish. There is a scallop height
attribute which specifies the stepdown such that the height of the material
left between Z heights does not exceed the scallop height. However, if the
calculated value is smaller than the Min. Z increment, it is set to Min.
Z increment.
Start Angle and End Angle - determine over what portion of a full
circle the picture is generated, and whether the tool travels in a clockwise
or anticlockwise direction:
Start Angle > End Angle - tool travels clockwise.
End Angle > Start Angle - tool travels anticlockwise.
Scallop height
Absolute scallop height between passes for isoline milling, projection
milling finishing passes and Z-level finishing. This distance is measured
along the surface and represents the maximum cusp height between
neighboring passes as shown here.
This attribute only applies if the scallop height checkbox (see page 391)
is selected.
Start point(s)
The Start point(s) attribute controls the initial points for Z-level finish
(see page 350) toolpaths.
It only works for toolpaths that are closed loops. Start point(s) can
either be a single point or a curve made from a connected line. The
closest point on the toolpath loop relative to the start point is found
and that point is used as the starting point for the loop.
The blue start point controls the location of the start of each toolpath.
See also 3D leads/step tab (see page 310) for information on transitions
between toolpaths.
Stepover
Planar stepover distance for finishing with projection techniques. This is
the distance between toolpath center lines as shown here. This distance is
measured in the XY plane and then the toolpaths are projected onto the
surfaces of your feature. This attribute only applies if the scallop height
check box (see page 391) is deselected.
Stepover rapid distance
Stepover retract distance is used just to determine when to feed vs.
rapid to the next toolpath.
This only applies to stepovers between toolpaths.
Use Retract gap distance to prevent retracting over a gap in a
toolpath. Stepover retract distance is a 3D distance. If not explicitly
set, the stepover threshold is the tool diameter plus twice the allowance.
For a rough operation, allowance in this context is the Finish allowance.
For finish operation it is Leave allowance.
This figure shows how the tool stays on the metal with an increase in
Stepover retract distance.
For Z level rough, this attribute applies to all features except pocket
features without stock curves. This attribute controls the outer extend of
boss features and the amount that pocket feature cuts beyond its
boundary. The default value is 100% which puts the edge of the tool on
the boundary. A number greater than 100 extends the toolpaths beyond
the boundary. A number less than 100 essentially offsets the outer
boundary and clips the toolpaths against this closer boundary.
Surface join tolerance
This is relevant to swarf and trim.
This value may be used to disassociate the machining tolerance from the
tolerance used to define what is a gap between surfaces. Occasionally a
machining tolerance will be chosen that is smaller than the gap between
surfaces. When this occurs, two segments of toolpath will be created. To
ensure one continuous toolpath across a gap, you may use a larger surface
joining tolerance.
Tolerance (3D)
Tolerance sets how close the milling will be to the mathematically ideal
surface. This does not guarantee that your feature is machined to this
tolerance in all locations if the tool you select is incapable of cutting
within that tolerance in constrained areas. If your part shows a faceted
appearance, set the tolerance to a lower value.
Set this attribute separately for roughing and finishing passes.
Toolpath corner %
Effective only during Z-level rough, a non-zero Toolpath corner %
replaces sharp corners with rounded corners. Defines the maximum
deviation from the sharp corner. The maximum this can be set to is 40%
of stepover. This means that if you have a 10mm stepover the maximum
deviation from the sharp to the rounded corner is 4mm.
A larger smoothing tolerance will reduce this 'spike' in the toolpath, but
will affect more of the toolpath near the area:
Upper offset
With a multiple cut, swarf operation, the Upper offset attribute is used
to start the toolpath above the upper edge of the part. This example shows
an upper offset of 10 mm:
: bottom edge
Z end
Z end sets the distance along the Z axis below which the operation will
not mill. You may want to use Z end on an earlier operation then follow
it with an operation using the Z start attribute so you control the
toolpaths efficiently.
Z increment (3D)
Z increment sets the distance the tool moves down in the Z axis with
each pass.
Default 3D attributes
Surface mill attributes
Click the attribute for further explanation:
Tolerance (see "Tolerance (default attribute)" on page 425)
Parallel angle (see "Parallel angle (default attribute)" on page 425)
Tool diameter (on page 425)
Tool end radius (on page 425)
Scallop height (see "Scallop height (default attribute)" on page 425)
Check allowance (see "Check allowance (default attribute)" on page 425)
Slope limitation angles (see page 304)
Finish allowance (see page 425)
Troubleshooting 3D toolpaths
Troubleshooting Z level roughing (see page 350)
Troubleshooting isoline milling (see page 360)
Troubleshooting projection milling methods (see page 325)
Troubleshooting Z level finishing (see page 356)
Extending
FeatureCAM
FeatureCAM add-ins
FeatureCAM can be extended using its application programming
interface (API). Detailed information on this interface is available in the
FeatureCAM API help file, available under the FeatureCAM Help menu.
But a few topics are available in the online help:
Loading the example add-ins that were installed with FeatureCAM (see
page 428)
Running the API examples provided with FeatureCAM (see page 429)
Installing new add-ins (see page 427)
Creating toolbar buttons for macros (see page 430)
Assigning a macro to a toolbar button (see page 431)
User-defined features (UDFs)
3. Press the new button to create lines that matches the outline of your
stock.
4. You are done. You've loaded and used an add-in.
Not all add-ins create buttons. See Creating Toolbar Buttons for
Macros (see page 430) for information on creating buttons.
The following examples are installed along with FeatureCAM in the addins folder (in Program Files\FeatureCAM\addins). You will find
additional documentation about each example if you open the .bas file
using Notepad.
CenterIndexedStock.bas - center the stock about the stock axis
for purpose of indexing.
HoleRecog.bas - event handlers for hole recognition that support
colored surfaces.
MakeStockGeometry.bas - make geometry (lines) that
coincide with the stock. Pictured above.
MoveSetupToUL.bas - move the setup to the upper left corner
of the stock (against the hard jaw).
SelectHeight.bas - select surfaces and faces at a height that
matches a selected object.
NewDocumentLayers.bas - automate shop practice by
initializing a new document with particular layers.
MakeHexagon.bas - make lines that form a hexagon around the
selected arc or circle.
The first time you click your new button, it will ask you for the name of
the macro to run. Enter SelectHeight and click OK.
You may return to this dialog at any time to reassign any custom toolbar
button (the hammer) to a different macro by right-clicking on the button
after it has been placed into a toolbar.
Now, whenever you click the toolbar button, the SelectHeight macro will
be executed. If a message comes up saying that the macro doesn't exist,
then either you spelled it incorrectly, or you failed to load the
SelectHeight.bas add-in.
Even if you loaded the add-in and spelled the macro name correctly,
clicking the button will probably cause some type of error that comes
from the SelectHeight macro itself. This is because you don't know how
to use the SelectHeight macro yet. What does the SelectHeight macro
do? You can open the macro in the Sax Basic IDE to find out.
Feature Recognition
(RECOG or 3D)
Feature recognition is the process of creating manufacturing features
directly from solid or surface models. Feature recognition requires the
FeatureRECOGNITION option (formerly SolidM) for FeatureMILL2.5D.
It is included in FeatureMILL3D.
Overview of feature recognition (see page 433)
Types of features that can be recognized (see page 434)
Methods of feature recognition (see page 442)
How to recognize features from surfaces (see page 449)
How to recognize features from surfaces using curve chaining (see page
452)
How to recognize all holes in a setup (see page 451)
How to recognize pockets and bosses from top or bottom surfaces (see
page 453)
How to recognize drafted features (see page 454)
Hole recognition (see page 436)
Slot recognition (see page 438)
Boss recognition (see page 439)
Pocket recognition (see page 441)
Side recognition (see page 441)
The cylindrical voids are only surfaces, not holes. What looks like a
FeatureCAM pocket feature is actually only a collection of surfaces.
While it has been possible to extract edges from the solid model and join
them into curves for features, this process can be time consuming.
The features that you recognize from a solid model are the same as any
that you create from scratch. The same feature-based automation applies
so that you can quickly and easily create part programs.
Hole recognition
Four types of holes can be recognized.
Hole type Surfaces recognized from
Plain
Counter
bore
Counter
sink
Counter
drill
Slot recognition
Only straight slots can be recognized. They are recognized from straight,
parallel side surfaces. You must select surfaces on both sides of the slot.
In the example below, the shaded surfaces are the selected surfaces. The
extent of the slot is defined by these surfaces. Note that the flat bottom
surface is ignored.
For interrupted slots, select surfaces on each end. In the picture below, the
slot is interrupted, but can be created by selecting the wall surfaces at
either end.
If the feature you are trying to recognize is a straight cut that extends off
the side of the part, as in the yellow region of the part shown below, use a
side feature (see page 441). You cannot recognize such a feature as a slot,
since there aren't two opposing side walls.
Note that chamfers, draft angles and bottom radii cannot be recognized,
but you can add these parameters to the slot in the Dimensions page of
the New Feature wizard. See Slot feature for more general information
on slots. See How to recognize features from surfaces (see page 449) for
a description of the overall process. See Feature recognition surface
requirements (see page 451) for further information on how surfaces are
used in feature recognition.
Boss recognition
Bosses are features that must be closed. This means that the cross-section
of the feature must form a loop.
Bosses can be created by recognizing features directly from surfaces (see
page 449) by using curve chaining from the solid model (see page 452) or
automatically (see page 445).
If you are recognizing the feature directly from surface data keep in mind:
It is often easiest to select the surfaces from the top view after
clicking Hide All Nonvertical Surfaces from the Hide menu.
Bosses require a closed curve. Once you select your surfaces, view
them from the top. The selected surfaces should form a loop as
shown in this example.
If you don't see a loop as in the following example, you must select
additional surfaces to fully define the pocket.
Pocket recognition
Pockets are features that must be closed. This means that the crosssection of the feature must form a loop.
Pockets can be recognized using one of these four methods:
1. Pockets with bottoms and walls all around can be automatically
recognized (see page 446) from solid models. This is the only
method that can recognize islands and bottom radii.
2. Recognition from selected bottom surfaces (see page 453).
3. Recognition from selected side surfaces (see page 449).
4. By extracting feature geometry and chaining curves (see page 452).
This is the only method that can be used to recognize drafted
pockets (see page 454).
See also Pocket feature and Feature recognition surface requirements (see
page 451).
Side recognition
Side features can be created using the Automatic (see page 448)
method, or from side surfaces.
Use a boss (see page 439) or pocket (see page 441) for closed features.
If you are recognizing the feature directly from the side surfaces, keep in
mind:
It is often easiest to select the surfaces from the top view after
clicking Hide All Nonvertical Surfaces from the Hide menu.
Chamfers, draft angles and bottom radii cannot be recognized, but
you can add these parameters to the feature in the Dimensions
page of the New Feature wizard.
See also Boss feature and Feature recognition surface requirements (see
page 451).
2. Automatic option of the New feature wizard (see page 445) - The
Automatic option of the New Feature wizard is applicable to
holes, pockets, bosses and side features. It is more limited to how
much of the part can be automatically recognized and you must
recognize each type of feature with separate runs of the wizard.
3. Automatic recognition of turned features - This option is only
available through the Import wizard.
The following example shows the milling features that are extracted using
each method. The figure below shows the three side features created by
the automatic feature recognition wizard. The model has the advantage
that the two slots are cut by the top feature. It has the disadvantage that
top circular pocket is not represented by a single pocket.
2. The boss must have walls all the way around it.
3. If the part has multiple bosses at the same Z height, they must be
included in a single boss feature. (If they are not, each boss will cut
away the other). The surface of each individual boss must be the
same for them to be included as a single feature.
Bottom radii are recognized. Chamfers are not recognized, but can be
interactively added to a feature (see page 446). Drafted bosses cannot be
recognized automatically. You must use Chain feature curves option (see
page 454)to recognize drafted features.
The pocket boundary and the island boundaries. Note that the
islands must be distinct from the boundary, but they can be of
different heights. The island of this solid will automatically be
recognized.
This figure shows the pocket that is recognized if an elevation is set to the
bottom of the boss.
The type of side features that are recognized using this method fall into
three categories:
1. Through cavities - Pockets that go all the way through the part are
recognized as side features. The light blue region of the figure
below is an illustration.
2. Open side features that are on the border of the part. The yellow
region of the image below is such a feature.
3. Outer boundaries. The material from the stock boundary to the part
boundary is removed using a side feature. Note that if your stock
boundary and part boundary are the same, a side feature will still
be recognized, but no toolpaths will be generated.
Blind pockets and bosses that formed from closed curves not recognized
as side features. They should instead be recognized as pockets and bosses.
4. Select your feature type. Remember only pockets, bosses and sides
can be recognized using curve chaining.
5. Click Extract feature from solid model and click Next.
6. Click Chain curves and click Next.
7. The geometry for the features is projected onto the plane of the
UCS. Chain the appropriate geometry. See Feature recognition chaining for more information.
8. The top and bottom page is displayed. Enter the top and bottom
values or click the Pick buttons and graphically pick the locations.
Click Next. For more information see Feature recognition - top &
bottom.
9. Confirm the extracted dimensions of the feature. Modify the
feature's dimensions if desired and click Next.
10.The Strategies page is displayed. Click the desired attributes
depending on your manufacturing preferences. Click Next. See
Strategy tab for information on the specific attributes.
11.The Operations page is displayed. This page displays the
operations that will be used to manufacture the feature along with
the names of the selected tools and calculated feed and speed
values. If these values are acceptable, click Finish. If you want to
change the tooling or feeds and speeds click Next and follow the
instructions on the screen.
4. Select your feature type. Remember only pockets, bosses and sides
can be recognized using curve chaining.
5. Click Extract with FeatureRECOGNITION and click Next.
6. Click Chain curves. Wall angle and elevation values are shown.
7. If you know the angle, enter it. If not, click the Draft Angle label.
The dialog will warp out of the way. Click two points on the same
vertical isoline as shown below. The dialog returns.
8. For the Elevation enter the Z coordinate of the top of the feature
or click the Elevation label and click the top of a wall of the
drafted surface. Click Next.
9. The geometry for the features is projected onto the plane of the
UCS. Chain the appropriate geometry. See Feature recognition chaining for more information.
10.The top and bottom page is displayed. Enter the top and bottom
values or click the Pick buttons and graphically pick the locations.
Click Next. For more information see Feature recognition - top &
bottom.
11.Confirm the extracted dimensions of the feature. Modify the
feature's dimensions if desired and click Next.
12.The Strategies page is displayed. Click the desired attributes
depending on your manufacturing preferences. Click Next. See
Strategy tab for information on the specific attributes.
The Operations page is displayed. This page displays the operations
that will be used to manufacture the feature along with the names of the
selected tools and calculated feed and speed values. If these values are
acceptable, click Finish. If you want to change the tooling or feeds and
speeds click Next and follow the instructions on the screen.
Rerecognition wizard
The Rerecognition wizard compares a new solid model with an
existing set of features. It is assumed that you have imported a new solid
model that is a variation on the initial model. If are trying to recognize the
initial features from a part model use automatic feature recognition (see
page 443).
If you are going to rerecognize a model, you should make sure that you
use the same alignment.
The Rerecognition wizard automatically recognizes features from the
new solid and then compares the new features to the existing features and
classifies the new features into the categories of unchanged (see page
457), new (see page 457), modified (see page 457) and deleted (see page
457).
FeatureCAM attempts to rerecognize both individual features and
patterns of features.
Unchanged features
These features are identical to existing features. They will be ignored in
the rerecognition process.
New features
These features are not part of the existing features and therefore are
assumed to be new. The Rerecognition wizard will offer you the
opportunity to add these features to your part.
Modified features
These features have the same shape or size as existing features, but
parameters like depth, bottom radius or chamfer distance have been
modified. The Rerecognition wizard will ask you if want to replace the
existing features with their modified versions.
Deleted features
These features exist in the current set of part features, but were not found
in the new model. You are offered by the Rerecognition wizard the
option of deleting these features. There are many possible reasons that
this feature is in your existing set of features but was not automatically
recognized, so you should be careful about deleting these features. If the
feature has clearly been deleted, you can comfortably remove it. If the
feature was created through interactive methods, you probably want to
keep this feature. If you are uncertain, you should preview each feature
and decide on an individual basis.
Tombstone machining
(TOMB)
If your milling machine is equipped with a tombstone, FeatureCAM
makes it easy to take advantage of this high production feature.
You must license the Tombstone machining option to use tombstone
machining.
Overview of tombstone machining (see page 459)
Specifying tombstone dimensions (see page 459)
Creating global fixture coordinate systems from setups on placed parts
(see page 460)
Creating global fixture coordinate systems on the tombstone (see page
461)
Creating a tombstone machined part (see page 462)
Adding a part to the tombstone (see page 462)
Specifying ordering of tombstone operations (see page 462)
Saving and opening tombstone parts (see page 463)
Edit button (see page 463)
Delete button (see page 463)
Reload button (see page 464)
button
1. Click a setup.
2. Click the Edit button.
3. The Tombstone setup information dialog box comes up for editing.
Overview of 5-axis
positioning (5-axis
Pos)
5-axis positioning provides a convenient method of manufacturing parts
that require milling on multiple faces by minimizing setups. The figure
below shows an example of a part that requires milling from 4 different
orientations. With 5-axis positioning, this entire part can be milled with a
single program.
Vertical with stacked tables - These machines are vertical mills that
rotate about X-axis then around the Y-axis. These machines are also
known as B over A machines.
Machines with tilting heads
FeatureCAM supports machines with tilting heads as long as they have
the following two capabilities:
3D coordinate transforms - The control must allow programming of 2.5D
features in the X and Y planes. This means that the depth of features are
always in the Z or -Z directions.
Tool length offset - The touch-off point (or zero point) of the tool must
move with the rotated tool.
The specific machine architectures support are as follows:
C rotary table and B tilting head - These machines rotate about X and
then the head rotates around the Y-axis.
C rotary table and A tilting head - These machines rotate about Z and the
head rotates around X.
B and A tilting head - Rotates about Y using a table and then X in the
head.
A and B tilting head - Rotates about X using a table and then Y in the
head.
B and 45 Degree angled A tilting head - Rotate about Y, then rotate about
X with a head that is angled by 45 degrees. This head is also known as a
huron head.
The default and alternative orientations for each 5 axis machine type are
shown below.
Horizontal with stacked tables (rotate about Y then X)
Default is to keep B 0 to 180, then find A. Alternative is to keep B 0 to 180, then find A.
Vertical with stacked tables (rotate about X then Y)
Default is to keep A 0 to 180, then find B. Alternative is to keep A 0 to 180, then find B.
C rotary table and B tilting head
Default is to keep B 0 to 180, then find C. Alternative is to keep B 0 to 180, then find C.
C rotary table and A tilting head
Default is to keep A 0 to 180, then find C. Alternative is to keep A 0 to 180, then find C.
C swiveling and A tilting head
Default is to keep A 0 to 180, then find C. Alternative is to keep A 0 to 180, then find C.
B and A tilting head
Default is to keep B 90 to -90 if setups Z is positive and 90 to 270 if
setup's Z is negative, then find A. Alternative is to keep B 90 to 270 if
setup's Z is positive and 90 to -90 if setup's Z is negative, then find A.
A and B tilting head
Default is to keep A 90 to -90 if setup's Z is positive and 90 to 270 if
setup's Z is negative, then find B. Alternative is to keep A 90 to 270 if
setup's Z is positive and 90 to -90 if setup's Z is negative, then find B.
Turn/milling
(TURN/MILL)
FeatureTURNMILL allows the combination of turning and milling
features on lathes with powered rotary tools. FeatureTURNMILL
supports the normal Z and X axes of turning combined with the C and
optional Y-axis.
The yoke shown in the left-hand figure, could be manufactured with a C
axis lathe in two setups or using a C axis lathe with a subspindle. The
right hand figure is a piece that requires a Y-axis due to the flat pockets
on the top and bottom of the piece. (If these pockets were wrapped, they
would have a curved bottom and then they could be manufactured
without a Y-axis.)
When creating features, you are given the choice of creating turning
features or turnmill features (see page 479). Turning and turnmill features
can be mixed in a single setup. Turning features are identical to those on a
2-axis lathe and milling features are created the same as for a 3-axis mill,
except that you are given new choices for positioning and orienting the
features either on the OD or on the face of the part.
Turnmilling
Turnmill Overview (see page 477)
Beginning a turnmill part (see page 478)
Turnmill feature type dialog box (see page 479)
Features appropriate for millturn (see page 479)
Turnmill location dialog box
Tool selection for turnmill features (see page 480)
Feed rates for turnmill features (see page 481)
Polar interpolation in turn/mill (see page 481)
Feature location
This dialog helps you select the location point of the feature. This point
that you are specifying corresponds to the red X in the diagram.
To complete this page:
1. If you want to type the coordinate, type the values into the X, Y
and Z locations
2. If you want to graphically pick the location, click the Pick point
button. The dialog will warp into a title bar with a single button
with a red X on it. (Click this button if you want to cancel your
selection)
3. Pick the point with the mouse. Remember that the snap modes
control what the cursor will snap to. After you pick the point, the
dialog returns to the screen.
4. If you are creating a milled feature, you can set an angle, A, that
represents a counter-clockwise rotation around the feature location.
5. Click Next.
Rotary tools cannot be explicitly created, but if you manually select a tool
for a turnmill operation, it is copied and the copy is designated as a rotary
tool.
Rotary tools cannot be used for turning operations.
Introduction to
FeatureWIRE for
FeatureMILL users
FeatureWIRE is structured similarly to all other FeatureCAM products
and the steps are used to walk you through the process.
A model of the stock is displayed in the graphics window.
Geometry and curves are used to describe the shape of the part.
The geometry and curves are included in features and toolpaths are
derived from these features.
Toolpaths are simulated in the graphics window using line drawings
or 3D shaded graphics. 3D simulation also allows the simulation of slug
removal (see page 483).
Toolpaths are translated into machine specific code using the
appropriate post processor.
Differences between FeatureWIRE and other FeatureCAM products
include:
1. The diameter and type of wire you are using are specified as part of
the Stock wizard instead of on individual operations.
Die
The Die feature requires one or more closed curves (see page 484). It is
assumed that the region(s) outside of the curve(s) is the part that you
keep. As a consequence, the wire travels on the inside of the curve(s).
Punch
The Punch feature requires one or more closed curves (see page 484).
The wire travels on the outside of the curve(s).
Side
The Side feature can use one or more closed or open curves (see page
484). The Punch or Die features provide more cutting options for closed
curves. You can optionally place the wire on either side of the curves. A
side feature must have at least three arcs or lines in it including the lead
moves.
This button reverses the direction of the selected curve. Note that
FeatureCAM automatically sets the direction of the curves so this option
should not be necessary most of the time.
There are two additional check boxes. Use the Show lower curve
option to display the corresponding bottom curve for each curve selected.
Check Hide surfaces when finish to have the surfaces hidden after
you leave this dialog.
button.
button.
button.
button.
Operations (FeatureWIRE)
The operations that you select control the types of strategy attributes that
are displayed on Strategy tab. More than one operation can be created
by selecting the primary operation from the menu and then selecting the
Cutoff or Contour check boxes that appear to the right of the menu.
Retract (see page 494)
Stop (see page 495)
Pocketing (see page 497)
Zig-zag (see page 498)
Cutoff (see page 499)
Contour (see page 499)
Retract operation
Available for both 2-axis and 4-axis features.
The contour is not cut completely but is stopped shortly before the
contour end point. The distance of this position from the contour end
point is set in the Stop Length field. This option is generally used when
cutting multiple contours whereby the cut part should not be separated
from the work piece - e.g. when the program should run automatically
overnight.
A cutoff operation is normally used after this operation to cut the part of
the contour that is not cut by the Retract operation. Cut Off machines
the left over part in the opposite direction to the machining curve.
Stop operation
Available for both 2-axis and 4-axis features.
A stop command is inserted into the wire path together with a further stop
at the end of the contour. The distance of the new stop position from the
contour end point is defined in the Stop Length field. If you wish to
overcut the contour end position, you can also define an Overlap. In
centerline simulation, the locations where the wire stops are shown as
small squares. A stop operation has two different locations where the wire
stops.
General rules
The machining curve must define a closed pocket
The start position of the cut is set automatically to a point on the
boundary. The wire then feeds to the center of the pocket and then
cuts from the inside toward the boundary.
If you wish to ensure that the wire starts in a particular position (to
thread the wire for example) you should define a start point. The
toolpath then starts at the start point and then feed to the center of
the pocket.
No attempt is made to check if the stepover value is larger or
smaller than the wire diameter.
Cutter compensation does not apply to a pocketing operation
because it outputs a wire path that is already corrected (that is, no
compensation is entered on the machine).
General Rules
The machining curve must define a closed pocket
The start position of the cut is set automatically to a point on the
boundary. The wire then feeds to the beginning of the zig-zag
pattern.
If you wish to ensure that the wire starts in a particular position (to
thread the wire for example) you should define a start point. The
toolpath then starts at the start point and then feeds to the beginning
of the zig-zag pattern.
By the definition of the cut Angle (see page 510) you can control
the direction of the wire path and also the start point of the cycle
(see page 498).
No attempt is made to check if the stepover is larger or smaller
than the wire diameter.
Cutter compensation does not apply to a pocketing operation
because it outputs a wire path that is already corrected (i.e. no
compensation is entered on the machine).
bottom left.
bottom right.
top right.
top left.
The chosen angle can naturally lie between the examples shown above. In
this case the start point is set to the nearest of the positions shown. On
extremely complex contours it may be necessary to experiment with the
cut angle to find the optimum start point.
Cutoff operation
Available for both 2-axis and 4-axis features.
This option is normally used after a contour has been cut with the Auto
Path option Retract.
Cut Off cuts the part of the contour that is left by the Retract option.
The machining takes place in the reverse direction to that of the
machining curve i.e. from the contour end point to the stop position. The
wire stops before pulling away from the part. This stop location is shown
as a small square.
Contour operation
Available for both 2-axis and 4-axis features.
General Rules
The curve can be open or closed. A contour operation traces the entire
length of the curve. The number of passes is determined by Contour
passes (see page 508). A contour operation can be optionally added to
retract, stop, pocket, zig-zag or cutoff operations by selecting the
Contour option on the Strategy tab.
If you want the contour to overlap, enter the amount of overlap you want
in the Contour Overlap box.
Attributes
Strategy tab
Click the Strategy tab in the feature's Properties dialog to access the
Strategy attributes:
Stop Length
This parameter is used for Retract, Stop or Cutoff operations.
It defines the distance from the normal contour end position to the
inserted stop or end position.
Total passes
The total number of passes to take to cut the feature. If a feature has a
Retract, Stop or Cutoff operation these operations will each be
performed Total passes - Contour passes. If a feature has a contour
operation, Total passes must be at least 2. Total passes must be between 1
and 9.
Leave allowance
Leave allowance is the amount of material to leave after the contour pass.
Retract length
The Retract Length attribute is used for Retract, Stop or Cutoff
operations.
It defines the distance that the wire retracts from the part at the conclusion
of an operation.
Offset method
The Offset Method attribute controls whether the offsetting of the wire
path is performed on the machine using cutter compensation (see page
506) or by FeatureCAM (see page 506). Select Cutter comp to perform
the offsetting on the machine, or Offset Toolpath if you want
FeatureCAM to perform the offsetting.
See also Working with wire radius compensation (see page 505).
Working with wire radius compensation
To cut a workpiece to the finished size the Wire radius compensation
function on the NC-machine is normally used. Activating this function
with a particular value causes the machine to calculate a new path for the
center of the wire. The compensation value is normally composed of the
wire radius plus the spark gap allowance plus any finishing allowance
that may be required. The compensation value is normally entered in a
Compensation Register on the machine.
In every case you should ensure that the appropriate linear lead-in and
lead-out moves are contained within the program to enable the
compensation to be switched on and off.
The output of the commands to activate and deactivate the compensation
is automatically carried out by the software on the first and last moves.
For further information see:
Radius compensation on the Machine (see page 506)
Radius compensation in FeatureCAM (see page 506)
Wire radius compensation on the machine
When using the Wire Compensation command, the center path of the
wire will be calculated and corrected directly by the nc-machine. The
compensation amount is normally entered in a Compensation
Register on the machine controller and activated by an appropriate
command within the nc-program. The format of the command to activate
the compensation and to control the compensation direction is dependent
upon the nc-machine type. The FeatureWIRE software supports the
output of these commands both for single and multiple cuts
(backwards/forwards cutting or Main/Sub-Programs)
The following parameters control the use of wire compensation on the
machine:
Total passes (see page 504)
Leave allowance (see page 504)
Contour passes (see page 508)
Uni-Directional (see page 508)
Uses macro (see page 508)
Wire radius compensation in FeatureCAM
If the wire radius compensation is carried out by FeatureCAM the
appropriate compensation value and direction will be automatically used
to produce a wire path that is already corrected. The path cannot be
altered by changing the offset register of the nc-machine. This may be
necessary for example, when cutting a contour which contains elements
or arcs which are smaller than the required compensation amount and
thus cannot be cut using the machine registers.
The following parameters control the use of wire compensation:
Total stock (see page 508)
Leave allowance (see page 504)
The calculated wire path represents the center of the wire, that is
the actual amount that will be left on the curve is dependant upon
the values set for cutter compensation.
Stepover
Used for pocketing and zig-zag cycles
This parameter defines the step over between passes for the Pocketing
and Zig-Zag cycles.
Contour stock
Contour Stock is the amount of material to leave for the contour
operation.
Cleanup pass
This option is used to create a finishing cut at the end of a ZigZag
operation. The contour will be cut with a contour parallel finishing path to
remove any rough edges left by the step-over between passes.
Finish allowance
This is the amount of material left after a ZigZag pass. Even if a cleanup
pass (see page 510) is used, the finish allowance still remains.
Stepover
This parameter defines the step over between passes for Cutoff, Stop,
Retract and Contour operations. It applies when the offset toolpath
(see page 505) option is selected.
Stop code
For stop operations you can choose the stop code from among the
following choices.
M00 is program stop. This stop will be always be performed.
M01 is optional program stop. There is a setting on the machine tool to
observe or skip these stops.
Start tab
Start/end point (FeatureWIRE)
When this page is displayed in the wizard, the feature is displayed by
showing a ruled surface. If the feature is not displayed, click here (see
page 486).
Leads are non-perpendicular by default. If you want the lead to be
perpendicular, select the Pick only perpendicular lead box
before you click the Pick location button. Click the start point and
FeatureWIRE highlights the corresponding perpendicular point
when you mouseover the curve segment. Click to accept it.
Die and Punch Features
For 2 and 4-axis die or punch features, a start point is automatically
calculated. You can change the start point for a die or punch feature using
the following procedure:
1. If the feature has multiple curves, select the appropriate curve from
the Curve list.
2. Click the Pick location
button.
If you want to force the wire to start on the curve, you cannot simply
double-click. You must move your second pick (the one that indicates the
curve segment) slightly so that you are not picking the same point twice.
If you are creating a 4-axis feature, follow the above procedure for both
the upper and lower curves.
Side Features
For 2 and 4-axis side features, the default is to start at the first point of the
curve. To add new linear moves at the start or end of a curve:
1. If the feature has multiple curves, select the appropriate curve from
the Curve drop down list.
2. Click the Pick point
There are four different ramp styles that arc onto the contour. The
diameter of the arc is specified as a percentage of the tool diameter. The
same diameter arc is used to ramp off the contour and then the wire
returns to the start point.
Teardrop:
Bullet:
Arc:
U-Shape:
Misc tab
Wire cutting/threading
Wire cutting/threading offers four settings to control the output of wire
threading or wire cutting commands.
No wire threading or wire cutting commands are
output in the NC-program.
The commands to thread the wire and cut the
wire are output automatically at the start and
end of each operation within the feature.
The wire cutting command is output at the end
of each operation within the feature (but no wire
thread command at the start). When viewing the
toolpath in center line simulation, the Cut
location is denoted with a small circle.
The wire threading command is output at the
start of each operation within the feature (but no
cut wire command at the end). When viewing
the toolpath in center line simulation , the
Thread location is shown as a small plus sign.
The following options are available for Retract, Cutoff, Stop and
Contour operations:
The machine will cut to the intersection point of the two lines.
Modify outside corners (see page 515)
Modify inside corners (see page 515)
Modify both (see page 516)
Modify outside corners
A radius will be inserted into the wire path at each outside sharp corner.
This can be useful for reducing unnecessary movements and for
producing cleaner corners.
Triangular
The path follows a triangular shape at an inside corner. Specify the length
and width of the triangle.
Rounded
Auto round
If Auto round is set, arcs are inserted at all sharp corners. This is
applicable only if Cutter comp. is set and you have a leave allowance
or if Cutter comp is not set. If you already have modify outside corners
(see page 515) set, it will not perform any further rounding on these
corners. It will round inside corners (even if modify inside corners (see
page 515) is set) by inserting an arc before and after the circular corner as
shown below: The radius of the inserted arcs is equal to the radius of the
wire.
Thickness: Pick an existing thickness from the drop down list or enter a
new thickness. If you do not specify a unit then it defaults to the unit of
the part. For millimeter enter mm (that is 5 mm). For inches enter in. (that
is 0.25 in.). Do not forget the period.
Wire: Pick an existing wire type or type a new name.
Wire Dia.: Pick an existing wire diameter or enter a new one. The unit of
the diameter is handled the same as the wire thickness.
Machine: Select an existing machine name from the drop down list or
type a new machine name.
After you enter the values, click OK.
Cutting condition tables can contain values for cutting anywhere from 1
to 9 passes. Select the number passes and click the New button to add the
feed, water and cutter compensation registers (see page 518).
Comp. Reg.
This field sets the number of the Compensation Register of the NC
machine which is used for wire radius compensation. The value held
within this register is the amount by which the wire will be corrected to
the left or right of the defined wire path when the function for wire
correction on the machine is switched on (normally G41 or G42)
Comp. Val
This field sets the wire radius correction value for the given offset register
on the machine. The value is normally the sum of the wire radius + spark
gap + any finishing allowance required. For most machines, the
compensation value is referenced through the compensation register, so
there is no need to set this value.
Network security
version (Net)
If you are licensing three or more copies of FeatureCAM, you can now
purchase a network security version that removes the requirement of a
security key for each computer running FeatureCAM.
Centralized Administration - The licensing issues are all concentrated
on the server computer. This centralized administration provides easier
maintenance for large installations.
Flexibility - The FeatureCAM network licensing provides concurrent
licensing. This means that you purchase a certain number of licenses that
can be used anywhere on your network, and that computer does not need
to have a security key attached. For example, if you license 5 copies of
FeatureMILL, up to five copies can run simultaneously as long as the
computers are connected to the network.
Security Keys Not Required for Each Computer - With network
licensing, a security key is not required for each computer. Instead, the
licensing is performed across your company's internal network.
Overview of multi-axis
multi-turret turning
(MTT)
FeatureCAM's multi-axis multi-turret turning is used for production
turning: for making large lot sizes of a particular part. Sometimes called
4-axis turning, synchronized turning, or twin-turret turning, It's all about
reducing the cycle time of a part. The NC programmer uses two 2 to 4
turrets to do multiple operations at once, thereby shortening the cycle
time. And when combined with the closely-related turn/mill capabilities
of FeatureTURN/MILL, you can achieve another benefit of being able to
machine complex parts in fully automated fashion with a single setup.
Machine Capabilities
FeatureSYNCTURN supports a variety of different machine
configurations
Multiple turrets. Each turret can cut on either main or sub spindle.
The turrets can be cutting simultaneously.
Multiple controllers. Typically one controller per turret. All of the
turrets can be cutting at the same time. Synchronization is done
with wait commands. Contrast this with a lathe with a single
controller in which only the active turret can move. The other turret
is locked out.
Multiple spindles. Main and sub.
B axis is supported. One of the turrets can be B-axis configuration
with a rotary tool.
XBUILD issues
Turret DB is entirely new and must be documented: C-Angle Offset is the
default location of the tool.
Keywords <TURRET-NUM> <SYNCH-NUM1-5>
Turrets tab
The turrets tab is displayed in the Manufacturing Results Window
on the right-hand pane of FeatureCAM. It is only visible if you are doing
synchronized turning.
To display this tab:
1. Click the Results tab in the upper right corner of the FeatureCAM
screen.
2. Click the Turrets tab at the bottom of the window.
There are two viewing options for the Turrets tab, which you select from
the options at the top of the tab:
Time view (see page 524)
Operation view (see page 524)
Time view
The Time view lists each spindle on the left-hand side of the
window. Each turret that can operate on the spindle is listed below each
spindle. Along the top of the window is a time scale in minutes. The time
scale can be shortened or lengthened by rolling the wheel on the mouse or
clicking within the time scale and dragging. The operations performed on
each turret are listed in boxes under the time scale. In the example shown
below, the machine has two spindles and two turrets that can cut parts
loaded into either spindle. The main spindle has a roughing operation that
is performed simultaneously on both turrets. The identical length of the
boxes surrounding the roughing operations shows that they will take the
same time to cut.
Synchronizing operations
Assign an operation to a turret
Synchronization for a single operation
Operation view
Unlike in the Time view, the Operation view displays the feature
name alongside the operation name.
Operations are displayed vertically, in the order they are machined, in two
columns. Operations cut by the Upper turret are displayed in the
column on the left and operations cut by the Lower turret are displayed
in the column on the right. Drag and drop operations within the grid to
change their order or turret.
Select more than one operation by holding down the Ctrl key.
A red line is displayed in the list to show the sync point. The two
operations and all subsequent operations move below it.
You can also use synchronization to force one operation to run before
another.
In the example above, we want the hole2 drill operation on the Lower
turret to run before the main_off off Main spindle operation on the
Upper turret. To do this:
1. Select the operation that you want to run first, in this case hole2
drill.
2. Press and hold the Ctrl key and, from the other column, select the
operation that you want to run next, in this case main_off off
Main spindle.
3. Either:
Right-click on either of the selected operations and select Set
sync for 'radial_pattern1.hole2.drill' before
'main_off.off Main spindle'; or
Click the Set sync for 'radial_pattern1.hole2.drill'
before 'main_off.off Main spindle'
button at the top
right of the Turrets tab.
A red line is displayed in the list to show the sync point. hole2
drill is above the sync point and main_off off Main spindle and
all subsequent operations are displayed below it.
Follow turning
Follow turning is typically performed when roughing. Each turret
removes a standard depth of cut. The second turret removes a depth of cut
below the cut left by the first turret. The turrets wait or synchronize at the
start of the cut. One turret is a fixed distance in front of turret 2. The
image below illustrates follow turning. The top tool is in front of the
bottom tool and the bottom tool is cutting deeper in X.
Machine simulation
(MSIM)
Mixing units is supported, that is, you may model your machine in
millimeters, and use it when simulating an inch *.fm document and
vice-versa.
Keep the model simple. Only the necessary details of a machine
should be modeled. Modeling every chamfer, fillet and tiny detail
is only going to slow the simulation down.
At the moment, there are several attributes which are based on the
name of the solid. This means if you wish to rename some or all of
the solids, you should use the rename commands before you begin
using the machine design commands.
At the moment, FeatureCAM cannot distinguish a crash
(sometimes called a clash or gouge) and the case where a table
slides along another table such that the two tables share a common
plane. It is therefore advisable to avoid modeling such solids. The
use of solid offset or transform by small amounts (for example,
.005 inches) will eliminate false gouges in the simulation.
Machine Design Concepts (see page 534)
Machine Design Tutorial (see page 539)
Full Machine Simulation Overview (see page 536)
Lathe Design Overview (see page 532)
There are some important rules that the solid designer should follow in
terms of turret positions and orientations with respect to the chuck
position and orientation. That is, lathe tools, or more specifically, lathe
tool inserts cut the stock when they are parallel to the setup's XZ
plane. As such, you must design your lathe machine so that a lathe tool in
slot 1 can be moved into the XZ plane. FeatureCAM will not initially
rotate the turret. The figure below shows a turret that is modeled
incorrectly. The turret solid cannot be moved such that the tool in slot #1
can cut in the XZ plane of the chuck without rotating the turret. In this
situation, you should rotate the turret solid so that the tool is in the XZ
plane of the chuck.
FeatureCAM assumes that the tools will point toward the center of the
chuck. If that is not the case with the machine you are modeling,
FeatureCAM will need the flexibility to move the turret so that the tool
points toward the center of the chuck. In the example shown below, the
tools are parallel to the XZ plane, but they do not line up with the chuck's
center. In this case you should tell FeatureCAM that part of your machine
moves-in-Y, when in reality, your machine cannot move in the Y- axis.
FeatureCAM needs to move the turrets in Y so that the tools can be
translated into the chuck's XZ plane.
It is not necessary or desirable to include the tool holders in the *.md file.
However, the tool blocks are part of the lathe machine.
Parent/Child Relationships
A machine can be thought of as a hierarchy. For example, when the slide
on a lathe moves back and forth, the turret moves with it in lock-step. The
turret is considered to be a child and the slide is considered to be a
parent. In this manner, if the G-code specifies a certain movement, you
can assign that movement to the parent and all of the children will move
along with it. That way you don't need to specify how every piece of the
machine moves independently.
Movement
A piece of the machine can be assigned to a particular movement. For
example a slide on a lathe could be assigned the moves in Z movement.
So whenever the G-code has a Z move, then the slide moves
accordingly. Then if the slide is a parent of a turret, the turret will move
too.
Top-Most Table
A milling machine has a top-most table that the fixture, vise, or stock
from the FM file must mate to. A turning machine has a similar concept
with the main-spindle chuck.
Mate
A mate is a term from assembly modeling (or constraint-based
positioning). Suppose there are 2 similarly sized cubes in space, randomly
oriented and you want cube1 to be totally coincident with cube2 so that a
specific corner of each cube occupies the same point as a specific corner
of the other cube, and the edges are parallel and, in fact,
coincident. Suppose further that there is a UCS which describes the
position of the interesting corner of each cube and the orientation of the
edges of that cube. We wish to mate the UCS of cube2 to that of cube1,
that is, we find a transformation (translation and rotation) such that the
origins of the UCS's are made to be concentric, and the X, Y, and Z
directions are the same. That is, there is one transformation (and only
one) which takes cube1 (or cube2) and moves it to where you want it.
Examples
You should try running the examples that ship with FeatureCAM. In the
Examples\Machine Design folder you will find several folders each
containing three files:
1. A machine design file (*.md)
2. A post processor file (*.cnc);
3. and a sample part file (*.fm)
If you
1. Load the post processor,
2. Load the *.fm file, and
3. Set the *.md file as the machine design file for each setup,
Then you'll be able to see full machine simulation.
button.
2. Clicking on an object.
This just temporarily removes the object from the simulation. It does
not delete it permanently.
Let's specify how the machine moves. The first piece is the quill.
The quill is represented as a single solid in the part file. You can
see the quill displayed in the Part View and in the graphics
window as shown in the following screen grab.
3. Set movesin_z to move in Z under the Tool quill section and set
mvs_in_x to move in X under the Table section.
1. Using the usual UCS tools, create a new UCS based upon the
STOCK UCS. Translate it up in Z by 100mm. This will place it on
the top of toptable as shown below. Let's say that you called it
UCS2.
1. Using your UCS creation tools, create a new UCS using the
alignment wizard. Use the Revolved Surface option, and select
face_31 of the quill solid. This new UCS, let's say it is called
UCS3, will be a mating point for the spindle.
2. Then, using the Add Tool Location menu item from the
Machine Design menu, establish your new UCS (UCS3) as
being on the quill. You could have just visited the Add Tool
Location dialog and created the UCS from within there instead.
Save Your New Machine
Save your machine in a new file. Use the Save As command so that you
don't overwrite the example file so you can run the tutorial again
sometime.
Using Your New Machine
In order to use your new machine, perform the following steps:
1. Open a *.fm file.
2. Edit the setup that you want to simulate (if you have more than
one setup, then you'll need to edit each one).
Specify movement
If a part on a machine moves independently, the way it moves must be
specified using the Specify movement dialog. If the solid moves only
through the association with its parent solid, you do not need to specify
any additional movements for that solid.
There are two major categories of movements. There are translational and
rotational check boxes for each category. Those movements specified
under the Tool Quill category move in the same direction as the tool. If
the tool moves in the +X direction, the solid will also move in the +X
direction. Solids in the Table category move in the opposite direction. To
affect a +X tool movement, a table solid must move in the -X direction.
Once you determine whether the solid is a Tool Quill or a Table solid,
you should indicate how the solid moves by checking the appropriate
check boxes. For Tool Quill solids, check Moves +delta X, Moves
+delta Y, or Moves +delta Z for translational movements. Check
rotates +A, rotates +B, or rotates +C for rotational movements. For
Table solids the translational choices are Moves -delta X, Moves delta Y, or Moves -delta Z and the rotational movements are rotates A, rotates -B, or rotates -C.
To complete this dialog:
1. Select the solid.
2. Check the appropriate type of movements.
3. Click Apply.
Parent/child relationship
The first step in creating a simulation machine is to specify the
relationships between the different solids. In the figure below, the Table
C is located on top of Table A. If Table A moves, then Table C should
move along with it. This is specified by indicating that Table A is the
parent of Table C. You specify this type of relationship by using the
Parent/child relationships item in the Machine Design menu.
All solids must be associated with the Machine. The machine is not an
actual solid, but it represents the top level of the machine. All solids must
be connected to the machine to be included in the simulation. The
parent/child relationships are displayed in the part view under the
Machine category. The following image shows the hierarchy for a
simple table-on-table machine.
Top-most table
The top-most table solid is the solid to which the stock and clamps will be
attached. That is, the stock and clamps in the machine simulation will
move around with the solid that is specified in this dialog as if they were
children of the solid.
For a lathe, this will be the main spindle or chuck. For mills, it will be the
top table solid. Use the Top most table command in the Machine
Design menu.
To complete this dialog:
1. Pick the solid.
2. Pick the UCS on the top of the solid where you want the part
mounted. Note that if your part has its coordinate system located on
its top, you can offset the solid in the Simulation Information page
of the Setup wizard.
3. Click Apply.
For a lathe or turn/mill machine, make the main spindle or (main) chuck
the top-most table (there's also a Subspindle command), and set the
UCS as you would on a turning part, that is, X is up and Z is left-toright. Recall that the UCS mating is done considering the Setup's
directions. That is, the origins of the UCS are made to be concentric, and
the X, Y, and Z directions are the same.
For 4-axis indexed parts, the combination of the .fm's setup's clamp
location and the Top- most table location should translate the stock
such that the index axis of the part is aligned with the table's
rotation axis. If this is not true, the simulation cannot rotate the
machine about the index axis.
The Top-most Table UCS is the most crucial UCS to get right
especially for a turning machine. FeatureCAM's simulation will align
(transform) the whole machine so the the top table UCS is aligned with
the setup (minus the offsets found in Edit Setup - Simulation
Information page). That is, the machine is transformed such that the +X
of the top table UCS is aligned to the setup's +X, +Z to +Z, and the
machine is translated such that the setup's origin minus Simulation
Information offsets is the same point as the top-table UCS origin. With
a turning machine, the +X direction should point towards the main/upper
turret (if there is no upper turret, it points away from the lower turret),
and should have its origin at the center of the main spindle. The
simulation movements take place in this coordinate system. That is, if
you've used Machine Design - Specify Movement to indicate that a
turret slide can move in X, it is the X direction of the top-table UCS that
indicates the direction of translational freedom.
Subspindle
If you are modeling a lathe with a subspindle, the solid representing the
subspindle must be identified. Use the Subspindle command from the
Machine Design menu to identify the solid.
To complete this dialog:
1. Select the solid.
2. Click Apply.
This command allows you to designate which solid represents the
subspindle. In a sense, this is akin to the Top-most Table dialog, that is,
FeatureCAM has to know which solid holds the part when cutting on the
subspindle.
If the stock is ever parted with a cutoff operation, the right-most
stock will become a child of the subspindle solid.
Milling Machines
For most milling machines, the tool location is a single point at the center
of the base of the spindle as shown below. The +Z axis points away from
the part. The choice of the X and Y directions of the UCS are relatively
arbitrary.
Lathe Overview
For lathes, tool locations represent locations to mount tool blocks. The
bottom half of the dialog is specific for turning turrets. If a turret solid has
a local coordinate system (see page 555), multiple tool locations can be
added all at once given the UCS for tool location slot number 1. The UCS
for slot 1 is rotated around the solid's LCS origin and Z axis the given
number of times. For instance, if a turret holds 12 tools, create a UCS for
tool slot #1 with the -Z axis pointing toward the part. Using that UCS,
type the number 12 into the # of tools edit box, and 12 tool locations will
be added to the turret solid. If you add a single tool location to a solid and
click ok, the next time you add a tool location to the same solid, adds a
tool location for slot #2 to the solid. The exception to this rule is when
you add multiple tool locations using the multiple turret locations. In this
situation existing locations are overwritten. Also particular to turning
machines, you must specify the mounting direction of the tool intended
for this tool location. That is, does it specify a tool position on the face of
the turret for cutting on the main spindle, a tool position on the face for
cutting on the subspindle, or an OD mounted tool which could cut in
either direction. The figure below illustrates these kinds of tools.
When adding a tool location for a turret, the Which turret section tells
FeatureCAM if this is a main turret or sub turret, and also specifies
whether the turret is above or below the stock. These settings should
match the information in the .cnc file.
Lathe Details
Follow these steps to complete this dialog for lathes:
1. Select the solid.
2. Click Existing UCS and then select the UCS from the graphics
window or click Create UCS use alignment wizard and then
create the UCS. Remember that the -Z axis of the UCS should
point away from the part you will be cutting.
3. If your solid has a local coordinate system (see page 555) you can
specify additional locations that will be replicated around the local
coordinate system origin by entering a positive number for # of
tools. See the description under lathe overview for more details.
4. Specify the mounting direction as described above.
5. Specify the turret location as either Main upper, main lower,
sub lower or sub upper.
6. Click Apply.
The directions of the tool location UCS may be somewhat confusing
when adding a tool location for a turning machine/turret, but think of it in
terms of a milling machine. An OD turning lathe tool (or a rotary-X tool)
is going to be aligned such that the tool holder is parallel to the -Z axis
of the tool location's UCS. That is, the positive Z axis of the UCS should
point into the turret. This is true for an upper or a lower turret.
Tool location orientations are the same for milling and turning. +Z points
into the quill or turret. In the image below both a machine tool spindle
and lathe turret for illustration purposes only.
There is also an option for X-rotary tools - you can mount them on the
OD of the turret or on the face of the turret. If, when adding a tool
location on the turret, you specified the tool position was on the face of
the turret, you should use the face-mounted option here in this dialog as
well. (The converse is also true, if the OD mounted tool was used as a
tool location, please use the OD mounted X-tool block). Currently, if you
use any left-handed turning tools, you must add a left-handed tool
block. (Eventually, FeatureCAM could use a mirror of the right-handed
tool block). If you cannot mount a tool to the OD of your turret, you do
not need to define an OD mounted tool block. You must, however, have
at least one solid tool block defined for every tool-type that you intend to
simulate.
If you do not define an OD-turning toolblock, FeatureCAM will attempt
to use an OD mounted X-tool block for any OD turning tools. In this
manner, you can generally define a machine with only two toolblocks,
one for OD turning and X-tools, and another for ID boring bars and other
Z-tools. Currently, you cannot use same solid for different types of
toolblocks.
This may be somewhat confusing when adding a tool location to a
toolblock, but think of it in terms of a milling machine. The tool is going
to be aligned such that the tool holder is parallel to the -Z axis of the tool
location's UCS. This is true whether you are considering milling live-tool
holders, OD turning holders, or ID turning boring bars, or Z-aligned
drills. The positive Z direction will point into the tool block.
You need only to define tool blocks for the main turret. Tool blocks with
appropriate transformations will be used for the sub-turret automatically.
Solids are identified as tool blocks by using the Tool block for turret
command from the Machine Design menu.
To complete this dialog:
1. Select the solid.
2. Select the first UCS. This UCS is the mounting location to turret
shown in the figure below. This location will be mated with the
tool location specified for the turret. The dialog labels this location
as: This UCS will match up with the tool location on the
turret.
The tool holder will be positioned with the back of the tool along the Z
axis of the tool location UCS and will extend below the tool block by the
Tool holder width labeled A in the Holder tab (see page 96) of the
Turning tool properties dialog. Additionally, the tool tip is located a
distance of the Tip-to-back Dimension labeled F in the Holder tab of
the Turning tool properties in the local X direction of the tool location
UCS (the turning stock Z direction).
How does
FeatureCAM make its
decisions?
2. Pick feeds and speeds based upon the material being machined.
3. Generate a roughing pass, possibly in multiple Z steps depending
upon the depth of the pocket.
4. Generate a finishing pass.
5. If the pocket has a draft angle, cross-section curve or corner radius,
see Manufacturing draft angles or bottom ra (see page 568)dius
regions.
There are many variations on this process. The process can be fine-tuned
primarily in two places:
the Default Attributes dialog.
to tune only a feature, use the Tools (see page 309), Milling,
Strategy and Misc. property tabs for the feature.
The tooling database also has a large impact on how a boss is machined,
and the feed/speed database helps to determine the feeds and speeds used.
See also pocket feature.
3D manufacturing
3D manufacturing is not as automated as 2.5D manufacturing is.
3D Milling tool selection is governed by the Tool diameter and Tool
end radius settings in the Surface Mill tab of the Default Attributes
(open Default Attributes by selecting Default Attributes in the
Manufacturing menu). FeatureCAM uses that tool to manufacture the
part unless you override the selection on a feature by feature basis.
In areas where the tool fits, the surfaces are milled within the finish
allowance up to the tolerance setting for the surface feature. If the tool is
too large to fit in the more constrained areas of a surface, that area is left
unmilled. If the surfaces contain a gap smaller than the tool diameter, that
gap is bridged by a straight line.
The feature is milled up to the check allowance (see page 402) for any
check surface(s) (see page 277) set with the feature.
Configuring HyperTerminal
HyperTerminal is easy to use to send and receive NC code from the
machine. The first time you use HyperTerminal, set up an icon for
communication with the machine tool. All the parameters for machine
communication are linked to the icon link you created. In later sessions,
you only have to double-click the icon instead of re-entering the
communications settings.
1. Launch Hyperterminal from the Start menu.
2. Double-click the Hypertrm.exe icon. You may or may not see the
.exe extension depending on your computer's configuration.
3. You may be prompted to install a modem. If you don't have one,
click No and proceed with setting up a communications icon.
4. Enter a name for the icon and pick an icon from the group.
5. Click OK.
6. Set the list box at the bottom of the screen to Direct to COM1 (or
whichever port you will communicate through. Click OK and a
communications properties box appears.
7. Your machine tool should have recommended communication
settings. If so, use those settings here.
8. Click OK. HyperTerminal is configured to communicate with your
machine.
You may also need to review how to send and receive files from the
machine.
EZ-UTILS
To run the EZ-UTILS program, double-click the EZ-UTILS icon. When
the EZ-UTILS main screen appears, there are three menus at the top of
the screen: To CNC, From CNC, and Other. These menus contain
commands to communicate with various CNC controls.
EZ-UTILS is an unsupported module that is provided to
FeatureCAM users free of charge. FeatureCAM regrets that it
cannot provide customer support on this application.
To CNC menu
From CNC menu
The From CNC menu shows three commands. These are all used to
accept a file sent from a CNC control to the FeatureMILL system via a
hard-wired cable which is attached to both the CNC control and the
FeatureMILL computer.
Settings menu
Connecting to the SX15 or DX32
Connecting the EZ-UTLS system to BOSS 8, 9, or 10
Connecting to the EZ-Trak SX
Connecting to Heidenhain Interact I and II
Cables
You will need an RS-232 adapter cable to connect the computer to the
communications cable leading to the CNC machine. The adapter cable
may also be used to connect the computer to a serial port expander (ABC
switch box). The adapter cable can be plugged into the COM1 or COM2
port, at the back of the main unit.
The cable can be a 9-pin or 25-pin connector at the computer end.
The manual contains an illustration of the required wiring pattern
for the cable.
Support information
Technical support
Technical support is available through:
Your FeatureCAM reseller
FeatureCAM website
Delcam USA. Send mail to sales@FeatureCAM.com or call 1-888393-6455 for pricing information.
Manufacturing errors
Manufacturing errors occur when FeatureMILL is unable to complete the
tool path generation for a part. When an error occurs, the user is unable to
run any simulation, post to NC code or save NC code. Errors appear
between lines of asterisks (*) in the operation sheet listed after the
operation in which the error occurred. Errors are also displayed in the Op
List tab with a red exclamation point icon in the left margin. Warnings
are also tagged using an exclamation point on a yellow triangle icon.
If an error is detected during toolpath generation, the Code generation
failed dialog is displayed.
If you click Yes in this dialog, the first error in the operations list will be
highlighted. If you click No, the errors will still appear in the operations
list, but you must explicitly ask to step through the errors by clicking
Next Error.
If an error occurs during toolpath generation, three error buttons appear in
a separate toolbar in the left-hand corner of the window to enable you to
read and fix the errors. The buttons perform the following functions:
Selects the next error in the operations list.
Selects the previous error in the operations list.
Provides options for fixing the error that is selected.
If you click Hint while an error is selected in the Manufacturing
Operations Sheet, a series of dialogs appears to help you fix the error.
See also Error hints dialog (see page 576).
Prev Display the previous option for fixing the error. This button is
only for navigating through the errors. Pressing it does not commit you to
accepting this approach to fixing the error.
Next displays the next option for fixing the error. This button is only for
navigating through the errors. Pressing it does not commit you to
accepting this approach to fixing the error.
Action accepts the proposed method of fixing the problem. The specific
types of actions proposed include: Add Tool, Manager, and Override.
If you select this option, FeatureMILL will step you through fixing the
error.
Troubleshooting 3D toolpaths (see page 426)
Warning codes
Code
Cause
Suggested Action
1. Accept Copy tool from
another crib.
2. Create a tool.
3. Override with a different
tool
4. Select a different crib.
5. Modify feature.
See TSD02W.
See TSK12W
See TSK12W
TSJ11W
Grind tool.
Grind tool.
Grind tool.
TSI02W
TPL02W
TPL03W
TPL04W
TPL05W
TPL06W
TPL07W
Undercut detected
TPL08W
TPP01W
1. Accept
2. Modify feature
Error codes
Code
Cause
Suggested Action
1. Copy a tool from drilling
operation another crib.
2. Create a tool.
3. Override with another tool.
4. Select a different crib.
5. Modify feature.
TSB01
TSC01
TSE01
TSF01
TSI01
TSJ01
TSK01 Endmill tool not found for profile See TSA01 action
milling operation.
TSK02 Selected tool not valid for profile
chamfering operation.
TSM0
1
FS001
FS002
FST01
Contact distributor.
Change parameters
Change tool.
Change parameters.
Adjust tool.
Change tool.
DCT0
1
Index
.
.md file 536
<
<ABS-SHIFTY> 135
<ABS-SHIFTZ> 135
<ABS-STEP1> 135
<ABS-ZCLEAR> 135
<ABS-ZRAPID> 135
<ANG-CFEED> 135
<ANG-DPM> 135
<ANG-FPM> 135
<ANG-INVTIME> 135
<ARC-X> 135
<ARC-Y> 135
<ARC-Z> 135
<BOL> 135
<BOT-LALLOW> 135
<CHIP-TAP> 135
<COMP-END> 135
<COMP-MID> 135
<COMP-NUM> 135
<COMP-ON> 135
<COMP-START> 135
<COMP-STAT> 135
<COMP-VAL> 135
<COOLANT> 135
<CW-SPINDLE> 135
<CYCLE> 135
<CYCLE-DONE> 135
<CYCLE-MACRO> 135
<CYCLE-RTRCT> 135
<DATE> 135
<DEEP-TAP> 135
<DEPTH> 135
<DRILL-CPTED> 135
<DRILLING> 135
<DWELL> 135
<EOB> 135
<EXP-LENGTH> 135
<FEED> 135
<FINI-ALLOW> 135
<FIXTURE> 135
<FLOAT-TAP> 135
<FM-NAME> 135
<FSHIFTX> 135
<FSHIFTY> 135
<FSHIFTZ> 135
<HELIX-PITCH> 135
<HOLDER-NAME> 135
<INC-DEPTH> 135
<INC-MACX> 135
<INC-MACY> 135
<INC-MACZ> 135
<INC-STEP1> 135
<INDEX> 135
<INDEXING> 135
<IS-INC-MAC> 135
Index 585
<IS-WORLD> 135
<IS-ZINDXCLR> 135
<LAST-TOOL> 135
<MACH-TIME> 135
<MACRO#> 135
<MCSID> 135
<MIN-STEP> 135
<MOTION> 135
<NEXT-TL> 135
<NO-DRAG-X> 135
<NO-DRAG-Y> 135
<NOSE-RAD> 135
<OFFSET#> 135
<OFFSET-CH> 135
<OP-PASS> 135
<OP-TYPE> 135
<OV-LENGTH> 135
<P1> 135
<PITCH> 135
<PLANE> 135
<PROG-NAME> 135
<RADIUS> 135
<REGION-DATE> 135
<RIGID-TAP> 135
<ROT1-ANSI> 135
<ROT1-MATH> 135
<ROT1-WIND> 135
<ROT2-ANSI> 135
<ROT2-MATH> 135
<ROT2-WIND> 135
<SEG-CMT> 135
<SEGM-ID> 135
<SEQ> 135
<SHIFTX> 135
<SHIFTY> 135
<SHIFTZ> 135
<SIDE-LALLOW> 135
<SPEED> 135
<SPINDLE> 135
<SPND_S_OFF> 135
<SPND_S_ON> 135
<S-RAD> 135
<START-ANG> 135
586 Index
<STEP1> 135
<STEP2> 135
<STEPOVER> 135
<TIME> 135
<TOOL> 135
<TOOL-CMT> 135
<TOOL-DIAM> 135
<TOOL-ID> 135
<TOOL-LENGTH> 135
<TOOL-NAME> 135
<TOTAL-ANG> 135
<TPI-PITCH> 135
<UDF-COMMENT> 135
<UDF-TEXT> 135
<USE-FIXTURE> 135
<WAS-WORLD> 135
<WRAP> 135
<WRAP-Z-DOWN> 135
<WRAP-Z-UP> 135
<X-CEN> 135
<X-CHANGE> 135
<X-COORD> 135
<X-VECTOR> 135
<X-WRAP> 135
<XY-PLANE> 135
<Y-CEN> 135
<Y-CHANGE> 135
<Y-COORD> 135
<Y-VECTOR> 135
<Y-WRAP> 135
<YZ-PLANE> 135
<Z-CEN> 135
<Z-CHANGE> 135
<Z-CHANGED> 135
<ZCLEAR> 135
<Z-COORD> 135
<Z-DOWN> 135
<Z-INC> 135
<Z-INDEX-CLR> 135
<ZRAPID> 135
<ZSURF> 135
<Z-UP> 135
<ZX-PLANE> 135
3
3D Attributes 399
3D leads/step tab 310
3D Manufacturing 570
3D Milling tab and Manufacturing
attributes 314
3D Strategy tab 277
4
4-axis Die feature (Wire) 488
4-axis match curve 492
4-axis Punch feature (Wire) 489
4-axis Side feature (Wire) 489
4-axis turning 521
4th axis indexing - How the clearance
plane is calculated 149
4th axis indexing - Specifying the tool
change position 148
4th axis indexing with a single setup Positioning features 146
4th axis indexing with multiple setups
147
5
5-axis positioning
Overview 465
Saving and opening parts 463
Using a single coordinate system
473
Using fixture offsets 475
A
ABS-DEPTH 135
ABS-SHIFTX 135
ABS-SHIFTY 135
Add surface curve 223
Adding a new material 119
Adding a new tool grade for turning
operations 78
B
Barrel Cams 155
How to Create 156
Index 587
C
Cables 573
Cams 155
Barrel 155
Cap example 191
CATIA V4 direct import 26
CATIA V5 direct import 27
Center point 339
Centerdrills 90
Chamfer mills 85
Change link to arc 223
Change link to line 222
Change point 222
Changing the direction of a segment
of a parting surface 264
Changing the fonts for the reports in
the Manufacturing Feedback
window 65
Check allowance 402
Check allowance (default attribute)
425
Check surfaces 277
Closed lofted solids 243
Common milling tool parameters 84
Comparision of surface surface
intersection and trimm a surface
with a curve 219
Comparison of surface and solid
modeling 232
Completing the multiple fixture part
166
588 Index
Configuration 163
Configuring HyperTerminal 572
Contour passes 508
Contour stock 509
Contouring - wire radius
compensation 505
Contouring Cycle 499
Contouring Cycle Cut Off Option Auto Path 499
Contouring Cycle Overlap 507
Contouring Cycle Retract Option Auto Path 494
Contouring Cycle Stop Length 501
Contouring Cycle Stop Option - Auto
Path 495
Controlling the shape of solid fillet
joints 250
Coolant 281
Coons example 183
Counter bores 86
Counter sinks 86
Counterbore 83
Countersink 83
Creating a constant radius solid fillet
249
Creating a cube solid design feature
246
Creating a form tool 81
Creating a shell solid design feature
254
Creating a solid form core or cavity
faces of a solid 260
Creating a solid from the stock
dimensions 246
Creating a solid modeling operation
from a feature 245
Creating a tombstone machined part
462
Creating holder curves 106
Creating or modifying spindles 112
Creating or modifying tool holders
113
D
Default conical corner 487
Default feed/speed values for turning
124
Defining the base solid in the solid
wizard 237
Delete surface curve 223
Deleted features 457
Deleting a feed/speed table 121
Deleting faces 262
Derive surface from feature 221
Detecting gouges 58
Detecting of gouging with tool
holders and spindles 111
Die feature (Wire) 484
Digitized data import/export options
28
Display a single Z level 66
E
Edge protection 286
Edge rollover 286
Editing a multiple fixture design 163
End angle 100
End Clearance 100
End cut 101
Endmill 83
Endmill tools 87
Error codes 581
Error hints dialog box 576
Example of multiple fixture part 162
Examples of solids of revolution 239
Explode solid 263
Export 31
Exporting DXF Files 37
Exporting IGES Files 38
Extend 201
Extend example 202
Extrude 170
Extrude sample 171
Extrude solid design feature 237
Extrude surface solid design feature
246
EZ-UTILS 573
EZ-UTLS" 573
EZ-UTLS:To CNC 573
F
face 230
Face mills 88
Index 589
Facemill 83
Feature and operation editing using
the oper. list tab 69
Feature location 480
Feature recognition 432
Feature recognition examples 435
Feature recognition surface
requirements 451
Feature to surface example 221
FeatureCAM Addins 427
Features appropriate for millturn 479
FeatureWIRE feature types 483
Feed optimization 130
Feed optimization parameters 131
Feed rates for millturn features 481
Feedrate optimization example 133
Feeds and speeds 118
Fillet 210
Fillet restrictions 214
Finish allowance 510
Finish allowance (3D) 425
First feed override % 412
Five axis machine types 466
Fixture and clamp collision detection
59
Flat 196
Flat example 197
Flat srf support 341
Flowline guide 361
Form Tools 81
Format of digitized files 29
Fourth axis rotation 145
Fourth axis wrapping 143, 150
Full Machine Simulation 536
G
General Import/Export Options 32
General information on manufacturing
errors 575
Generate single program for all setups
481
590 Index
H
Holder tab 96
Holder Type 105
Hole recognition 436
Honeycomb pattern 285
Horizontal + vertical strategy 367
Horizontal + Vertical with Parallel on
Shallow 367
Horizontal + Vertical with Spiral on
Shallow 368
Horizontal Tombstone Machining
458
How a bore feature is manufactured
569
How a cutoff feature is manufactured
570
How a thread feature is manufactured
569
How a turn feature is manufactured
568
How a turned face feature is
manufactured 570
How a turned groove feature is
manufactured 569
How bosses are manufactured 562
How chamfers are machined? 562
How faces are manufactured 563
How federates are scaled 124
How holes are manufactured 561
How is a face groove machined? 563
How is a round machined? 566
How is a simple face groove
machined? 564
How is an ID or OD groove
machined? 564
How pockets are manufactured 564
How rectangular pockets are
manufactured 565
How sides are manufactured 566
How slots are manufactured 567
How step bores are manufactured
567
I
IGES import 29
Iimporting STEP files 27
Import/Export Options 34
Importing 17, 20, 26
ACIS 19
AutoCAD 17
Catia 26
IGES files 29
Mechanical Desktop 17
Parasolid 19
SolidEdge 19
SolidWorks 19, 20
Unigraphics 19
Importing Solidworks files 20
Importing Autodesk Inventor files
20
Importing Catia Files 26
Importing Catia V5 files 27
Importing dimensions from DXF and
DWG files 18
Importing DWG and DXF files 17
Importing IGES files 29
Importing Pro/E files 27
Importing SolidEdge files 28
Importing Solidworks assemblies 20
Include hidden silhouettes 257
Indexing 143
Individual blocks 164
Index 591
K
Keep toolpaths with view change 52
L
Layout 163
Lead in/out plane 312
Lead style (FeatureWIRE) 512
Leave allowance 412, 504
Length (C) 102
Limitations of planar remachining
379
Loading a part program 135
Loading the Example Add-ins that
Were Installed with FeatureCAM
428
Lofted example 188
Lofted solid design feature 242
Lofting 186
M
Machine Design 536
Machining Contouring Cycle 499
592 Index
N
Name 98
NC part program 65
Nested 164, 165
Network Security Version 520
New Crib 76
New cutting condition 517
New feature - pocket recognition
options 454
New feature new strategy 277
New feature strategy 283
New features 457
New material button 98
New Tool 76
Next row stepover 414
Non-solid result 230
O
Offset method 505
Op list tab 65
Operations (FeatureWIRE) 494
Orientation tab 107
Outside sharp corner toolpath 514
Overlap Contouring Cycle 507
Overriding the tool feed or speed for
multiple operations at once 70
Overview - Machining strategies
493
Overview Pocketing Cycle 497
Overview Zig-Zag Cycle 498
Overview of 4th axis wrapping 151
Overview of blend surfaces 226
Overview of combine solids 252
Overview of cut solid with parting
surface 250
Overview of feature recognition 433
Overview of feeds and speeds 117
Overview of fillets 211
Overview of indexing 144
Overview of isoline milling 359
Overview of pencil milling 365
Overview of planar remachining 376
Overview of plunge roughing 368
Overview of projection milling
methods 323
Overview of select core/cavity 258
Overview of shell solid design feature
254
Overview of silhouette curves 255
Overview of solid fillets 248
Overview of solid from 2.5D feature
245
Overview of solids 230
Overview of spindles and toolholders
110
Overview of stitching 244
Index 593
P
Parallel angle 324
Parallel angle (default attribute) 425
Parallel toolpaths 323
Part Compare 45
Part compare example 46
Part compare rest material > 54
Part surfaces 276
Part View for solids 232
Parting surface 263
Parts List 164, 166
Pause on gouge 50
Pausing a toolpath simulation 43
Pencil milling 365
Planar remachining operation 375
Plunge roughing 368
Pocket recognition 441
Pocketing Cycle Overview 497
Polar interpolation in turn/mill 481
Post options FeatureWIRE 138
Post options for Milling 135
Posting your program 135
Power calculation samples 49
Power graph samples/min 49
Preview simulation button 44
Previewing the automatically selected
tool 73
594 Index
R
Radial toolpaths 339
Rapid cut converston tolerance 54
Ream 83
Reams 88
Recognition 432
Recreating tooling and feed/speed
databases if they become corrupt
129
Region example 198
Region of interest 43
Removing curve pieces from a 4-axis
wire curve 492
Removing tool life restrictions on a
tool 116
Reorder 348
Reports 63
Restrictions for tool life management
114
Restrictions of 4th axis wrapping
159
Restrictions of indexing 149
Restrictions of isoline milling 360
Restrictions of plunge roughing 369
Restrictions of projection milling
techniques 325
Restrictions of surface from curve
mesh 186
Restrictions on blend surfaces 228
Retract length 504
Retract Option Auto Path Contouring Cycle 494
Revolved example 174
S
Save NC 138
Save Options 140
Save result files during rapid cut 51
Save STL Dialog Box 38
Saving an NC part program to disk
138
Saving and opening multiple fixture
parts 166
Scallop height 392
Scallop height (default attribute) 425
Scallop height checkbox 391
Scallop height stopovers 426
Selecting core or cavity faces from a
solid 259
Selecting solids 234
Selecting tools by diameter 92
Serial port pinouts 574
Setting a feed or speed value for a
milled operation 124
Setting the length of tool extending
past the holder 111
Shaft Height (A) 103
Sheet 230
Show holder 47
Show pause on gouge dialog 50
Show spindle 48
Show tool animating 52
Side angle 100
Index 595
596 Index
Sweep 175
Trimming 203
Trimming with another surface
216
Untrimming 207
Surface-surface trimming 216
Sweep 175
Sweep example 178
Sweep solid design feature 241
Switches 388
T
Tap 83
Taps 90
Target horsepower 134
Target part tessellation tolerance 55
Technical Support 575
The Stock axis 150
Thread mills 91
Tip angle 94
Tip radius 95
Tolerance (3D) 421
Tolerance (default attribute) 425
Tombstone 462
Adding a part to the tombstone
462
Coordinate systems from already
placed parts 460
Creating global fixture coordinate
systems on the tombstone 461
Creating tombstone document 462
Delete button 463
Edit button 463
Order of operations 462
Overview 459
Reload button 464
Specifying tombstone physical
dimensions 459
Tombstone edit button 463
Tombstone Machining 458
Tool colors 47
Tool cutting tolerance 50
U
Unattached design features 233
Unchanged features 457
Unigraphics Import 19
Untrim 207
Update graphics every ____
machining minutes 54
Use arc ramp in/out 313
Use lead in/out 311
Use linear lead in/out 313
Using a form tool or insert drill for
drilling operations 82
Using an insert drill for both drilling
and boring 83
Using open curves for solid extrudes
238
Using open curves for solids of
revolution 240
Using simulation VCR controls 42
V
Variable taper table 488
Index 597
W
Warning codes 577
Width 98
Wire cutting/threading 514
Wire EDM cut data 119
Wire EDM Taper 486
Wire radius compensation 505
Wire radius compensation - on the
machine 506
Wire radius compensation via the
software 506
Wire visual diameter 56
Working with imported geometry 31
Wrap feature around Z-axis 479
Wrap tolerance 151
Wrapping 150
Wrapping overview 151
Z
Z end 424
Z increment (3D) 424
Z index clearance 149
Z level finish 350
Z level rough 339
Z level slice classification 285
Zig-Zag Cycle - Define Start point
498
Zig-Zag Cycle Overview 498
598 Index