Edgecam Advanced Milling License V2015 R1 Rev 3.0 PDF

Advanced Milling License
Advanced Milling
Copyright
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result in civil or criminal penalties.
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specifically disclaim any implied warranties of satisfactory quality or fitness for any particular
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Page 2 of 181 Rev 3.0 Vero Software Ltd

Advanced Milling
Contents
Copyright ................................................................................................................................2
Contents .................................................................................................................................3
License Restrictions ................................................................................................................6
Example Part Files ..................................................................................................................6
System Requirements and Supported Operating Systems .....................................................6
Edgecam Knowledge Base ..................................................................................................................... 6
Conventions Used in This Guide.............................................................................................7
Terminology ............................................................................................................................................ 7
Pre-Requisites ........................................................................................................................9
Licensing Requirements .......................................................................................................................... 9
Before You Start .....................................................................................................................9
Setting Your Defaults .............................................................................................................................. 9
Advanced Milling ...................................................................................................................10
Plunge Roughing Cycle..........................................................................................................................10
Flow Surface Cycle ................................................................................................................................10
Pencil Mill Cycle.....................................................................................................................................10
Project Toolpath.....................................................................................................................................10
Project Boundary Collapse .....................................................................................................................10
Project Flow Curves ...............................................................................................................................10
Project Circular Pattern ..........................................................................................................................10
Hole Cycle .............................................................................................................................................10
Roughing Cycle .....................................................................................................................................10
Profiling Cycle ........................................................................................................................................10
Plunge Roughing Cycle ........................................................................................................11
Exercise 1 Plunge Roughing ......................................................................................................... 14
Flow Surface Cycle ...............................................................................................................19
Exercise 2 - Flow Surface Cycle ....................................................................................................... 20
Exercise 3 - Flow Surface - Trim Toolpath to Surface Side .............................................................. 23
Profiling Cycle .......................................................................................................................27
Bottom to Top ........................................................................................................................................27
3D Profiling: ...........................................................................................................................................27
Undercut ................................................................................................................................................27
Exercise 4 Rest Profiling Cycle And Bottom To Top ...................................................................... 29
Exercise 5 - Profiling Cycle Undercut Machining and PCI Templates ............................................... 31
Creating Surfaces from Faces ..............................................................................................36
Exercise 6 Wireframe 3D Profiling And Surface From A Solid.ppf ................................................. 37
Pencil Milling .........................................................................................................................47
Exercise 7 Pencil Mill Cycle ........................................................................................................... 48
Project Toolpath Cycle ..........................................................................................................50
Exercise 8 - Project Toolpath Cycle.................................................................................................. 51
Exercise 9 - Advantage of Projecting Toolpaths ............................................................................... 54
Project Boundary Collapse - Finishing ..................................................................................58
Exercise 10 - Project Boundary Collapse ......................................................................................... 58
Project Circular Pattern .........................................................................................................60
Exercise 11 - Project Circular Pattern Cycle ..................................................................................... 61
Project Flow Curve Finishing ............................................................................................................ 64
Exercise 12 Projection Flow Curves Cycle .................................................................................... 66
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Hole Cycle Helical Milling .................................................................................................. 69

Hole Cycle - Back Boring ...................................................................................................... 70
Exercise 13 Hole Cycle Helical and Back Boring........................................................................... 71
Roughing Cycle - Adaptive Feedrates .................................................................................. 79
Exercise 14 Roughing Cycle Adaptive Feedrates ............................................................................ 80
Secondary Z Axis, Quill Support on Horizontal and Vertical Machines. ............................................ 82
Exercise 15 Quill Support Horizontal ............................................................................................. 84
Exercise 15a Quill Support Vertical ............................................................................................... 85
Extracting Silhouette Profiles from Geometry ....................................................................... 87
Exercise 16 Body/Faces Silhouettes ............................................................................................. 87
Exercise 16a Body/Faces Silhouettes 2 ........................................................................................ 88
Angled Head Support ........................................................................................................... 89
Manual Angled Heads ........................................................................................................................... 89
Programmable Angled Heads ................................................................................................................ 89
Feature Finding Holes Inside a Bore .................................................................................... 90
Creating Angled Heads In The Toolstore .............................................................................. 91
Tool Dialog - Angled Head Tab .............................................................................................................. 91
Exercise 17 Angled Head Drill With Parametric Graphics ............................................................. 93
Exercise 18 Angled Head End Mill With Solid Graphics ................................................................ 95
Exercise 19 Manual Angled Head Drilling Internal Holes............................................................... 99
Exercise 20 Manual Angled Head Milling .................................................................................... 103
Workshop 1 ........................................................................................................................ 106
Legacy Surface Creation .................................................................................................... 108
Understanding Entity Dependencies................................................................................... 108
Exercise 1 Entity Dependencies.................................................................................................. 108
Selecting Different Entity Types .......................................................................................... 110
Exercise 2 Entity Types............................................................................................................... 110
Continuous Entities ............................................................................................................. 111
Explode ............................................................................................................................... 111
Exercise 3 Manipulating a Continuous Entity .............................................................................. 112
Use of Interchange Files ................................................................................................................ 114
IGES Import ........................................................................................................................ 114
IGES Import Healing and Conversion Options ..................................................................................... 115
Exercise 4 Loading IGES files- Clean and Heal .......................................................................... 116
Surface Entities................................................................................................................... 118
Rendering Surfaces ............................................................................................................ 119
Creating Primitive Surfaces ................................................................................................ 119
Exercise 5 Creating a Component from Primitive Surfaces ......................................................... 120
Creating Functional Surfaces ............................................................................................. 123
Creating a Surface of Revolution ........................................................................................ 124
Exercise 6 - Creating a Surface of Revolution ................................................................................ 125
Creating a Ruled Surface ................................................................................................... 127
Exercise 7 - Creating a Ruled Surface ........................................................................................... 128
Exercise 8 - Correcting a Problem Ruled Surface .......................................................................... 130
Creating a Tabulated Cylinder ............................................................................................ 132
Exercise 9 - Creating a Tabulated Cylinder .................................................................................... 133

Advanced Milling
Creating a Coons Patch ......................................................................................................135

Exercise 10 - Creating a Coons Patch Surface............................................................................... 136
Exercise 11 Surface Creation Revision Exercise ......................................................................... 138
Creating Flowed Surfaces ...................................................................................................139
Flow Type ............................................................................................................................................139
Exercise 12 - Creating a flowed surface ......................................................................................... 140
Creating Fillet Surfaces.......................................................................................................142
Exercise 13 Fillet Surface ............................................................................................................ 143
Exercise 14 Variable Fillet Surface .............................................................................................. 145
Exercise 15 - Surfaces Fillet and Blends ........................................................................................ 147
Blending Corners .................................................................................................................................149
Manipulating Surfaces ........................................................................................................151
Trimming Surfaces ...............................................................................................................................151
Exercise 16 Basic Trimming of Surfaces ..................................................................................... 152
Exercise 17 - Trimming A Surface Against Another Surface ........................................................... 154
Surface Boundaries ............................................................................................................157
Creating a Surface Boundary ...............................................................................................................157
Exercise 18 - Creating a Surface Boundary.................................................................................... 159
Exercise 19 Using Boundaries To Aid Machining ........................................................................ 161
Full Surface Part Creation ...................................................................................................163
Exercise 20 - Creating A Surface Component ................................................................................ 163
Exercise 21 Surface Project Command ....................................................................................... 170
Preparing An IGES file For Machining ................................................................................173
Exercise 22 - IGES File preparation ............................................................................................... 173
Preparing a Solid Model File For Machining .......................................................................178
Exercise 23 - Placing Surfaces on a Solid Model ........................................................................... 178
Document Revision Control ..................................................................................................................180
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License Restrictions
You may discover that you are unable to work with some of the exercises due to license restrictions.
In order to remove any license restrictions, you can set Edgecam to run in Homework Mode. To
activate Homework Mode, Right click over the CLS in the windows task bar notification area, and
select the option from the menu.
Homework Mode enables the user of a licensed system to run Edgecam with access to all
functionality except for NC code generation.
Homework mode emulates the educational Homework license.
Useful when training for example, to evaluate higher levels of license than currently in
use.
Homework Mode allows you to experience all available licenses in Edgecam. This feature will allow
you to save files. The file extension is not a standard .PPF extension but is an .EPF.
You will not be able to re-load an .EPF file into a licensed version of Edgecam.
You cannot generate CNC data from an .EPF File.

Example Part Files
There are a number of sample part files mentioned within this training guide. This data can be
accessed either from a Training CD or specified folder.
If selecting from a USB Stick this will generally be E:\ Advanced Files\Advanced Milling License
Parts.
Some files may not be opened away from the classroom due to licensing restrictions.
System Requirements and Supported Operating Systems
For the latest up to date information visit http://www.edgecam.com/systemrequirements.
Edgecam Knowledge Base

Tips on FAQ http://www.edgecam.com/faqs/

Advanced Milling
Conventions Used in This Guide

To enable you to use the information in this guide effectively, you need to understand the used in the
guide to represent different types of information.
Buttons on the screen are represented as the button text in bold within square brackets.
For example: Click on [OK].
Keys on the keyboard are represented as bold lettering in between <> characters.
For example: Press <Enter>.
Menu options are represented as a path with the main and sub menus in Bold and
Capitalised and separated with .
For example: Select File Open.
Field names are represented as bold text. And the value to be entered will be
represented by Bold Text.
For example: Enter the value 50 in the Offset field. Or
When prompted for the X, Y or Z values type X100Y50Z0 <Enter>.
Denotes a Left Mouse Button Click
Denotes a Right Mouse Button Click
This is a note. It contains useful or additional information.
This is a reference. It directs you to another part of the user guide.
This is a thought box. It is generally used in exercises and contains a question for
you to consider.
This is a warning, it contains information that you must not ignore.

This is a tip. It is generally used in exercises and offers further advice.
1. This is the first line of a number list item
2. This is the second item of the numbered instructions, which you must
3. Follow in sequence.
This is a list
of items, in which
The order is not important.
Terminology
Whilst reading this manual some of the terminology and terms maybe new to you.
Examples of these are:
Pick = Select = Left Click.
Construction Plane (CPL) = Origin = Datum
Tick or Right Click will confirm your selection/ignore/finish a command prompt.
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Trainee Notes

Advanced Milling
Pre-Requisites
This lesson assumes that you have previously completed training in.
Getting Started
Essential Milling
Standard Milling
Wireframe Essential Design would be advantageous.
You must successfully complete these lessons before beginning work on the
following exercises.
Licensing Requirements
This manual is aimed at users with the Edgecam Advanced Milling (Edgecam_EN3M0-0 or ENPPP-0
for Advanced Production) licence with or without a solid loader license. This is 3rd of 4 levels of
license.
Edgecam License levels are 1.Essential, 2.Standard, 3.Advanced, 4.Ultimate.
Before You Start

Setting Your Defaults
Before starting these exercises ensure that you have set Edgecam to a suitable mill default.
Refer to the Getting Started manual for more information on Defaults.
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Advanced Milling
This manual covers most of the licensed Options covered within the Advanced Milling License for
Wireframe, Surface and Solid machining.
New Cycles introduced at this level are:
Plunge Roughing Cycle
Flow Surface Cycle
Pencil Mill Cycle

Single Pass
Project Toolpath
Project Boundary Collapse
Project Flow Curves
Project Circular Pattern

Extra Functionality within existing Cycles:
Hole Cycle
Helical Hole
Back Boring, Fixed and Retractable Inserts
Roughing Cycle
Adaptive Feedrates
Profiling Cycle
3D Profiling
Undercut Machining
Optimisation, Bottom to Top
Rest Profiling
Other Areas:
Surface from Solid Models
Secondary Z Axis Quills
Angled Head Support
Surface Creation

Advanced Milling
Plunge Roughing Cycle

The Plunge Roughing cycle machines away stock in a series of Z axis (plunge) pecks.
Select Machining Milling Cycles Plunge Roughing.
Here are some key points:

To reduce tool wear and breakage the tool is pulled back from the cutting face before
the Z-retract.
You can incrementally approach the full depth value in a series of plunges. This can be
useful in avoiding swarf clearance problems in tight pockets, for example.
The feedrate can be reduced towards the bottom of the plunge to compensate for the
increased cutting area of angled inserts.
The cycle is not designed around centre cutting tools, and is not intended to be used with them. This
means, for example, that you need to have an approach strategy for pocket regions, such as a pre-
drilled hole.
Plunge Roughing is primarily used for machining pockets and external stock - in deep mould and
dies for example. Long tools gain stability from a cutting force directed up the tool axis rather than as
a side force.
Material is removed as a series of concentric passes. The tool works around the pass with repeated
plunges, stepping sideways by the Recommended Stepover (%) distance between plunges. Once
the pass is complete the tool advances by the Maximum Forward Step distance, to start the next
pass.
There are 3 possible prompts.
Select features to machine, Select the solid model. Tick or Right Click.
Select containment boundary entities (Finish for none), Ignore. Tick or Right
Click.
Select pre-drill points, Tick or Right Click to finish.
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General Tab
The two step values are constrained to maximum values within the cycle to avoid upstands of
material being left between plunges.
Depth Tab
Maximum recommended Forward Distance is limited by insert length.

The cycle is not optimised for centre cutting tools (though you could use such a tool). For example:
The advance between plunges cannot be more than the tool radius.
You need an approach strategy, such as a pre-drilled hole, for pocket regions (you need
a centre point defined)
The depth of a plunge cannot be deeper than the previous plunge within a region (so to
rough out a doughnut you would need to machine the outside working inwards, then the
hole in the middle working outwards).
To reduce tool wear and breakage, a Lead Out move pulls the tool back from the cutting face before
the Z-retract. You can set the angle (from the XY plane) and length of the Lead Out (Approach tab).
Using the Floor Approach settings, the feedrate can be reduced towards the bottom of the plunge to
compensate for the increased cutting area of angled inserts.

Advanced Milling
Approach Tab
The depth of the cycle is the same as other cycles (specified as a value or derived from model
geometry). However full-depth plunges cannot always be made (for example because of swarf
clearance problems in a pocket). In this case you can set a Cut Increment value, when there will be
multiple passes round the profile, each increasing in depth by the cut increment.
The Approach Type is critical to the cycle, you must ensure that the appropriate parameters have
been set. Similar to the Roughing Cycle, consider the definition and shape of the tool.
Contouring Tab
Wireframe Only, as other cycles.
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Advanced Milling
Exercise 1 Plunge Roughing

1. Open the file1 - Plunge Roughing.ppf.
Observe how a single drill cycle has been used to drill two holes that have dis-similar
depths. How has this been achieved?
2. Select Machining Milling Cycles Plunge Roughing. Fill in the modifiers.

General Tab
Model Type: Solid Mill Type: Climb Offset: 1 Tolerance: .1
Maximum Forward Step: 5 Recommended Stepover (%): 60
Stock Type: None

Advanced Milling
Depth Tab
Clearance : 5 Level: 0 Depth: 0 ( all Associative)
Cut Increment and Minimum Pocket Depth: Null
Approach Tab
Approach Type: Pre-Drill Pre-Drill Tool Diameter: 17
3. Select [OK]. Follow the prompts.
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Select features to machine, Select the solid model. Tick or Right Click.
Click.
Select pre-drill points, select the two point entities representing the centre of the holes.
Tick or Right Click to finish.
4. Open the Simulator and inspect the machining.
5. Return to Edgecam.

Advanced Milling
6. Edit the Plunge Roughing Cycle. Using different values in the Recommended Stepover
(%) and Maximum Forward Step.
General Tab
Edgecam will safe guard the Recommended Stepover (%) and Maximum Forward Step
values. You cannot go above the tool radius & 70% respectively. Undo the change.
7. Edit the Plunge Roughing.

Depth Tab
Cut Increment: 12.5, the cycle should Peck the pockets.

10. Edit the Plunge Roughing cycle.
Depth Tab
11. Minimum Pocket Depth: 15, the shallow pocket is only 12mm in depth. You will observe
the cycle will ignore this feature.
12. Re-set Cut Increment and Minimum Pocket Depth to Null.
13. Edit the Plunge Roughing cycle.

Approach Tab
Lead Out, Angle: 45 Length: .25, each toolpath leads off at depth.
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14. Edit the Plunge Roughing Cycle.
Approach Tab
Approach Type: Helix Maximum Plunge Depth: 5 Ramp Angle: 10

17. Undo the last Edit.
Think of reasons why the cycle stops machining the deeper of the two pockets?
18. Edit the Plunge Roughing Cycle.
General Tab
Stock Type: Current Stock
19. Re-save as 1 - Completed Plunge Roughing.ppf.

Advanced Milling
Flow Surface Cycle

Select Machining Milling Cycles Flow Surface.
The Flow Surface cycle follows the flow of the surfaces which is ideal for machining fillets and 3D
surfaces/solids. It is based upon the 5 axis Cycle. The cycle offers the following benefits:
Improved surface finish
Helical support to reduce link moves
Multiple face and surface support
General Tab
Blend between Two Curves: Cuts blend between two curves you specify.
Blend between Two Surfaces: Cuts blend between curves where two surfaces you specify intersect
the drive surface.
Number of Cuts: By default, the distance between cuts is determined by the % Stepover setting
If you specify a Number of cuts, the cutting stops when this value is reached.
Trim Toolpath to Surface Side: When checked for Blend between Two Surfaces strategy the
toolpath will be contained to within the 2 surfaces selected.
Refer to the online Help for all other options.
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Advanced Milling
Exercise 2 - Flow Surface Cycle

1. Open the file 2 Flow Surface Cycle.ppf.
2. Select Machining Mill Cycles Flow Surface.

3. Fill in the modifiers.
General Tab
Strategy: Blend Between Two Curves Mill Type: Climb
Cut Order: Standard Tolerance: .05 Cusp Height: .05
Set appropriate speeds and feeds
Cut Order maybe greyed out. Un-check Helical on the Control Tab.
You cannot have both a %Stepover and Cusp Height.
Depth Tab
Clearance: 15 Associative: Checked

Advanced Milling
Control Tab
Helical: Checked
Leads & Links Tabs

Ignore
4. Select [OK]. Follow the prompts
Select drive surfaces, Pick all the Radii in the loop below. Tick or Right Click.
Pick first Curve, Pick all the top edges of the Radii. Tick or Right Click.
Pick second Curve, Pick all the bottom edges of the Radii. Tick or Right Click.
Select check surfaces, Ignore. Tick or Right Click to finish.
Although Features can be created and machined, this is not necessary.
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Advanced Milling
5. The Flow Surface toolpath will appear.
6. Enter the Simulator and check the toolpath.

8. Save as 2 Completed Flow Surface Cycle.ppf.
Note the ability of the cycle to machine over Holes or gaps without the need of Caps
or other surfaces.

Advanced Milling
Exercise 3 - Flow Surface - Trim Toolpath to Surface Side

The next exercise will show how to restrict toolpath without the need of a containment boundary.
1. Open the part 3 Flow Surface Trim Toolpath To Surface Side.ppf.
2. Select Machining Milling Cycles Flow Surface.

3. Fill in the modifiers below.
General Tab
Strategy: Blend between Two Surfaces Mill Type: Climb Tolerance: .1
%Stepover: 15
Depth Tab
Clearance: 5 Associative: Checked
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Control Tab
All Un-Checked
Leads Tab
Type: None
Links Tab
As below

Advanced Milling
Select drive surfaces, Pick the Domed face. Tick or Right Click.
Select check surfaces, Ignore. Tick or Right Click.
Select first edge surfaces, Pick the left hand face. Tick or Right Click.
Select second edge surfaces, Pick the right hand face. Tick or Right Click to
finish.
5. The resultant toolpath machines too much of the component.
6. Edit the Flow Surface cycle.

Control Tab
Trim Toolpath to Surface Side: Checked
7. The Toolpath now trims back to the side of the Feature only.
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Advanced Milling
This works the same with surfaces, the toolpath will only be applied to the side of
the toolpath Normals.
8. Check the toolpath in Simulator.

9. The toolpath is not correct as it gouges the part.
View comparison compares the Stock against the Solid.

11. Expand the Flow Surface Cycle and Edit the Check surfaces(1).
Select check surfaces, Pick the solid Javelin(1/2). Tick or Right Click.
12. Regenerate the cycle.
13. Check the Toolpath in Simulator.

14. The toolpath is now correct.
15. Save as 3 Completed Flow Surface Trim Toolpath To Surface Side.ppf .

Advanced Milling
Profiling Cycle
New options at Advanced level are listed in detail below.
Depth Tab
Bottom to Top: Check to cut the lowest level first and work upwards.
Control Tab
3D Profiling: Check this if you want to machine Wireframe profiles that curve in three dimensions, or
that are in a plane that is not parallel to the CPL. Ideal for chamfering 3D Parts.
Undercut: Check this if you want to machine undercuts. This is only available when you are using an
undercutting tool (T-Slot or Lollipop) that has as an Undercut Distance specified. You also need
Model Type set to Surface or Solid.
You should leave this unchecked unless you are actually machining undercuts, to minimise
processing times. With Undercut checked, the Rest Profiling tab settings become unavailable.
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The toolpath will undercut up to a maximum of the specified Undercut Distance. This means that
where the geometry demands a larger undercut, passes are still made but material is left un-
machined.
These parameters are used to calculate where material could not have been removed by previous
machining; for example in sharp corners where large tools cannot reach, or which have been
excluded by the Minimum Radius setting. This is mainly for 2D situations, as in this example where
the tool rapids down to machine just the corners of the profile (which the previous tool was too large
to reach into).
Previous Tool Diameter: The tool diameter on which to calculate the leftover material, to be
removed by the rest profiling. Leave or set this to blank or 0 if you do not want to rest profile.
Previous Minimum Radius: The Minimum Radius value on which to calculate the leftover material,
to be removed by the rest profiling. Leave or set this to blank or 0 if you do not want to rest profile.
Note
The values need not apply to any actual machining, they are valid even if there is no
previous machining in the sequence.
You cannot rest profile if Undercut is checked in the General tab (the Rest Profiling tab
settings become unavailable).
There is only one pass round the profile. If this does not remove all the rest material (for
example if the rest tool radius is too small), this material is left in place.
The rest cycle will start machining where the 'previous tool' was calculated to stop being
able to follow the profile. As this calculation is affected by the cycle tolerance, you might
want to specify an overlap onto the previous machining, using the Start and End profile
extensions (cycle dialog's Start/End tab).

Advanced Milling
Exercise 4 Rest Profiling Cycle And Bottom To Top

1. Open the part '4 Rest Profiling Cycle And Bottom To Top.ppf'. A Sequence has
been created and a Profiling cycle applied.
2. Select Rapid Result.
3. Use View Comparison to see the material left from the Profiling cycle.
4. Use the Enhance Zoom to get a clearer view of the corner area.
6. Copy the existing Profiling Cycle.
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7. Edit the copied Profiling Cycle.
Control Tab
Rest Profiling: [Edit] Previous Tool Diameter: 8
8. Select [OK].The Toolpath now only machines in the corner areas left by the previous
cycle.
If the toolpath re-machines an areas that are not required, create a containment boundary.
9. Check the toolpath in Rapid Result.

11. Edit the copied Profiling Cycle.
Depth Tab
Bottom To Top: Checked
12. Select [OK]. The Toolpath now starts at the lowest point in Z.
13. Resave as 4 - Completed Rest Profiling Cycle And Bottom To Top.ppf'.

Advanced Milling
Exercise 5 - Profiling Cycle Undercut Machining and PCI Templates

1. Open the file 5 Profiling Cycle Undercut Machining and PCI Templates.ppf.
2. The component has already been part machined. A Profiling cycle is in place machining a
port requiring undercut machining. Note that Undercut is checked on the Control Tab in
the cycle but there is no undercut machining.
3. Edit the 16.0 MM DIA LOLLIPOP CUTTER. You will notice that the Undercut Distance
has been omitted. Without a value here the cycle will not undercut.
More Tab
Undercut Distance: 2
How has this value been reached?
4. Select [OK].
5. Take into the Simulator to check the Toolpath.

6. The other Port Requires Profiling Undercut machining also.
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7. Select Machining Move Index.

General Tab
Position To, Name: Top
Safety Zone, Clearance Type: Radius Distance: 400
8. As the containment boundary, Hole feature, on the first Profiling cycle is on a different
CPL the cycle will not copy. To ensure that we have the same settings in the next cycle
we shall create a PCI template of the first cycle.
Modifier values are modal in cycles only when you initially set the cycle. Subsequent edits are
not modal. Modality settings can be changed in File Preferences.
9. Right Click over the Profiling Cycle in the Sequence Window and select PCI
Template.
PCIs/ Java script are an unlicensed part of Edgecam. Any command in Design
and/or Manufacturing can be recorded and replayed to repeat a certain process or a
number of commands. PCI Templates is one such method of capture. Parts can
then be run from Spread sheets from to Design to a manufactured part and CNC
code with no user input.
Ask your Trainer what PCIs and Strategy Manager can do for you in automating your
manufacturing process.

Advanced Milling
10. Select [Browse] and on the Desktop create a file name called Profiling and select
[Save].
11. Select [OK].
12. Left Click Profiling. Select [OK].
When the PCI is run, the profiling cycle dialog window will open allowing edits if required. If
not selected, the command prompts only will be shown.
13. Select File Macros Run. [Browse] for the Profiling.pci on the Desktop.
Check that the File Types is set correctly.

14. Select Run.
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15. The Profiling cycle window will appear. As the Port is at a different Level and Depth,
change the values.
Depth Tab
Level: 0 Depth: 0, Both Associative
Select features to machine, Pick the Solid model. Tick or Right Click.
Select containment boundary entities (Finish for none), Pick the 1: Hole Feature.
Tick or Right Click.
Select point/line for nominated start point (or Finish), Ignore. Tick or Right
Click to finish.

Advanced Milling
17. A Profiling Cycle will be placed on the second port.
18. Note the many lead movements on the top of the port. The Profiling cycle is not suitable
for this area.
Which cycle is more suitable for the machining the Radius and Cone?
19. Edit the second Profiling cycle.
Depth Tab
Level: -32 Associative: Checked Depth: -44 Associative: Un-Checked
20. Select Machine Move to Toolchange.

21. Pick a suitable Ballnose cutter and create a Flow Surface cycle to finish machine the
radius and Cone at the top of each the port.
22. Save as 5 Completed Profiling Cycle Undercut Machining and PCI
Templates.ppf.
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Advanced Milling
Creating Surfaces from Faces

The Copy from Surface option can be found in the Features Geometry. It allows you to create
surfaces from the faces of solid models.
It is useful when working with surface cycles e.g. Parallel Lace.

Gives you the ability to trim or extend these surfaces to improve or help define a 5-Axis
cycle.
Used in conjuction with other Surface commands (Surface menu) an existing solid body can be used
and manipulated to correct areas of the toolpath where the original solid model is not available.

Advanced Milling
Exercise 6 Wireframe 3D Profiling And Surface From A Solid.ppf

The component has a Parallel Lace cycle already applied. The holes were laced over as Caps were
found when Feature Finding Hole Features. These were selected along with the solid model. The
cycle though is limited to machining the exact surface. The Toolpath can only be extended in the
direction of cut using Leads. This example will show extracting a surface from a solid and resizing
this for machining
1. Open the file 6 - 3D Profiling And Surface From A Solid.ppf.
2. Select Setup Features Geometry.

General Tab
Copy From: Surface
3. Select [OK]. Follow the prompt.
Select individual faces. Select the top face of the solid. Tick or Right Click to
finish.
4. Show only the Surface Layer. A trimmed surface has been extracted.
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5. Select Setup Edit Explode. Select [OK] and follow the prompt.
Entity to explode. Select the Trimmed Surface. Tick or Right Click.
6. Select [OK]. The Surface will be exploded back to its original size.
7. Turn off the Rendering , select and Delete the 5 Surface Curves.
If you do not delete the Surface Curves when the Surface is subsequently trimmed, it will trim
back to these entities.

Advanced Milling
8. Show Only the Geometry & Surface Layer.
9. We require an arc with which to trim the surface against.

10. Select Features Geometry.
General Tab
Copy From: Edges Create: Individual Curves

2D Snap: Active CPL: Top Level: 50
Select an edge to create a line, arc or continuous. Select the Edge on the base of
the solid. Tick or Right Click.
12. An arc will be created at Z50.
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13. We will repeat the above command to create our 3D Wireframe geometry.
14. Select Features Geometry. Follow the Prompt.
General Tab
Copy From: Edges Create: Individual Curves
2D Snap: In-Active
Select an edge to create a line, arc or continuous. Select the Edge on the top of the
solid. Tick or Right Click.
16. As the 2D Arc is size of the solid we need to edit this to make it larger. Double Left
click on the Arc.
General Tab
Radius: 54
17. Select Setup Surfaces Extend.

General Tab
Factor: .1

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18. Place in the Top view. Follow the prompt.
Select surface on edge to be extended. Select each edge in turn to extend. Tick
or Right Click to finish.
19. Select Setup Surfaces Trim Surface. Select [OK]. Follow the prompt.
Select surface to trim. Select the surface anywhere inside the Arc.
Select entities (or Finish). Select the Arc. Tick or Right Click twice to finish.
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20. We now have an oversize surface to machine.
21. Show the 2 Toolpath Layers.

22. Edit the Parallel Lace cycle in the Sequence Window.
Re-Pick Surfaces. Follow the prompt.
Select surfaces to machine, Deselect All existing Picks then Pick the new Trimmed
Surface. Tick or Right Click.
Re-Pick Boundary. Follow the prompt.
Select containment boundary entities (Finish for none), De-select All existing Picks
, Tick or Right Click to finish.
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23. Select [OK].
24. The Tool path now extends beyond the solid.
25. We shall now place a chamfer around the top edge of the part.
26. Select Machining Mill Cycles Profile Mill.

27. Fill In the modifiers.
General Tab
Model Type: Wireframe Mill Type: Climb
3D Profiling: Checked Offset: -2
Depth Tab
Clearance: 5 Level: 0 Depth: -2.5 Cut Increment: Null

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Control Tab
3D Profiling: Checked
Ignore all other Tabs

28. Select [OK]. Follow the prompts
Select line/arc/continuous/curve as profile, Select the 3D Continuous. Tick or

Right Click.
You may find it easier to pick by hiding certain layers or Toolpaths.

Select new start point for profile chain (or Finish). Ensure the arrow is on the outside
of the profile. Tick or Right Click.
Select start/end point to alter, ignore. Tick or Right Click.
Click.
29. Show the Stock Layer.
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30. Check the toolpath in the Simulator.

32. Save as 6 Completed 3D Profiling And Surface From A Solid.ppf .

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Pencil Milling
The cycle can be found here Machining Mill Cycles Pencil Mill.
You use the Pencil mill cycle to clean up material remaining on a surface from a previous finishing
cycle, for example the cusps left at the end of a parallel lace cycle. It consists of a single pass along
internal surface edges and intersections.
You can select any number of surfaces, STL models or solid models for this cycle which will then
detect all internal surface edges and intersections and place a toolpath at that point. The order of
machining should, where possible, try to link intersections together to form a continuous path. This
will have the effect of keeping the tool down on the surface.
A shortest path between successive curves will be taken to reduce the length of non-cutting moves
As part of the data input for this cycle, you will be able to define containment boundaries. Any pencil
toolpath outside specified containment boundaries will be discarded and those that cross the
boundaries will be trimmed to their edges.
You can only use Ballnose or Bullnose cutters for a Pencil mill cycle.
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Exercise 7 Pencil Mill Cycle

1. Open the component '7 - Pencil Mill.ppf'. You can assume that part has been
thoroughly machined with both Rough and Finishing cycles, however there is still material
left behind on the internal edges and intersections.
2. Select Machining Milling Cycles Pencil Mill.

3. Fill in the modifiers below.
General Tab
Mill Type: Climb Tolerance .05
Depth Tab
Clearance: 45 Level & Depth: <None>
Control Tab
Ignore
Lead Tab
Type: None
Links Tab
Ignore
4. Select [OK] and follow the prompts.

Advanced Milling
Select surfaces to machine. Select the solid model. Tick or Right Click.
Select containment boundary entities (Finish for none). Ignore. Tick or Right
Click to finish.
5. A Toolpath will be placed on the solid.
6. Enter the Simulator and check the toolpath.

7. Return to Edgecam
8. Save as '7 - Completed Pencil Mill Component.ppf'.
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Project Toolpath Cycle

You can finish 3D parts by projecting an existing 2 D toolpath.
The Toolpath can be projected onto Solids and Surfaces.

The command can be found in Machining Mill Cycles Project Toolpath.
The Project Toolpath cycle finishes surfaces by projecting the toolpath from an existing cycle onto
them.
The existing cycle:
Must be an Area clear, Lace, Profile, Slot, Face mill, Text, Roughing or Profiling.
Must have a single pass toolpath; that is it cannot have a Cut Increment set. This would
lead to unpredictable results.
Must have its Model Type option set to Wireframe (applies only to Roughing and
Profiling cycles).
With the toolpath defined by the existing cycle, the Project cycle defines the approach strategy and
the depth parameters. The project toolpath cycle incorporates automatic gouge avoidance. It defines
the approach strategy and the depth parameters.
General Tab
Offset: The toolpath offset from the surface. Note that this is a three dimensional offset
from the surface. The offset can be negative but the value must be smaller than the
radius value of the tool.
Refer to the Help file for other modifiers.

Advanced Milling
Exercise 8 - Project Toolpath Cycle

In this exercise, you will machine text onto a surface, which looks like this:
1. Open the file 8 - Project Toolpath Cycle.ppf.
2. Select Machining Milling Cycles Text and fill in the modifiers.

Depth Tab
Clearance: 30 Level: 25 Depth: -3
3. Select the [OK]. Follow the prompt.
Select first text entity to machine, pick the text. Tick or Right Click to finish.
4. A Text cycle will be created.
5. Select Machining Milling Cycles Project Toolpath. Fill in

the modifiers.
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General Tab
Offset: Null Tolerance: .05
Depth Tab
Clearance: 10 Level and Depth: <None>
Control Tab
Minimum Contact Angle: Null Maximum Contact Angle: Null
Lead Tab
Type: None
Links Tab
Ignore
6. Select [OK]. Follow the Prompts.

Advanced Milling
Select surfaces to machine, pick the Ruled surface. Tick or Right Click to
finish.
7. The toolpath will be projected onto the surface.
Try placing a large negative value in the Depth modifier. Do you think the toolpath will
move through the surface?
8. Edit the Project Toolpath cycle and try experimenting with different Offset values and
settings on the Lead and Links tabs.
9. Save as '8 - Completed Project Toolpath Cycle.ppf'.
10. Open the file 8a - Project Machining.ppf. Experiment with the Cycles modifiers.
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Exercise 9 - Advantage of Projecting Toolpaths

Like all Edgecam 3D/Surface machining toolpaths the Project cycle is completely Gouge Free. Due
to Edgecams machining engine (triangulation method) the tool cannot penetrate the surfaces.
The following example demonstrates this theory and allows the user to understand the advantage in
using a projected toolpath over a 3D Wireframe cycle.
The Slot Cycle and Profiling cycle allow the use of 3D wireframe geometry.
1. Open the part file called 9 Wireframe 3D and Project Toolpath Comparison .
2. Two Sequences have been created, one by use a 3D Profiling cycle, the other, by using a
3D Slot cycle. These show the limitations of these cycles.
3. Set the View to Front. Select Properties.
Clipping Tab
Y Level, Negative : Checked

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4. Simulate the toolpath in Edgecam. Note how the tool gouges the solid.
5. Check the Toolpath in the Simulator.
Ensure The Project Machining is the active Sequence.
7. Select Machining Mill Cycles Slot and fill in the modifiers.

General Tab
Strategy: 2D
Depth Tab
Clearance: 75 Level: 70 Depth: 0
Lead & Link Tabs

Ignore
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Pick features to machine, Pick the Plain Line. Tick or Right Click to finish.
Select new start point for profile chain (or Finish), ignore. Tick or Right Click.
9. Select Machining Milling Cycles Project Toolpath. Fill in the

modifiers.
Depth Tab
10. Select [OK]. Follow the Prompts.
Select the surface to machine, pick the solid model. Tick or Right Click to
finish.
11. The Projected toolpath maintains a consistent contact on the surface of the component.
12. Check the toolpath in the Simulator.

14. Save as 9 Completed Wireframe 3D and Project Toolpath Comparison .

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Project Boundary Collapse - Finishing

The project boundary collapse cycle is similar to the project toolpath cycle in that a concentric
machining cycle is projected to a 3D Component. However, project boundary collapse can produce
the toolpath automatically and project it in a single step. Furthermore, the cycle also supports
containment boundaries.
An example of the cycle is shown here:
Exercise 10 - Project Boundary Collapse

1. Open the file 10 Project Boundary Collapse.ppf.
How were the Wireframe 2D profiles created?
2. Select Machining Milling Cycles Project Boundary Collapse.
3. Set the following modifiers.

General Tab
%Stepover: 15

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Depth Tab
Control, Lead & Links Tabs

Ignore
Select surfaces to machine, Select the solid model. Tick or Right Click.
Select line/arc/continuous/curve as profile. Chain the single wireframe profile.

Tick or Right Click.
Select containment boundary entities (Finish for none). Ignore. Tick or Right
Click.
5. The Projected Toolpath will be created.

6. Repeat the process by creating a second cycle for the remaining profiles. On this
occasion select both profiles at the same time.
7. Save as 10 Completed Project Boundary Collapse.ppf .
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Project Circular Pattern

You can project circular cycles onto any 3D Shape (internal or external) in order to achieve a high
finish with minimum input, when machining round bosses or pockets.
Pre-defined projection machining techniques increase the speed of programming as well as
providing the most appropriate pattern for the contour of the model.
The project circular pattern cycle allows you to select one of three strategies to create the following
toolpaths:
Radial strategy Concentric strategy Spiral strategy
This is an example of a radial toolpath:
The Project Circular Pattern cycle can be found in Machining Milling Cycles Project Circular
Pattern.
Some of the main options are:

General Tab
Strategy: Determines what circular pattern to project. Select between.
Radial: Control the finish by specifying either a Planar Distance, or a Stepover
representing the distance at the outer edge between adjacent cuts, or the Step Angle
between cuts. The three options are mutually exclusive.
Concentric: To control the finish, specify either a Planar Distance or a Stepover
representing the distance between adjacent cuts.
Spiral: To control the finish, specify either a Planar Distance, or a Stepover that
represents the distance between adjacent cuts. The two options are mutually exclusive.
Start: indicates whether the toolpath start at the inside or outside arc.
Start Angle: the angle at which to start the cycle.
End Angle: restricts the cycle to a segment of the circle.
Direction: indicates whether to cut clockwise or anti-clockwise.
Constant Cut: check this option if a segment has been specified using the end angle parameter.
The resulting effect depends on which strategy has been selected.
Step Angle: (radial strategy only) the angle between cuts for a radial strategy.
Advanced Milling
Exercise 11 - Project Circular Pattern Cycle

In this exercise, you will compare the different techniques you can use to machine a surface
component.
1. Open the file 11 - Project Circular Pattern.ppf'. The outer arc entity is concentric to
the model.
2. Select Machining Milling Cycles Project Circular Pattern. Fill in the

modifiers.
General Tab
Strategy: Radial Start: Inside Direction: Clockwise % Stepover: 10
Depth Tab
Control Tab
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Ignore
Lead Tab
Type: None
Link Tab
Ignore
3. Select [OK].Follow the prompts.
Select the surfaces to machine, Pick the solid. Tick or Right Click.
Select outer arc, select the arc at the top of the component.
Select inner arc, ignore. Tick or Right Click.
Select containment boundary entities (Finish for none), ignore. Tick or Right
Click to finish.
4. The toolpath will be placed on the solid.
5. Try placing values in to the Start and End Angle modifiers on the General tab. What
effect does this have on the resulting toolpath?
6. Show inner Arc Layer in the Layers window.

Advanced Milling
7. Expand the Project Circular cycle and edit the Inner arc. Follow the prompt.
Select inner arc, Pick the inner arc. Tick or Right Click.
9. Try machining this component again, this time using the concentric or spiral projection
strategies.
10. Experiment with other modifiers.
Does this make any difference to the surface finish?
11. Save as 11 Completed Project Circular Pattern.ppf'.
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Project Flow Curve Finishing

The cycle can be found in Machining Milling Cycles Project Flow Curves.
The Project Flow Curves cycle lets you specify two geometric entities to guide the direction of
machining.
The first pass follows the first selected curve (when viewed from above) and the final pass follows
the second selected curve. Intermediate passes gradually blend from the first curve to the second.
You must select two entities from which to generate the toolpath. Valid entity types are lines, arcs,
curves and continuii.
The Start point of the cycle is taken from the nearest end of the first selected entity. Once this point
has been reached, the tool feeds directly along the first entity. The number of passes is calculated
from either the specified % Stepover or a Planar distance, but the final pass always feeds directly on
the second entity (even if this is an uneven cut). The two options are mutually exclusive. The
Stepover value specifies the maximum gap between adjacent stripes in the XY plane. However, this
means that the gap will be smaller than specified in some places.
You can control the link move between toolpath stripes using Constant Cut. When this box is
unchecked, the toolpath lace cuts between stripes. When the box is checked, the tool always cut in
the same direction as the first entity and retracts clear at the end of each stripe
This cycle is particularly useful if the grain of the surface being machined is important.
General Tab

Advanced Milling
Cut Across: Check to change the direction of the cut to be between the ends of the
curves. Each straight-line stripe links one curve to the other proportionally along the
length of the two curves. The link moves between stripes follow the selected entities.
Constant Cut: Check this box if a segment has been specified using the End Angle
parameter. The effect depends on which Strategy has been selected.
You cannot chain the flow entities
The end at which you click on the first curve entity defines the start point of the cycle. The first
entity you select defines the direction of the first pass and the second entity you select
defines the direction of the final pass.
You must slect near the same end of both curve entities, otherwise the resulting toolpath is twisted
between the two curves. For example, if you select the following curves by clicking at the points
shown, Edgecam creates the following toolpaths:
Source entities Twisted toolpath Source entities Correct toolpath

If required, select the boundary entities to which you want to constrain the cycle.
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Exercise 12 Projection Flow Curves Cycle

In this exercise, you will machine an elbowed shaped component.
1. Open the file '12 Project Flow Curves.ppf'. This is an aerofoil component design
with two curve entities. The two curve entities were created by using the Surface
Boundary command.
2. Select Machining Milling Cycles Project Flow Curves. Fill in the modifiers.
General Tab
% Stepover: 15
Depth Tab
Clearance: 3 Level and Depth: <None>
Control Tab
Ignore
Lead Tab
Type: None

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Links Tab
Ignore
3. Select [OK].Follow the prompts.
Select the surfaces to machine, Pick the solid. Tick or Right Click.
Select first entity to flow along (cycle start point), select the lower Continuous.
Select second entity to flow along, select the upper Continuous.
Click to finish.
4. The toolpath will be placed on the surface.
What happens if you click on different ends of the flow curves?
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5. Expand the cycle and Edit the Boundary pick.
Select containment boundary entities (Finish for none), Pick the closed continuous.
7. Edit the cycle again and experiment with the following.

Cut Across Constant Cut %Stepover
8. Save as '12 Completed Project Flow Curves.ppf'.

Advanced Milling
Hole Cycle Helical Milling

The Hole cycle is capable of the Helical milling of a Hole Feature. There is full post processor
support for this in the .CGD file for the Mazak Tornado G130 cycle and the TNC cycle DEF 208. This
includes a chamfer option with a different pitch feed. This reduces the amount of tool changes
required to finish a Hole Feature.
General Tab
The Helical option will only appear when a milling cutter is selected.
Helical Tab
Included Chamfer Angle: A chamfer angle for the top of the hole. Leave this blank if you do not
want a chamfer.
This is unavailable with Model Type set to Solid (General tab), as in this case the chamfer geometry
can be taken from the hole feature.
Canned cycle output is only supported if this setting is 45 (otherwise longhand is used).
Depending on the code generator, the chamfer portion the toolpath is output as either:
A series of 180 arcs, of reducing radius.
A series of straight lines approximation.
Chamfer Dia: The diameter at the top of the chamfer. Leave this blank if you do not want a chamfer.
This is unavailable with Model Type set to Solid (General tab), as in this case the chamfer geometry
is taken from the hole feature.
Tool Corner Lead Angle: An additional chamfer angle on the tool end face (over and above the
tool's standard parameters). This is unavailable if the tool has a corner radius set.
Tool Corner Lead Width: An additional chamfer width on the tool end face (over and above the
tool's standard parameters). This is unavailable if the tool has a corner radius set.
Chamfer Pitch: The pitch of the helical toolpath when cutting the chamfer (if defined).
Hole Pitch: The pitch of the helical toolpath when cutting the main hole.
For threaded Hole features the pitch of the thread is always used, and this setting is ignored .
Bottom Finishing: If checked, the tool makes a complete revolution at Depth without advancing, to
flatten the bottom of the hole.
For threaded Hole features, this setting is overridden to unchecked, and you see a warning.
If unchecked, the tool starts to retract immediately after reaching depth.
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Hole Cycle - Back Boring

With a valid tool selected the Hole Cycle can support the Back Boring and Back Facing Cycles.
This allows the use of 2 new tools that can now be created and stored within Toolstore. The Back
Boring tools can either be a Fixed insert which would mean the tool would enter the hole with the
spindle stopped and an offset applied to in X or Y to clear the bore. Step back onto centre and
machine. The retractable insert can be sent straight down the centre of the bore as centrifugal forces
keep the insert clear of the bore whilst rotating in the opposite direction to that for cutting. There is
full Post Processor support For the TNC Cycle Def 204 and the machining of Features
Bottom Clearance: The height (Z value) to which the tool plunges after feeding through the hole,
and where it makes its sideways move onto the centreline (for non-retracting tools) and starts
rotating, prior to cutting the back counterbore.
Bottom Level: A reference height (Z value) from which to measure the Depth value (so with an
associative Depth set this setting has no effect).
Bottom Depth: The height at which the back counterbore cutting is to stop. At this Z level the tool
stops rotating and makes the Back off Relief move.
Back Off Clearance: After reaching the Bottom Depth, the tool next moves downwards by this
amount, before the sideways relief move (for non-retracting tools) and retract back up the hole.

Advanced Milling
Exercise 13 Hole Cycle Helical and Back Boring.

1. Open the part 13 Hole Cycle Helical and Back Boring.ppf.
2. Select Machining Holes. . Fill in the modifiers.

General Tab
Model Type: Solid Strategy: Helical
Depth Tab
Clearance Associated to: Feature Depth Associated to: Full Hole Depth
Clearance: 5 Level: 0 Depth: -2 All values are Associative
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Control & Filtering Tabs
Ignore
Helical Tab
Chamfer Pitch: .1 Hole Pitch: .5 Bottom Finishing: Checked
3. Select [OK] and follow the prompt.
Select location for hole centre, Pick both hole features. Tick or Right Click to
finish.
4. A helical toolpath will be created.
5. Take into the Simulator and check for collisions.

7. Move to Toolchange.

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8. Select Machining Toolstore and create/select a 25mm Back Bore Fixed tool
from the Back Bore Tools filter on Hole tab.
9. Set the following modifiers if the tool does not exist.

General Tab
Tool Description: 25mm Back Bore Fixed Comment: 25mm Back Bore Fixed
Geometry Tab
Diameter: 25 Tip Angle: 5 Flute Length: 5
Teeth/Flutes: 1 Corner Radius: .2 Min Entry Diameter: 17
Insert Cutting Height: 10 Shank, Length: 70
Shank, Diameter: 10 Insert Type: Back Bore
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Mounting Tab
Z Gauge: 113 Graphic: ISO40-10mm Weldon.csv Offset: 50
10. Place the tool in Position 2.
11. Select Machining Holes.

General Tab
Model Type: Solid Side Clearance Direction: X+ Side Clearance: 1
Depth Tab
Clearance: 5 Level: 0 All Associative

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Ignore
Back Bore Tab
Back Off Clearance: -1 Bottom Clearance: -5 Bottom Level: 0
Bottom Depth: 0 All Associative
Select location for hole centre, Pick the left hand Hole feature. Tick or Right
Click.
13. The back Counterbore will be machined.
14. Take the part into Simulator .

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15. When Simulating here you will see the tool visually collide with the component as the tool
rapids to its start point below the component. However collision checking is switched off
as the tool doesnt actually look like this in real life, only when it rotates.
16. Return to Edgecam
17. Move to Toolchange.
18. Select Machining Toolstore and create/select a 25mm Back Bore Retract tool
from the Back Bore Tools filter on Hole tab. If the tool does not exist copy the 25mm
Back Bore Fixed tool.
General Tab
Tool Description: 25mm Back Bore Retract Comment: 25mm Back Bore Retract
Geometry Tab
Retractable Insert: Checked Insert Type: Back Facing

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19. Select [OK] and place the tool in Position 3.

General Tab
Ignore
There are no Side Clearance modifiers with a retractable insert

Depth Tab
Clearance: 5 Level: 0 All Associative

Ignore
Back Bore Tab
Bottom Clearance: -5 Bottom Level: 0 Bottom Depth: 0 All Associative
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Select location for hole centre, Pick the right hand Hole feature. Tick or Right
Click to finish.
22. The back Counterbore will be machined.
23. Check in the Simulator.
24. Exit the Simulator.

26. Save as 13 Completed Hole Cycle Back Boring.ppf.

Advanced Milling
Roughing Cycle - Adaptive Feedrates

Adaptive: Adjusts the feedrate to even out loading on the tool. For example in a narrow channel the
loading could be higher as the actual Stepover increases above the specified Stepover value; in this
case the feedrate would be reduced. Conversely for smaller cuts at less than the specified
%Stepover, the feedrate would be increased to reduce machining times.
Note that the adjusted portions of the toolpath are indicated by a colour change; a darker colour
indicates a reduced feedrate.
Also note that the adjustment is only made to XY feeds; it is not applied to any end cutting plunge
(ramp) moves.
The Adaptive Feedrates section is on the Control tab of the Roughing cycle.
Adaptive Feedrates: [Edit]
Minimum(%): A minimum value for the adapted feedrate, as a percentage of the originally specified
feedrate. Specify a value of 1 or 99 or any number in between. For example specify 50 for the
feedrate to never be reduced by more than half.
Maximum(%): A maximum value for the adapted feedrate as a percentage of the originally specified
feedrate. Specify a value of 101 or 500 or any number in between. For example specify 200 for the
feedrate to never be increased by more than double.
Increment(%): The feedrate can only be adjusted to certain values. This feedrate Increment is the
size of the steps between these values, as a percentage of the original feedrate.
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Exercise 14 Roughing Cycle Adaptive Feedrates

1. Open the file 14 - Roughing Cycle Adaptive Feedrates.ppf.
2. Check the colour of the main toolpath by editing the Toolchange instruction.
3. Check the colours found under the File Colours.
4. Edit the Roughing Cycle.

Control Tab
Adaptive Feedrates: [Edit] Adaptive: Checked
Minimum(%): 50 Maximum(%): 150 Increment(%): 15

Advanced Milling
5. Some of the toolpath colours are now darker. This is indicating that the Adaptive feedrate
is being applied in these areas.
6. Edit the Adaptive values, using the extreme figures in Maximum & Minimum.
Minimum(%): 2 Maximum(%): 199
7. You will observe that the majority of toolpaths is now subjected to Adaptive feedrate.
8. Edit the Adaptive values again, this time make both values 100
9. The majority of the toolpath is now represented by the standard X-Y Feedrate and so the
colour of the path is back to one colour.
10. Save as 14 Completed Roughing Cycle Adaptive Feedrates.ppf.
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Secondary Z Axis, Quill Support on Horizontal and Vertical Machines.

With a correctly configured .CGD file a secondary Z axis can be used within Edgecam.
In Code Wizard, when creating a new .CGD you have the chance to select an Auxiliary Z Axis in
either the Head or the Table
The Machine elements will show a Z2 Axis. This can be renamed in the Properties Window.
Within NC Style, G Codes and Modality you will find code options for the Quill.
Another set of Code Constructors will also be available.

Advanced Milling
On older Adaptive .CGD files the secondary Z Axis can be added.
Within Edgecam new commands will become available.

Select Machining Miscellaneous Select Z Axis to define which Axis is active.
Select Machining Move Tool Retract Auxiliary Z to retract.
A new drop down list becomes available in the Move to Toolchange command.
These options are only available if your post processer supports this function.
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Exercise 15 Quill Support Horizontal

In this exercise we will demonstrate the use of the quill on a Horizontal Machine. A sequence has
already been created using the secondary Z Axis.
1. Open the file 15 Quill Horizontal.ppf.
2. Take note of the Sequence and the switching between the primary and secondary Z
Axes.
You may rename either Axis in Code Wizard.
3. Take the part into Simulator.

4. The Quill extends out drill and tap the holes.
5. Close the Simulator.

Advanced Milling
Exercise 15a Quill Support Vertical

This example shows a Vertical machine
1. Open the part 15a Quill Vertical.ppf.
2. Take the part into Simulator and simulate the first sequence without the quill. You will
get a number of warnings on overtravel.
3. This can be switched on or off in Options Dialog Machining Tab.
4. Return to Edgecam. Although the part drills all the holes the lower set is off the limits of
the Z axis.
This can also be seen in Edgecam under Linear Axis limit checking.
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5. The Feedback window will inform you of this.
6. Simulate the second sequence. This utilises the secondary Z axis and stays within
machine limits.
7. Close Simulator.
8. Do not save any changes to the part.

Advanced Milling
Extracting Silhouette Profiles from Geometry

Copy from Body/Faces Silhouette can be found in Feature Geometry. This command allows
you to create a wireframe silhouette from a body or selected faces where an edge or loop does not
exist to extract.
Create geometry from faces that fall away or are rounded.

Explode extracted geometry and add offsets to leave material on areas where further
machining is required.
Great for leaving allowances on castings and forgings.
Exercise 16 Body/Faces Silhouettes

1. Open the file 16 Body Faces Silhouette.ppf.
2. Select Feature Geometry.

Copy From: Body/Faces Silhouette
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Select body or faces, Select the Solid. Tick or Right Click to finish.
You may have to <Tab> between the entities offered by Edgecam in order to select the solid.
4. A wireframe continuous profile will be created at the set Z Level.
Exercise 16a Body/Faces Silhouettes 2

1. 16a Body Faces Silhouette.ppf.
As the Geometry created is a Continuous this would have to be exploded in order to

manipulate it.

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Angled Head Support

Edgecam and the Toolstore offer support for angled head attachments on milling machines. You use
these on large components, for example to drill holes from inside the bore, or to Mill/Drill on angled
faces on 3,4 or 5 Axis Machines.
Angled heads can be defined manually in the Toolchange (Milling Cutter dialog) or selected from the
Toolstore, where an Angled Head tab is available.
In the Toolstore and Toolkits, angled attachments are treated as holders, with support for parametric
and user-defined graphics.
Code Generator and Code Wizard templates ensure full support this functionality.
Manual Angled Heads

When using Manually set Angled Heads the graphics for each Angular occasion must be either in the
Toolstore or in the Toolchange within Edgecam.
The Graphics will not automatically alter to the respective CPL.

At each CPL where machining takes place, the user must put the correct Tool offsets into the
machine control. When using solid graphics, a graphic must exist for each Head Angle change, the
Mounting angle can be changed independently of graphics.
The Move Index command is generally not used for the 3 Axis post. The offsets input by the machine
operator change the machining position relative to the Active CPL.
Programmable Angled Heads

A programmable Angled Head can be used in Edgecam by utilising a 3 + 2 Machining centre with a
Head/Head configuration. The machine graphics of the head would then be Angled Head and would
simulate accordingly to the Active machining CPL. Code would be handled by the Move Index
command.
This post would be suitable for Angled Heads only and no other machining as the
Simulation would be incorrect.
The Angled Head is generally only Programmable around the Head Angle.
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Feature Finding Holes Inside a Bore

On large components there is a requirement to drill holes from inside the bore or cavity on milling
machines with an angled head, and in some cases, mill/turn machines with a B-axis.
In Features Find Features you can find blind and through holes as:
Through Vertical holes around an axis (Inner or Outer)

Through Vertical holes offset from an axis (Inner or Outer)
Blind Vertical Holes (Outer)
Blind Vertical Inner Holes (Angled Heads Only)
Radial holes (Not For Manual Angled Heads)
Inner Radial holes (Not For Manual Angled Heads)
To find Blind Holes from inside a bore, check Internal Holes on the Hole Options
Advanced Button.
On all other Feature types there is no change. A CPL must be created and the
Features found upon this.

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Creating Angled Heads In The Toolstore

In the Toolstore you may create both parametric Graphics for the Angled head or Solid models as
.Meg files.
The image below shows Solid Model Custom Graphics.
These solid models can be used on any Tool Type.
A .meg file is a solid that has been copied from Edgecam or Part Modeler and
pasted into the Toolstore.
Tool Dialog - Angled Head Tab

Use this tab to define angled heads for milling machines. Angled head attachments are treated as
tool holders, with additional parameters defined on this tab.
You begin by creating a standard tool, using the Diameter, Flute Length and Length options on the
Geometry tab and a Z Gauge on the Mounting tab. Then, go to the Angled Head tab to define the
head parametrically.
Note that angled head attachments are assumed to have a fixed angle and fixed
linear dimensions. Where these are adjustable or where extension pieces can be
fitted each configuration is treated as a separate item that can only be changed at
Toolchange.
Angled heads are defined in tool co-ordinates, that is Z is coincident with milling tool centreline. The
holder offset (Mounting tab) can be used to position the angled holder with correct tool protrusion.
Note: When selecting a milling tool in Edgecam you can use the Angled Head tab
(Milling Cutter dialog) to manually define the head in the Toolchange, or select a
previously defined tool from Toolstore.
The dialog options are:
The 'active' dimensions for angled attachments are the upper and lower arm length, and the head
angle. For parametric graphics you also need to specify the upper and lower diameters, as well as
the extension for the lower body.
Head Angle: Adjust the head angle to match your machine's requirements.
Mounting Angle: Specify the orientation of the angled head tool in the spindle.
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Upper Arm and Diameter: The length and diameter of the upper body.
Lower Arm and Diameter: The length and diameter of the lower body.
Arm Offset: Specify a side offset for the lower arm body (can be a positive or negative value).
When specified, the lower centreline and cylinder will be offset by that amount in the machine Y
direction when loaded at C0 with the tool pointing in X- .
Lower Extension: Specify a rear extension that extends the lower cylinder beyond the spindle
centre.
Spindle
Ratio Tool to Spindle: Use this to add a gear ratio to adjust for the true spindle speed. This will be
used to convert the cycle speed (tool speed) to machine spindle speed. If left blank, a value of 1 will
be applied.
Invert Spindle Direction: Check this to change the spindle direction in cases where the angled head's
gears cause the spindle to be reversed.

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Exercise 17 Angled Head Drill With Parametric Graphics

1. Open the Toolstore from the Launcher.
2. [Create] a Drill.
General Tab
Tool Description: 10.2mm Drill @90 Deg Head Angle 0 Deg Mounting Angle
Comment: 10.2mm Drill @90 Deg Head Angle 0 Deg Mounting Angle
Geometry Tab
Diameter: 10.2 Tip Angle: 118 Flute Length: 40 Shank Length: 30
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Angled Head Tab
Head Angle: 90 Mounting Angle: 0 Upper Arm (Length): 100
Lower Arm (Length): 50 Upper Diameter: 70 Lower Diameter: 40
Mounting Tab
Z Gauge: 50
3. Select [OK]. The Tool will now be in the Toolstore.

4. The component we are going to machine also requires a M12 x1.75P Tap.
5. Copy the existing drill for each new tool and change the following modifiers.
General Tab
Tool Description: M12 x1.75P Tap @90 Deg Head Angle 0 Deg Mounting Angle
Comment: M12 x1.75P Tap @90 Deg Head Angle 0 Deg Mounting Angle
Tool Type: Tap
Geometry Tab
Diameter: 12 Thread Pitch: 1.75 Tip Angle: 180 Shank Dia: 10
2. Select [OK]. The Tap will now be in the Toolstore.

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Exercise 18 Angled Head End Mill With Solid Graphics

1. Open the Toolstore from the Launcher.
2. [Create] an End Mill.
General Tab
Tool Description: 10mm End Mill @90 Deg Head Angle 0 Deg Mounting Angle
Comment 10mm End Mill @90 Deg Head Angle 0 Deg Mounting Angle
Geometry Tab
Diameter: 10 Flute Length: 30 Shank Length: 30
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Angled Head Tab
Head Angle: 90 Mounting Angle: 0 Upper Arm (Length): 220
Lower Arm (Length): 110 Upper Diameter: 70 Lower Diameter: 25
Mounting Tab
Z Gauge: 40
3. Although it is possible again to use parametric graphics, we shall use a solid model
instead.
4. In Edgecam, Select File Open and browse to the part 18a - 90 Deg Angled
Head.ppf.

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5. Select the Features Ribbon and in the Features Window select all 3 solids, Right
Click and Output Model.
6. In the Angled Head Tab of the Open Tool, Paste.

8. The component we are going to machine also requires a 10mm End Mill @45 Deg.
9. Copy the existing End Mill in the Toolstore and change the following modifiers.
General Tab
Tool Description: 10mm End Mill @45 Deg Head Angle 0 Deg Mounting Angle
Comment: 10mm End Mill @45 Deg Head Angle 0 Deg Mounting Angle
Angled Head Tab
Head Angle: 45
10. In Edgecam, Select File Open and browse to the part 18b - 45 Deg Angled
Head.ppf.
11. Select the Features Ribbon and in the Features Window select all 3 solids, Right
Click and Output Model.
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12. In the Angled Head Tab of the Open Tool, Paste.

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Exercise 19 Manual Angled Head Drilling Internal Holes

1. Open the part 19 Drilling Internal Holes.ppf.
2. Select Features Find Features.

General Tab
Vertical Holes: Checked
Hole Options: [Edit] Internal Holes: Checked Radial Holes: Checked
Select Planes: [Edit] Front, Right, Left, Back & SP_Profile-4 : Selected
3. We dont require the Features 1, 3, 5 and 7. Delete these as you would use these to
machine externally.
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You will see that Internal Holes was checked to find the Blind Inner Hole. Through Holes
are found relative to the Z axis of the selected Planes.
4. We will now machine the First Internal hole at 90 Deg.
5. Select Machining Tooling Toolstore. . Select the Hole tab and the Drill Filter.
Pick the 10.2mm Drill @90 Deg Head Angle 0 Deg Mounting Angle.
6. Place in Position 1.
Note on the Angled Head Tab that the modifiers have been brought through from
the Toolstore.
7. Select [OK].

9. Fill in the modifiers to drill.

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10. Select the Hole Feature at 0 Deg Mounting Angle.
Note the CPL has indexed accordingly to drill the hole.
12. Select Move Tool Toolchange.

13. To Drill the other 3 Holes the Mounting Angle must be changed to suit each hole.
14. Copy Instructions 4, 5 and 6. Edit the Text on Instruction 9 to read ..Mounting Angle
To 90 Degrees.
15. Edit the second Toolchange, Instruction 11. On the General Tab, change the text to read
90 Deg Mounting Angle in both the Toolstore Modifier and Comment. On the
Mounting Tab change the Mounting Angle to 90.
You may be required to give the Tool another Offset depending on how your
machine deals with Angled Heads.
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16. Create another Hole cycle to drill the hole at 90 Degrees Mounting Angle.
17. Repeat this Process for the other 2 - 10.2mm Holes at 180 & 270 Degree Mounting
Angles.

19. Once Drilled, you may repeat the process to Tap all the holes.
What is a quick way of doing this?
20. There is another 5mm Blind hole either create a Tool in the Toolstore or copy an existing
tool as above and Drill this Hole also.
21. Save as 19 Completed Drilling Internal Holes.ppf.

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Exercise 20 Manual Angled Head Milling

When using Angled heads they are not always set at 90 Degrees. On this component we shall see
that the head can be set at 2 different angles using separate graphic files, as on this occasion or,
define yourself using the parametric graphics. CPLs have been created and Feature Found upon.
1. Open the part 20 - 3x Mill Angled Head.ppf.
2. On the Machining Ribbon Select Tooling End Mill and filter for tools with @. Before
selecting [Find].
3. Select the 10mm End Mill @90 Deg Head Angle 0 Deg Mounting Angle. Place in
Position 1.
4. The CPL will Index to the plane specified by the Tool.
5. Apply a Rough Mill Cycle to the side Pocket at 0 Deg Mounting Angle.
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6. Use the images below for reference.
7. Select Move Tool Toolchange.

8. Copy down instructions 2 and 3. Edit the Text to read, Set Head Angle To 45.
9. Select Machining Tooling End Mill and filter for tools with @. Before selecting
[Find].
10. Select the 10mm End Mill @45 Deg Head Angle 0 Deg Mounting Angle. Place in
Position 2.

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11. Apply a Rough Mill Cycle to the2D Pocket at 0 Deg Mounting Angle on the 45 Deg
Angled Face.
12. Check in the Simulator.
13. Machine all other Pockets with a Roughing Cycle. Copying the Commands/Comments
where appropriate and altering Mounting and Head Angles.
14. Save as 20 Completed 3x Mill Angled Head.ppf.
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Workshop 1
Open any file(s) to practise what you have just learnt.

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Legacy Surface Creation

Homework exercises on the creation of Legacy Surfaces inside Edgecam.
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Legacy Surface Creation

Within the Advanced license the user can create surfaces rather than solids. For the majority of
cases it is preferable to machine solid models or surfaces that have been extracted from a solid
model, extended and re-trimmed. The following exercises are how components were/are created
without a solid to machine. Some exercises maybe beneficial to know if you do not have a solid to
machine or have been given an .iges file to machine.
Understanding Entity Dependencies

When you create surfaces, the entities used within the transaction become dependent.
You cannot modify or delete a dependant entity. For example, you cannot delete the individual lines
that form a Coons Patch surface without first deleting the Coons Patch. You could, however, change
the line colour, style or layer, as this would not affect the dependent Coons Patch.
Edgecam displays the dependency flag as SET or CLEAR. For example, a boundary line of a Coons
Patch surface has the dependency flag stated as SET.
Exercise 1 Entity Dependencies

1. Open the file 1 - Entity Dependencies.ppf.
2. Verify either of the two entities present. Observe the Feedback Window, you should
witness that the entity dependency is clear:
3. Select Setup Surfaces Ruled.

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Select first entity, Select the Point.
Select second entity, Select the Arc.
5. A Ruled Surface will be created.
6. Verify either of the original entities. Observe that the dependency is now SET. Try to
delete either entity. You will be issued with the following dialog box.
The Ruled Surface is DEPENDENT on the existence of the Point and Arc entities. In
order to delete the point, you would first have to delete the ruled surface.
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Selecting Different Entity Types

When you are using a command that involves the selection of entities, for example when you are
deleting entities, you can restrict the types of entity that you can select. For example, you can specify
to restrict the selection of continuous entities, so that you can select the original entities that lie
beneath the continuous entity.
Exercise 2 Entity Types

1. Open the file 2 - Entity Types.ppf. Inspect the part, verify the presence of Surface
entities. The object of this exercise is to delete the Surface entities, keeping the
Wireframe structure.
2. Select the Setup Delete command. Follow the Prompt.

Select entity to delete.
Select Entity Types Filter . Select [None]. Surfaces: Checked. Select [OK].
3. Select all the entities by either a Window or, <Ctrl> and <A> keys together. Tick or
Right Click to finish.
4. Save as 2 Completed Entity Types.ppf.

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Continuous Entities
You convert multiple lines/arcs to a continuous entity, select Setup Geometry Continuous.
Delete Base Entities: Check this box to remove underlying entities once the continuous is created.
Name: Optionally specify a name for the continuous, for later use in selecting the continuous.
A continuous entity is created from a collection of adjoining entities. You can then work with the
continuous as a single entity, offering these advantages over working with the original collection, e.g.
You can select the continuous with a single mouse click.
There are quick methods for chamfering or filleting the corners within a continuous entity
using the Entity Data (Edit menu) command.
After completing the dialog and closing it, you select the entities for the continuous by chaining.
Note that selecting the entities individually, rather than chaining, will not work.
Explode
Use this command to, for example:
Break up Continuous entities into individual component entities.
Break up Grouped Hole features into individual Hole features.
To explode a Continuous Entity, select Setup Edit Explode.
Select [OK] and follow the prompt of Entity to explode. Pick a continuous to explode. Tick or
Right Click. Select [OK] to finish.
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The explode command creates copies of the original geometry.
Exercise 3 Manipulating a Continuous Entity

1. Open the file 3 - Continuous.ppf. The file consists of several line and arc entities.
2. Select Setup Geometry Continuous.

Delete Base Entities: Checked
You do not have to supply a Name.

3. Selecting [OK] and follow the prompt.
Select entities to form continuous (or Finish). Chain the Profile. Tick or Right
Click to finish.
4. Verify the profile, you will now have a Continuous.
5. Similar to an Arc entity, the Continuous has a Break Point. To understand and detect this
break point is very important when creating surface entities.

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6. Double Left Click on the Continuous to edit. Observe how the break point of the
continuous is in the same position as the cursor when you chained the profile. Alter the
colour of the continuous. Select [OK].
7. Select Setup Edit Explode.
Entity to explode, Select the Continuous. Tick or Right Click.
9. Select [OK] to finish.
10. The continuous will no longer exist and will be replaced by lines and arcs.
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Use of Interchange Files

Solid files originate from Solid Edge, Solid Works, Inventor, Pro/ Engineer etc. Sometimes you may
get 2D wireframe files from customers such as .DWG or DXF files.
The various forms of Interchange files available to load in Edgecam will depend on your Licence.
However, as a minimum, you may load in an IGES file.
You should understand that although this is the most efficient route for producing the component
design for wireframe, it is inevitable that you will have to manipulate the drawing. This is necessary
so the design lends itself to the manufacturing process. Examples of such manipulation include:-
Translating entities to the required datum
Deleting unwanted data such as title block and irrelevant drawing views
Verifying and measuring entities position
Scaling entities if necessary
Run the File Macros Run PDI remdup.exe to remove duplicated entities.
IGES Import
Edgecam supports two alternative IGES import systems (Standard IGES Import and New IGES
Import). If you have an IGES file that does not load using the standard IGES translator we
recommend that you try loading it using the new translator.
Edgecam supports IGES files generated in a version later than IGES 3.0 and up to IGES 5.2
inclusive, subject to the list of supported entity types.
The new or Old IGES import setting can be found in File Preferences.

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IGES Import Healing and Conversion Options
Edgecam offers a further useful facility for dealing with troublesome IGES files, Clean and Heal.
Healing attempts to fix geometric problems in the files, for example poor trim data or gaps between
adjacent surfaces.
The BREP (Boundary REPresentation) conversion converts any BREP solids in the file to surfaces
(with the option unchecked the BREP is ignored).
The resulting surfaces can also be loaded as a solid using the Load as Parasolid Body
option.
For Clean and Heal you need IGES Healing EN000-H
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Exercise 4 Loading IGES files- Clean and Heal

Clean and Heal (including BREP conversion) attempts to fix geometric problems in the files, for
example poor trim data or gaps between adjacent surfaces.
The BREP (Boundary REPresentation) conversion converts any BREP solids in the file to surfaces
(with the option unchecked the BREP is ignored).
Ensure you have New IGES import Checked in Options Preferences before starting
this exercise.
1. Open the file, 4 - Poor IGES.igs.

General Tab
All: Checked
Advanced Tab
None Checked
2. Select [Save as] and browse to the desktop. Assign any name for the logfile.
3. Select [OK].
4. The IGES file is now processed by the translator (old or new). You will be issued with a
number of warnings which you can dismiss with an [OK]. The file may be loaded in
depending on the translator. Inspect the part if visible.

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5. The Part does not load correctly. The log file may some information back to you.
Note: This version does not Import or IGES DE 1 - type 314 - cannot process
1. Manifold Solid B-Rep Object. IGES DE 67 - type 314 - cannot process
2. Sectioned Area Entity.
6. Select File New Milling Part.

7. Open the same IGES file again (New Translator).
8. In the IGES import dialog box,
Advanced Tab
Clean and Heal: Checked
9. Select [OK].
10. The file will now correctly translate and all surfaces are present.
11. Save the file as 4 Completed Poor IGES.ppf.
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Surface Entities
To create a 3D Sculptured part within Edgecam, you firstly begin by creating a wireframe design
(lines, arc, continuous and splines) and then attach Surface entities.
You can create and manipulate many different types of surface entities all resulting
in the culmination of a complex 3D component.
There are also many ways in which you can modify existing surfaces to produce different effects, and
heal surfaces you have imported from other CAD systems.
The type of surface you select will depend on the drawing and design parameters with which you are
dealing.
You should bear in mind the following points when deciding which surface type to use:
What sort of data are you working from?
How accurate is your starting data?
How do you want to machine the surface?
Do you want to alter your design in the future?
How does the surface type affect manufacturing speed and efficiency?
You use surfaces to design a wide range of components, including:
moulds
dies
aerospace parts
woodworking
automotive parts

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Rendering Surfaces
You render a surface by clicking on the Render icon as with Solid models.
This example shows the wireframe and rendered images of a surface design:
Wireframe Rendered
Creating Primitive Surfaces

As an introduction to the principals of Edgecams Surface designing techniques, the following
exercises will demonstrate the usage of Primitive surfaces. A Primitive surface will move through the
full 3D designing principals within one command. It will:-
create the under pinning wireframe design
choose the correct surface entity
attach the surfaces
Primitive surfaces consist of ruled surfaces and surfaces of revolution.
Edgecam provides the following commands to create primitive surfaces:
Displays the Cone dialog. Create cones with

Cone specified dimensions, with or without an end
surface.
Displays the Cylinder dialog. Create cylinders

Cylinder with specified dimensions, with or without end
surfaces.
Displays the Slab dialog. Create slabs with

Slab specified dimensions.
Displays the Sphere dialog. Create spheres with

Sphere specified dimensions.
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Exercise 5 Creating a Component from Primitive Surfaces

In the following exercise, we will learn how to create a simple component using primitive surfaces.
We will use this part in a later exercise in order to enable Edgecam to attached fillet surfaces.
Ensure the view is set to Top throughout this exercise.

1. Select File New Milling Part.
2. Select Setup Surfaces Primitives Cone. Fill in the modifiers below.

Closed: Un-Checked Radius: 30 Angle: Null Height: 25
You can enter only two of the three possible parameters in the Cone dialog.
Select the centre of the base of the cone. Type a Coordinate of X50Y150. Select
[OK]. Tick or Right Click to finish.
4. An open cone will be created.
Edgecam has created the underlying wireframe geometry (in this case, an arc and a
point) and then created a ruled surface between these entities.
5. Select Setup Surfaces Primitives Slab. Fill in the modifiers below.

Length: 400 Width: 200 Depth: -100

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Select location for slab. Type a Coordinate of X0Y0. Select [OK]. Tick or Right
Click to finish.
7. A Slab will be created.
8. Select Setup Surfaces Primitives Cylinder. Fill in the modifiers below.

Closed: Checked Radius: 30 Length: 30

Select the centre of the first end of the cylinder. Type a Coordinate of X200Y100.
Select [OK].

Select the centre of the opposing end of the cylinder. Type a Coordinate of IZ20.
Select [OK]. Tick or Right Click to finish.
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11. A Cylinder will be created.
12. Select Setup Surfaces Primitives Sphere. Fill in the modifiers below.
Hemisphere: Checked Radius: -50
Enter a negative radius to invert the hemisphere.

Select the centre of the sphere. Type a Coordinate of X310Y100. Select [OK].
14. A Sphere will be created.
15. Your design should now look like this in the Isometric view.
16. Save as 5 - Completed Primitive Surfaces.ppf.

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Creating Functional Surfaces

Now that you are familiar with the basic principles of surface designing, you will next learn the rules
of functional surfaces. Each Surface Function creates its own unique form and will demand certain
design constrains are observed.
Edgecam provides the following commands to create functional surfaces:
Displays the Revolution dialog. Create surfaces

Revolution of revolution, optionally with a specified start and
end angle.
Displays the Ruled dialog. Create ruled

Ruled surfaces.
Displays the Tab Cylinder dialog. Create

Tabulated Cylinder tabulated cylinder surfaces.
Displays the Coons Patch dialog. Create Coons

Coons Patch patch surfaces with a specified blend type.
Displays the Flowed dialog. Create flowed

Flowed surfaces with a specified flow type, optionally
with blended ends.
Displays the Fillet dialog. Create smooth blends

Fillet between intersecting surfaces with a specified
start and end radius.
You can also use Coons patches to create aesthetic surfaces.

Refer to the Edgecam Help files for a comprehensive description of each command.
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Creating a Surface of Revolution

Select Setup Surfaces Revolution.
You create a surface of revolution by sweeping one entity around an axis. You would typically use a
surface of revolution to create conical or spherical surface shapes, such as cones, chambers; tubes
and bottle moulds.
For example, you can sweep an arc about a line to create a sphere, or you can sweep a line about
another line which share a common end point to create a cone, like this:
You can control the specific position of the surface by specifying the angles of the start and end
points on the arc of revolution, if required.
The angle is measured from the entities which are being swept, not 0 absolute.
If you do not specify start and end angles, Edgecam rotates the selected entity about 360.
Once you have entered your specifications, you must first select the entity to sweep which will form
the surface. This can typically be an arc, line, Spline curve or a continuous entity. You must then
select the entity which will form the axis of rotation. This can only be a line.

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Exercise 6 - Creating a Surface of Revolution

1. Open the part '6 - Surface of Revolution.ppf'.
2. Select Setup Surfaces Revolution.
Select entity to be swept to form surface. Pick an arc. Tick or Right Click to
finish.
Select entity to form axis of rotation. Pick the line. Tick or Right Click to finish.
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4. A Surface of Revolution will be created
5. Edit the Surface of Revolution.

Start Angle: 45 End Angle: 270
6. Select [OK].
Notice how the revolution flows clockwise, as opposed to a normal radius arc, which
flows anticlockwise.
7. Undo the Surface of Revolution and repeat the above steps, this time selecting the
alternative arc entity.
8. Save as '6 Completed Surface of Revolution.ppf'.
9. Open the part '6a - Surface of Revolution.ppf and inspect the geometry and create
another Surface of revolution.

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Creating a Ruled Surface

The ruled surface is probably one of the most primitive and yet most commonly used surface types.
A ruled surface exists between two entities which act as boundaries. The boundary entities can be a
line, arc; curve or a continuous entity.
Select Setup Surfaces Ruled.
Once you have entered a name for the ruled surface, if required, you must select the two entities to
act as boundaries for the ruled surface.
You must Select the second entity in the same, corresponding position as the first, otherwise
the surface is twisted. For example, if you select the following lines by clicking at the points
shown, Edgecam creates the following surfaces:
Source Entities Twisted Ruled Surface Source Entities Ruled Surface
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Exercise 7 - Creating a Ruled Surface

1. Open the part '7 - Ruled Surface.ppf'.

Select first entity. Pick a line.
Select second entity. Pick the second line. Tick or Right Click to finish.
Make sure opposing ends of the lines are not picked or the surface will twist.
4. A Ruled Surface will be created
5. Save as '7 Completed Ruled Surface.ppf'.

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6. Open the part 7a - Ruled Surface.ppf.
Note the use of a continuous.

7. Create a ruled surface between the entities.
8. Save as '7a Completed Ruled Surface.ppf'.
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Exercise 8 - Correcting a Problem Ruled Surface

This lesson further demonstrates the importance of reliable base geometry. In this instance, the
Continuous entity plays a pivotal role.
Although you are dealing with a very simple shape, the exercise will demonstrate the following
underlying CAD principals.
Chaining
Verification command
Creating a Continuous
Explode command
Using the correct CPL & View Port
1. Open the part '8 - Problem Geometry for Ruled Surface.ppf'.
2. Create a ruled surface between the two entities as you did in the previous exercise. You
will notice that there is a problem:
Think about why this problem has occurred. How can you correct it?
3. Undo the ruled surface so that only the source entities remain.
4. Double Left click on both of the continuous entities in turn, to edit its attributes and
notice the position of the break marker. They are not in the same position.

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5. Explode one of the 2D profiles by using Setup Edit Explode . This has the
effect of removing the continuous, producing the original entities.
6. Convert the entities back into a continuous, using Setup Geometry Continuous
. Ensure that when chaining the entities, the break point is identical to the other slot
geometry.
7. Create the Ruled Surface ensuring that you position the cursor on the same
corresponding position on each continuous.
8. Save as '8 Completed Problem Geometry for Ruled Surface.ppf' .
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Creating a Tabulated Cylinder

You create a tabulated cylinder by sweeping a line along another entity. Edgecam will only allow you
to select a line entity within this command. Tabulated cylinder could be used to design metal channel
and water gutters.
For example, you can sweep a line along a circle to create a cylindrical surface shape like this.
Select Setup Surfaces Tabulated Cylinder.
There are 2 prompts.

Select entity to move along (flow Line). Arc; line, curve (Spline, B-Spline & Bezier) or
a continuous entity.
Select entity to transform. This can only be a line.

Advanced Milling
Exercise 9 - Creating a Tabulated Cylinder

1. Open the part '9 - Tabulated Cylinder.ppf'.
2. Select Setup Surfaces Tabulated Cylinder.

Select entity to move along (flow line). Pick the Spline.
Select entity to transform. Pick the line. Tick or Right Click to finish.
The Tabulated Cylinder could be created in one of two places depending on which
end of the line you pick.
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4. A Tabulated Cylinder will be created
5. Open the part '9a - Tabulated Cylinder.ppf' and create a Tabulated cylinder.
6. Save as '9a Completed Tabulated Cylinder.ppf'.

Advanced Milling
Creating a Coons Patch

A Coons patch surface exists between four bounding entities. The entities can be lines, arcs, curves
or continuous entities. One of the boundaries can be a point.
The bounding entities can be at any orientation but must intersect at their end points.
Select Setup Surfaces Coons Patch.
Select the blend type to determine the shape of the surface between the boundaries. If you select:
Linear, the display lines joining two curves are straight.
Bi-cubic, the display lines are bi-cubic curves which are normal to the bounding
entities.
Liner Blend Type Bi-Cubic Blend Type
When designing parts using the Coons patch, you do not have control over the way in which
the surface flows.
Once you have entered your specifications, you must select the four boundary entities for the
surface, then right-click to end the Coons Patch command.
You can select the four bounding entities in any order. The first entity you select defines the direction
of the U axis.
Coons Patches surfaces are referred to as Aesthetic Surfaces where the overriding factor is look and
not accuracy.
Refer to Edgecams On-Line help for further information concerning aesthetic surfaces
and Coons Patch command.
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Exercise 10 - Creating a Coons Patch Surface

1. Open the file '10 Coons Patch.ppf'.
2. Select Setup Surfaces Coons Patch.

First coon entity. Pick any entity.
Second coon entity. Pick another entity.
Third coon entity. Pick another entity.

Advanced Milling
Fourth coon entity. Pick another entity. Tick or Right Click to finish.
You can pick the entities in any order.

4. A Coons Patch will be created.
5. Save as '10 Completed Coons Patch.ppf'.
Is it possible to delete the entities that made up the Coons Patch Surfaces?
6. Open the part 10a Coons Patch.ppf.
7. Create a coons patch surface with the blend type set to Bi-cubic.
8. Set the view port to Front and notice the blend between the selected entities. Edit the
Coons Patch and change to Linear.
Bi-cubic Linear
9. Save as 10a Completed Coons Patch.ppf.
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Exercise 11 Surface Creation Revision Exercise

The part file represents a 90 elbow joint for water guttering. Inspect the base entities that have been
provided.
Having completed the last few exercises, we should now be able to create the surfaces required to
manufacture the part
1. Open the part '11 - Elbow Channel.ppf'.
2. We cannot machine the component with 3D cycles in its current state. Therefore, your
task is to create surfaces on the wireframe in order to produce the finished Elbow Joint
shape.
Think about the previous surfaces types that have been already discussed in this
training guide. Will a Continuous entity be useful in this situation?
3. Save as '11 Completed Elbow Channel.ppf'.

Advanced Milling
Creating Flowed Surfaces

The standard type of flowed surface is constructed by specifying a curve to act as an axis or flow
line, along which a cross section (defined by a second curve) is flowed. The cross section must lie in
a plane which passes through one end of the flow line. The flow line need not be planar, it can vary
in Z as well as X and Y, relative to the current CPL.
Source entities Resulting flowed surface
Normally, there is a 90 horizontal angle between the plane of the cross section and a tangent
through the end of the axis, but Edgecam does not enforce this restriction. However, this angle
remains constant as the cross section is flowed along the axis. In addition, the cross section will not
rotate about the flow line even though the flow line may twist in 3D space.
Optionally, you can specify a second cross section at the other end of the axis, which may be a
different size and shape to the first cross section. The resulting surface is a linear blend between the
two cross sections.
Select Setup Surfaces Flowed.
Blend Ends: Check to blend the initial cross section into another cross section at the other end of
the flow line.
Flow Type
Normal: Maintain the cross section normal to the flow line.
Vertical Sections: Maintain the cross section in a vertical orientation irrespective of whether the flow
line is parallel to the current CPL.
Parallel Sections: Maintain all cross sections parallel to the initial cross section.
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Exercise 12 - Creating a flowed surface

1. Open the part '12 - Flowed Surface.ppf', Inspect the entities that have been created.
2. Select Setup Surfaces Flowed . Fill in the modifiers.

General Tab
Flow Type: Normal Blend Ends: Un-Checked

Select an entity for drive line. Select the Arc.
Select cross section profile. Select the Line. Tick or Right Click to finish.
4. A Flowed Surface will be created.

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5. Undo the last command.

6. Create another Flowed Surface, switching the initial picks.
Select an entity for drive line. Select the Line.
Select cross section profile. Select the Arc.
7. Edit the Flow Surface and alter the Flow Type.
8. Save as 12 Completed Flowed Surface.ppf.

9. Open the part 12a - Flowed Surface.ppf.
Remember when there are two Cross-Sections you must Check the Blend Ends option.
10. Save as 12a Completed Flowed Surface.ppf.
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Creating Fillet Surfaces

A surface fillet creates a smooth blend between intersecting surfaces - a primary surface, and one or
more secondary surfaces. The Fillet command creates one curve on each surface the fillet touches,
following the curve of the intersection. This example shows a single cross-section, in the form of a
continuous entity, flowed along a curve:
When a fillet surface is created, a surface curve is generated on each of the intersecting surfaces to
mark the boundary of the fillet. This then allows you to use Setup Edit Trim Surface to trim
each surface to the edge of the fillet.
The cross section at any point along the fillets length is an arc of either constant or variable radius.
A fillet surface can be intersected, trimmed and filleted in the same way as any other surface type.
Select Setup Surfaces Fillet.
Trim Surfaces: Check to trim the selected surfaces back to the fillet edge.
Start/End Radius: The variable radius is defined by the Start Radius and End Radius parameters.
Certain limitations apply to the accurate generation of fillets:
The surfaces must not be parallel or nearly parallel at any point along the fillet.
The fillet cannot take place around a tight corner, the radius of which is less than the fillet radius.
Tolerance: Specifies a value to alter the smoothness of the fillet. Smaller tolerances result in
smoother fillets but take longer to calculate.
Search Grid density: Edgecam uses a 'search grid' to find the intersection. Usually a density of 2
gives satisfactory results. However, surfaces that overlap in a number of places, or only overlap by a
small amount, might need a higher search density. Higher densities take longer to calculate.
Name: Specifies a name for the surface. Use this name later to select the surface.

Advanced Milling
Exercise 13 Fillet Surface

1. Open the part file 13 - Fillet Trimming.ppf.
2. Select Setup Surfaces Fillet.

General Tab
Trim Surfaces: Un-Checked Start Radius: 20

Select the primary surface. Pick one of the surfaces.
Select the secondary surface(s). Pick the other surface. Tick or Right Click
twice to finish.
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4. The original surfaces are un-trimmed.

6. Repeat the above steps, this time Trim Surfaces: Checked.
7. Save as 13 Completed Fillet Trimming.ppf.

8. Open the part '13a - Fillet Trimming.ppf'.
9. Create a fillet surface with a Start Radius: 6.
The surfaces spikes should point outwards. Left Click to toggle the direction.
10. Save as 13a - Completed Fillet trimming.

Advanced Milling
Exercise 14 Variable Fillet Surface

1. Open the part 14 - Variable Fillet.ppf'.

General Tab
Trim Surfaces: Checked Start Radius: 4 End Radius: 8

Select primary surface. Pick the upper surface.
Select secondary surface(s). Pick the lower surface. Tick or Right Click
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Select side to fillet. Toggle the spikes outwards. Tick or Right Click.
Select side to fillet. Toggle the spikes outwards. Tick or Right Click twice to
finish.
4. The original surfaces are trimmed and a variable radius is applied.
5. Save as 14 Completed Variable Fillet.ppf.

Advanced Milling
Exercise 15 - Surfaces Fillet and Blends

The following exercise will take the fillet command a stage further. Specifically one will encounter
multiple fillets being created from Primary and Secondary surfaces. Furthermore, the Corner Blend
command will be used to clean up the fillet surfaces.
1. Open the part file called 15 Surface Fillets And Blends.ppf.

General Tab
Trim Surfaces: Checked Start Radius: 10

Select primary surface. Pick the upper surface.
Select secondary surface(s). Pick the other 4 surfaces around the box. Tick or
Right Click twice to finish.
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4. 4 Fillets will be created.
You will notice that the fillets overlap. We will deal with this issue later in the
exercise.
5. We now need to create 5mm fillets between the surfaces that make up the corners.
General Tab
Trim Surfaces: Checked Start Radius: 5

Select primary surface. Pick a wall, trimmed surface.
Select secondary surface(s). Pick an adjoining wall, Trimmed surface. Tick or

Right Click
Repeat for the other 3 corners. Tick or Right Click twice to finish.

Advanced Milling
9. Finish the part by creating a 10mm fillet between the sphere and the ruled surface, and 2
5mm fillets at the top and bottom of the cylinder, and finally a 2mm fillet at the bottom of
the cone.
Ensure the spikes are pointing out at this stage of the design.
10. The 10mm fillet and the 5mm fillets intersect one another at the corner of the component.
You will now use a new Surface command called Corner Blend to fix the problem.
Blending Corners
You can blend the corner at which three surface fillets meet, in order to create a rounded suitcase
corner like this.
The three fillet surfaces may have different radii, and they do not have to meet
along straight lines.
11. Edgecam creates one or two blend surfaces, depending on the types of fillet surface you
selected, and automatically trims the surface fillets back to the corner blend.
Each of the fillet surfaces must intersect in order to create the corner blend. If they do not
intersect, you will need to extend the required fillet surfaces first.
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12. Select Setup Surfaces Generate Corner Blend.
13. Follow the prompts to select all 3 radii in turn.
14. Repeat the process for the other 3 corners.
15. Save as 15 Completed Surface Fillets And Blends.ppf.

Advanced Milling
Manipulating Surfaces
Now you are familiar with different types of Edgecam surfaces, you will now learn how to manipulate
these surfaces to produce different effects with the following commands.
Displays the Project dialog. Project geometry onto one or more

Project surfaces.
Displays the Trim Surface dialog. Trim surfaces along surface

Trim Surface curves, producing trimmed surfaces on specified layers and in
specified colours and styles.
Blend the corners at which three fillets meet.

Corner Blend
Displays the Cross Sections dialog. Create one or more cross

sections through a surface.
Boundaries: Creates various types of entities, which accurately
mark the edge of a surface.
Bridge Surfaces: Is used to create a joining or bridging NURB
surface between two, three or four adjacent surfaces, to produce a
smooth transitional fit.
Setup Surfaces Generate
Cross Sections
Trimming Surfaces
A trimmed surface is a surface with a piece removed along a surface curve.
Untrimmed Trimmed
Surface curves are created during the trimming processed

There are two ways in which you can trim surfaces:
trimming a surface against a surface curve or other Edgecam entity
trimming a surface against another surface
Select Setup Surfaces Trim Surface
Select on the part of the surface that you want to keep during the trim command.
Select the surface curve(s) or entities against which the surface will be trimmed, then Right Click
to end the Trim command. Edgecam replaces the selected surface with a trimmed surface, in the
specified colour and style and on the specified layer.
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Exercise 16 Basic Trimming of Surfaces

The Trim Surface command is sometimes referred to as the Cookie Cutter (the term is derived from
when a section of pastry is cut using a template) The following exercise will maybe explain why this
term is used.
1. Open the part 16 - Surface Trim.ppf'.
2. Select Setup Surfaces Trim Surface.

Select surface to trim. Pick the Ruled surface inside the wireframe profile.
Select entities (or Finish). Chain the Wireframe profile. Tick or Right Click twice
to finish.

Advanced Milling
4. The Rules Surface will be trimmed.

6. Repeat the above process, on the prompt, Select surface to trim, pick the Ruled Surface
outside the wireframe profile.
7. Save as 16 - Completed Surface Trim.ppf'.
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Exercise 17 - Trimming A Surface Against Another Surface

1. Open the part '17 - Trim Surface.ppf'.
2. Trim the four cross sectional ruled surfaces against the central B-Spline (lofted Curve)
surface.
3. Select Setup Surfaces Trim Surface.

Select surface to trim. Pick the B-spline surface.
Select entities (or Finish). Chain the Wireframe profile. Tick or Right Click.

Advanced Milling
Select surface to trim. Pick the middle of each Ruled surface on the part you want to
keep. Tick or Right Click to finish.
5. The trimming is complete.
6. Save as 17 Completed Surface Trim.

Whilst Trimming Surfaces, you must position the cursor on the section of the surface to be
retained.
7. Practice trimming more components. Use the following examples:
17a - Trim Surface.ppf.
17b - Trim Surface.ppf.
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17c - Trim Surface.ppf.
8. The parts involved are all examples of trimming a surface against another surface. You
will discover that a surface curve is still used, as Edgecam has to produce an Intersection
command before trimming.
Where a surface is trimmed against another surface, Edgecam will allow you to trim
both surfaces. Observe the Display Banner. Having trimmed the first surface, the latter
section of the command prompts Select Surfaces to Trim, At this stage select the
remaining surfaces.

Advanced Milling
Surface Boundaries
You may want to create surface curves around the boundary of a surface. This could be to create a
surface between surfaces or to drive a tool along a surface curve on the edge of a surface (in Five
Axis machining). Depending on the surface type, a surface may not have a selectable edge (for
example, Spline, B-Spline and Bzier surfaces do not have edges, but ruled surfaces have two).
Select Setup Surfaces Generate Surface Boundaries
Creating a Surface Boundary

You use surface boundaries to mark the boundary edge of a surface, like this:
Original surface Surface with 2D boundary marked
This is useful in instances where you need to:

machine the edge of the surface with a 2D Machining command
create further design shapes from the original surface
control a surface machining toolpath with a boundary
Create the underlying wireframe from surfaces which have been imported from
interchange files.
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Generate
Specify the type of boundary that will be created for the selected surface(s). Choose between.
Surface Curves: Checking this option allows you to select surfaces only to generate
surface curves around the boundaries of the selected surface(s). Note that the surface
cannot be deleted because the surface curves are dependent on it.
If you generate a Surface curve, you can explode the curve into a Spline curve.
Base Entities: Checking this option allows you to select surfaces or surface curves to
be converted to lines, arcs, Splines or B-Splines.
2D Entities: Checking this option allows you to select surfaces, surface curves, Splines
or B-Splines to be converted to 2D curves at the current CPL level.
Tidy Base Entities
Check this box to replace a set of co-linear lines with a single line, and replace
sequential arcs of the same radius that also lie in the same plane with a single arc.
Outer Edges: (2D entities only) Check this box to join outer edges of the selected
surfaces to form a union. The resulting geometry will be created as lines at the current Z
level.
Note that surfaces without fully enclosing boundary curves such as spheres or
cylinders may not be taken into account. Also note that a surface that doubles back
will not return a boundary that represents the furthest extent of the surface.
If your boundary is required on a different Z Level to the surface, remember to pre-set the Z
level and 2D Snap option.
3D Curves
Curves: The boundary curves can be generated as either Splines or B-Splines.
Control Points: Specify the number of control points for the curves (the default value is
40).

Advanced Milling
Exercise 18 - Creating a Surface Boundary

The part has already been machined in so much that the component has been profiled around the
basic component shape. We now wish to select a ball nose cutter and finish machine the fillet area
only. This will require a containment boundary.
1. Open the part 18 - Boundary Creation.ppf.
2. Set the Z level to 25 and create a New Layer called Boundary.
3. Select Setup Surfaces Generate Surface Boundaries.

Generate: 2D entities Curve: Spline Control Points: 40
Outer Edges: Un-Checked
Select Surfaces or Curves. Pick the 5 Fillet surfaces below. Tick or Right Click
to finish.
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5. A boundary will be created.
Would this be suitable as a Containment Boundary?

7. Re-create the above command, this time Outer Edges: Checked.
8. A single closed profile will be created.
9. Save as 18 Completed Boundary Creation.ppf.

Advanced Milling
Exercise 19 Using Boundaries To Aid Machining

When machining component you may find the geometry supplied is not suitable. This may lead you
to fill in areas or cap them. On the next exercise we want to cap all the open areas on the top of the
component.
1. Open the part 19 - Working with Boundaries.ppf.

Generate: Base Entities Curve: Spline Control Points: 40
Select Surfaces or Curves. Pick the top 2 curved Surfaces. Tick or Right Click
to finish.
4. 2 boundaries will be created.
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5. Create a Ruled surface or surfaces to Cap the open area at the Top.
To create a single Ruled surface some of the Geometry will need exploding first and the
Continuii created.
6. Save the part file as 19 Completed Working with Boundaries.ppf.

Advanced Milling
Full Surface Part Creation

Exercise 20 - Creating A Surface Component
We shall now create the full surface part below learnt techniques used in previous exercises.
The following table lists the attributes of each surface. You should refer to this table throughout the
following exercise.
Surface Colour Layer
Surface of Revolution (A) Fire Engine Red Stage 1 Frame
Flowed Surface (B) Sky blue Stage 2 Frame
Tabulated Cylinder (C) Hot Pink Stage 3 Frame
Ruled Surface (D) Slate Blue Stage 4 Frame
Fillets (E) Gold Fillets
Ruled surface walls (F) Slate Blue Surfaces
1. Open the file '20 - Surface Part Initial Geometry.ppf'.
2. This diagram numbered for the purposes of this exercise.
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3. Show Only Stage 1 Frame Layer.
4. Create a New Layer called Stage 1 Surfaces. Change the Colour to Fire Engine Red.
5. Select Setup Surfaces Revolution.
Start Angle: 0 End Angle: 180
Select entity to be swept to form surface. Pick the continuous. Tick or Right
Click to finish.
Select entity to form axis of rotation. Pick the line. Tick or Right Click to finish.
7. The surface of Revolution will be created.

Advanced Milling
8. Show Only the Stage 2 Frame Layer.
9. Create a New Layer called Stage 2 Surfaces. Change the Colour to Sky Blue.
10. Select Setup Surfaces Flowed.

Blend Ends: Checked Blend Type: Normal

Select an entity for drive line. Pick the conic.
Select cross section profile. Pick an arc.
Select final section profile. Pick the other arc. Tick or Right Click to finish.
12. The Flowed surface will be created.
Select the two arcs by clicking on the same point of both entities, to avoid creating a twisted
surface.
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14. Create a New Layer called Stage 3 Surfaces. Change the Colour to Hot Pink.
15. Select Setup Surfaces Tabulated Cylinder.

Select entity to move along (flow line). Pick the Continuous.
Select entity to transform. Pick the top right of the line. Tick or Right Click to
finish.
17. The Flowed surface will be created.
19. Create a New Layer called Stage 4 Surfaces. Change the Colour to Slate Blue.

Advanced Milling

Select first entity. Pick a Continuous.
Select second entity. Pick the other Continuous. Tick or Right Click to finish.
22. The Ruled surface will be created.
Select the two continuii by clicking on the same point of both entities, to avoid creating a
twisted surface.
23. Show All Layers.
24. Show Only the End Caps Layer and make this the Active layer.
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25. Create 5 further Ruled Surfaces. These will cap off all the ends.
26. 5 completed Ruled Surfaces.
27. Show All Layers.

Trim Surfaces: Checked End Radius: 3

Select primary surface. Pick the Surface Of Revolution.
Select secondary surface(s). Pick the 3 Surfaces shown below. Ensure the spikes
point outwards on all surfaces. Tick or Right Click to finish.
Edgecam allows you to trim the surfaces as part of the Fillet command, ensure you Select the
surface on the portion to be retained

Advanced Milling
Remember to click on the part of the ruled surfaces that you want to keep.
31. Create 3mm Fillets on either of the large ends.
Ensure your fillet spikes point inwards on this occasion.

32. Your component will look like this.
33. Create 3 more 3mm surface fillets, between each end cap and the adjoining surface.
34. Save the component as '20 - Completed Surfaces Component.ppf'.
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Exercise 21 Surface Project Command

In respect to designing, the Setup Surfaces Project is very rarely used. The Project command
produces a Surface Curve which adopts the same shape and profile as the target surface. However,
the Surface Curve is of no use to us in terms of designing, therefore the curve has to be Exploded
.
When a Surface Curve is exploded, a Spline Curve is produced.

The following exercise demonstrates a situation where the Project command can be used.
1. Open the part file 21 - Surface Project.igs.
2. Set the View to Top.
3. Create two horizontal lines either side of the pocket and that are longer than the pocket.
Place on a Z level of 30mm.
4. Create a New Layer called Projected.

5. Select Setup Surfaces Project.
Select surface. Pick the top 2 Trimmed Surfaces. Tick or Right Click to finish.

Advanced Milling
Select entity to project. Pick the top 2 lines. Tick or Right Click to finish.
7. The Lines will be project onto the surfaces.
8. You cannot use the Surface curve to create new surfaces from. Therefore you must
explode the Surface Curves.
9. Select Setup Edit Explode.
Entity to explode. Pick the top 2 Surface curves. Tick or Right Click to finish.
11. Delete: Checked
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12. Select [OK].
13. Create a Ruled Surface between the Spline curves.
14. Save as 21 - Completed Surface Project.ppf.

Advanced Milling
Preparing An IGES file For Machining

This preparation process will produce the ideal circumstances for manufacturing within Edgecam.
This includes use of the following:
Explode command
Surface Boundaries
Surface Curves
Layers
Surface Trimming
Exercise 22 - IGES File preparation

1. Load the part file '22 - Lift Link.igs'.
2. There are no wireframe entities only Trimmed Surfaces.

3. Create a New Layer for the Pocket Boundary.
Generate: Base Entities
Select Surfaces or Curves. Pick the flat Trimmed surface. Tick or Right Click to
finish.
6. We will now cap the Pocket area with a Ruled Surface. Before we can create this we
require 2 Lines for the surface frame.
7. Select Setup Geometry Line. Create 2 Vertical lines approximately in the positions
below. Set the Level to 10.
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8. Select Setup Surfaces Ruled .Create a Ruled surface between the 2 lines that
covers the entire pocket area.
.
9. Show only the Pocket Boundary Layer.
10. Select Setup Surfaces Trim Surface . Trim the Ruled Surface to keep only the
centre portion to cap.
11. We are to Drill out the hole, rather than machine it away with an endmill. You need to find
out the size of the largest possible drill, then cap off the hole so the surface machining
cycle does not enter this area.
12. Select Setup Surface Generate Surface Boundaries.

Advanced Milling
Select Surfaces or Curves. Pick the 2 Trimmed surfaces below. Tick or Right
Click to finish.
14. Show Only the Pocket Boundary Layer.

15. Delete the unwanted entities, leaving behind the arcs.
16. Verify the size of the smaller arcs. This will be your drill sizes.
17. The resultant value will decide the diameter of the drill you must use to rough out the
recess.
18. Create Ruled Surfaces to Cap both of these holes.
19. We shall now cap the end cut out.

20. Create a New Layer called the Capped End. Show All Layers.
21. Select Setup Surface Generate Surface Boundaries.
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Select Surfaces or Curves. Pick the end Trimmed surface. Tick or Right Click
to finish.
23. Select Setup Edit Explode and explode the Trimmed surface onto the same
layer.
24. Show Only the Layer Capped End.

25. Delete the Surface Curve.
26. Select Setup Surfaces Trim Surface and Trim the B-Spline surface against the
arc.

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27. The preparation is now complete.
28. Re save as 22 - Completed Lift Link.ppf.
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Preparing a Solid Model File For Machining

Surfaces can also be created over a Solid model and machined at the same time. Wireframe
Geometry must first be taken off the Solid to create the frame for the Surface.
Use the Surface Option within the selected cycle to machine both entity types together.
Solid Machinist users can affect the physical shape of the component by a number of methods.
Feature Capping: pockets and recesses can be filled in using this method. This will
have the effect of stopping a toolpath entering certain sections of the model.
Suppressing: CAD modelling systems offer the ability to suspend or hide a feature. This
method is much preferable in comparison to permanently deleting features.
Exercise 23 - Placing Surfaces on a Solid Model

1. Open the part file 23 - Restraining Mount.ppf.
2. We shall create a Ruled Surface over the 2 Lugs to Cap off this area.
3. Select Features Geometry .

Copy From: Edges
Select an edge to create a line, arc or continuous. Pick the 2 edges below. Tick
or Right Click to finish.

Advanced Milling
5. Create a Ruled surface between the newly created line entities.
6. Save as 23 - Completed Restraining Mount.ppf.
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Document Revision Control
Rev 1.0 April 2013, V2013 R1. New document. Replaces Old Advanced Milling and 3D
Manufacturing. SBL. Re-Write, new exercises.
Rev 2.0 Oct 2013, V2014 R1. All new screen shots some grammar changes SBL, no
new exercises.
Rev 3.0 Jan 2015, V2015 R1. Many new screen shots. Move Angular Removed,
Angled Head Exercises added. SBL.

Advanced Milling
Index
Edgecam ............................................................ 2 Windows .............................................................2

part...................................................................... 2
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Edgecam Advanced Milling License V2015 R1 Rev 3.0 PDF

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Advanced Milling License

Copyright 2015 Vero Software Ltd. All rights reserved.

Windows is a trademark of Microsoft Corporation.

Page 2 of 181 Rev 3.0 Vero Software Ltd

V2015 R1 Rev 3.0 Page 3 of 181

Hole Cycle Helical Milling .................................................................................................. 69

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Creating a Coons Patch ......................................................................................................135

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You cannot generate CNC data from an .EPF File.

Edgecam Knowledge Base

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Conventions Used in This Guide

This is a note. It contains useful or additional information.

This is a reference. It directs you to another part of the user guide.

This is a warning, it contains information that you must not ignore.

Tick or Right Click will confirm your selection/ignore/finish a command prompt.

V2015 R1 Rev 3.0 Page 7 of 181

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Before You Start

Refer to the Getting Started manual for more information on Defaults.

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Plunge Roughing Cycle

Flow Surface Cycle

Pencil Mill Cycle

Project Boundary Collapse

Project Flow Curves

Project Circular Pattern

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Plunge Roughing Cycle

Here are some key points:

There are 3 possible prompts.

Select pre-drill points, Tick or Right Click to finish.

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Maximum recommended Forward Distance is limited by insert length.

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Exercise 1 Plunge Roughing

2. Select Machining Milling Cycles Plunge Roughing. Fill in the modifiers.

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3. Select [OK]. Follow the prompts.

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4. Open the Simulator and inspect the machining.

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7. Edit the Plunge Roughing.

8. Open the Simulator and inspect the machining.

12. Re-set Cut Increment and Minimum Pocket Depth to Null.

13. Edit the Plunge Roughing cycle.

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15. Open the Simulator and inspect the machining.

17. Undo the last Edit.

19. Re-save as 1 - Completed Plunge Roughing.ppf.

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Flow Surface Cycle

Refer to the online Help for all other options.

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Exercise 2 - Flow Surface Cycle

2. Select Machining Mill Cycles Flow Surface.

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Leads & Links Tabs

Select check surfaces, Ignore. Tick or Right Click to finish.

Although Features can be created and machined, this is not necessary.

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