ESPRIT 2009 Get Started Guide

Get Started
with ESPRIT
Get Started with ESPRIT 2009
Copyright © 2008 DP Technology Corp. All rights reserved. U.S. Patent No. 6,907,313. Other
U.S. patents pending.
Information is subject to change without notice.
No part of this manual may be reproduced, transmitted, translated in any form or by any
means, graphic, electronic, or mechanical, including photocopying, recording, taping, or by any
information storage or retrieval system, without written permission from DP Technology Corp.
The software described in this document may only be used or copied in accordance with the
terms of the furnished license agreement and/or non-disclosure agreement. It is illegal to copy the
software onto any medium except as specified in the license or non-disclosure agreement.
All DP Technology Corp. software products contain integrated security programs and/or plug-in
modules that are required for the software license to properly operate. It is a violation of the DP
Technology Corp. copyrights and U.S. Copyright law to disable or attempt to disable or remove
or otherwise operate the software without the security programs and/or modules installed. Any
software not supplied by DP Technology Corp. which is intended to allow the operation of the
software without the required plug-in security module and/or integrated security programs is a
copyright violation.
ESPRIT is a registered trademark of DP Technology Corp.
All brand or product names or proprietary file types mentioned in this document are trademarks
or registered trademarks of their respective holders. Contact the appropriate companies for
more information regarding trademarks and registration.
DP Technology Corp.
1150 Avenida Acaso
Camarillo, California 93012
USA
Phone (805) 388-6000
Fax (805) 388-3085
www.dptechnology.com
Printed in the United States of America
Contents
Welcome to ESPRIT 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installing ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Getting Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ESPRIT Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ESPRIT Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The ESPRIT Work Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Opening and Storing Files in ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Selecting Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Controlling the Display of Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Using Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ESPRIT Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ESPRIT KnowledgeBase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Create Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Create Milling Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Create Turning Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Create Wire EDM Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Mill a Standard Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Remove Excess Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cut the Pockets and Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Mill and Drill Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Create a Shop Floor Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Mill on a Rotary Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Cut Along a Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Rough and Finish the Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Copy and Rotate Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Mill a Mold Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Remove Excess Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Pre-Finish All Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Finish Near-Flat Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Finish the Blend Fillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Mill 5-axis parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Create 5-axis swarf operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Create a 5-axis contouring operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Create 5-axis composite operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Turn a Standard Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Remove Excess Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Finish and Groove the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Finish and Thread the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Perform the Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Turn an Advanced Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Create a Balanced Rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Drill and Groove Simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Mill/Turn a Face Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Transfer the Part to a Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Drill on a Rotary Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Mill with the B-Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Wire EDM a Die Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Create Draft Conic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Contour the Die Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Sort EDM Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Simulate the Slug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Wire EDM a 4-Axis Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Contour a Multi-Axis Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Welcome to ESPRIT 2009
ESPRIT has all the power you need to machine any part... Installing ESPRIT................................ 2
ESPRIT is a high-performance computer-aided manufacturing
(CAM) system for a full range of machine tool applications. Getting Help.......................................... 5
ESPRIT delivers powerful full-spectrum programming for 2-5 ESPRIT Support................................... 7
axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking
mill-turn machining, and B-axis machine tools.
ESPRIT’s high-performance capabilities include machining
any part geometry (solid, surface, or wireframe), universal
post processing to format G-code for virtually any machine
tool, and solid simulation and verification with dry runs
rendered in dynamic solids for optimal part quality and
consistency.
ESPRIT’s multitasking component provides powerful
capabilities for driving mill-turn machines, multi-axis
lathes, and Swiss-style machine tools. ESPRIT provides
synchronization of simultaneous cutting cycles using any
combination of turrets and spindles for milling or turning,
factory-certified post processors for all the leading
multitasking machine tools, and dynamic solid simulations
for dry run verification of the machining processes.
Get Started with ESPRIT will teach you all the basics of how
to machine your parts, plus show you advanced techniques
to help you get the most out of ESPRIT 2009.
Welcome to ESPRIT 2009 | 1

Installing ESPRIT
Prerequisites for ESPRIT 2 0 0 9
The installation program verifies all requirements before proceeding. If the system does not meet
requirements, the installation will abort until the system complies. Existing users should review
their computer systems to be sure that they comply with the latest ESPRIT installation and system
requirements.
The following operating systems are supported by ESPRIT 2009:
• Microsoft® Windows® XP SP2 x32 or x64 or Windows® Vista™ x32 or x64
The following operating system components are required by ESPRIT 2009:
• Microsoft® Internet Explorer version 6.0 or greater
• Microsoft® .NET Framework version 2.0.50727*
• Microsoft® SQL Server 2005 Express edition*
• SafeNet Sentinel drivers version 5.39 or greater*
The following are minimum hardware requirements for ESPRIT 2009:
• 800 MHz 32-bit (x86) processor or greater
• RAM requirements of a minimum of 512 MB, 1 GB or more recommended
• 32 MB video card capable of 16-bit color at 1024 x 768 and OpenGL rendering
• 20 GB hard disk drive
• 1 GB of free hard drive space
• CD-ROM or DVD-ROM drive
• Mouse
• Parallel or USB port (required for ESPRIT security)
* Microsoft® .Net, Microsoft® SQL Server 2005 Express and the SafeNet Sentinel drivers are all
included on the ESPRIT 2009 CD for your convenience; you will find them in the Prerequisites
folder. Components are provided in English only. For other languages, visit the download center
at the Microsoft website (www.microsoft.com) for your country or visit Sentinal Support at the
SafeNet website (www.safenet-inc.com).
Note: Older machines will run ESPRIT 2009, but the results will be less than ideal. The use of
additional memory or faster processors will directly improve performance and capacity. Sufficient
swap space is required to handle installation of ESPRIT 2009 as well as any files saved.
Securit y Module
Plug your Security Module into the appropriate port on your computer. If you have a parallel
Module, plug it into the primary parallel port (LPT1) at the back of your computer. Do not plug it
into a serial port. ESPRIT is not fully functional if the Module is not inserted correctly. Without the
Module, ESPRIT runs in “demonstration mode”. You can use ESPRIT, but you will not be able to
create NC code or store any files.
Take special care to protect your security module from loss or damage. It is an integral component
of the software and your license.
The only device you may attach to the back of a parallel Security Module is a parallel printer.
2 | Get Started with ESPRIT 2009

Important: Do not plug any tape backup systems, portable CD-ROMs, DVD players or recorders,
Zip drives, multi-function office systems (all-in-one printer/fax/scanner/copier devices) into a
parallel Security Module. These will damage your module.
If your Module becomes damaged, your ESPRIT software will not work until a replacement Security
Module and new password can be shipped to you at your expense. Module replacement is not
covered by Software Maintenance Contracts.
Lost or stolen Modules are your responsibility. Please check with your insurance carrier to be sure
your business insurance has them covered for the full value of your ESPRIT software.
Install ESPRIT from t he CD

Please set your computer’s date correctly before installing ESPRIT and do not change the date
thereafter.
Important: An incorrect date can damage the security module and render ESPRIT inoperative.
Your ESPRIT software will not work again until a replacement security module and new password
can be shipped to you.
If a virus protection software is installed on your computer, you need to disable it before installing
ESPRIT. The ESPRIT installation uses scripts that will be automatically blocked by your anti-virus
software unless virus protection is disabled. Make sure to turn the virus protection back on after
you install ESPRIT.
Note: Your system must meet the prerequisites listed on the previous page before you will be
allowed to install ESPRIT 2009.
1. Insert the ESPRIT 2009 CD in the CD-ROM or DVD drive.
2. Open the file ReadThisFirst.doc on the CD.
3. Follow the instructions to perform a new installation of ESPRIT 2009 or to upgrade from a
previous version of ESPRIT.

Use ESPRIT
ESPRIT 2009 is a single instance application and does not support multiple instances. ESPRIT does
not limit the number of instances running, but you may experience unexpected and undesirable
results in choosing to run more than one instance of ESPRIT at the same time.
Select the ESPRIT icon on your Windows desktop
Or,
From the Windows Start menu, select All ProgramsESPRIT 2009ESPRIT.
Other ESPRIT 2009 menu items:

DNC To Machine Tool: For advanced users, DNC customization
License Manager: Updates passwords for product additions and installs
NC Editor: NC file editing tool
Settings Manager: Imports, exports and resets ESPRIT user settings
KnowledgeBase: Database setup and management

Getting Help
The ESPRIT Help system is HTML-based, making it easy to navigate between topics to find the exact
information you need. You can access the online help system several ways:
• Press the F1 key at any time
• On the Help menu, click ESPRIT Help
• From within a dialog, click the Help button for specific help about that topic
To print any topic, select the Print button at the top of the Help window. To return to the main
topic window (displayed above), select the Home button. Use the Forward and Back buttons to
move back and forth through the topics you’ve already viewed.
There are four tabs in the navigation pane of the Help window that help you find the information
you need. If you do not want to view the tabs, select the Hide button. To display them again, select
Show.
• Contents. Displays information in a chapter format. Help topics are grouped logically by subject
area. Each time you select a topic in the list, it opens automatically in the right pane of the Help
window.
• Index. Displays topic information in alphabetical order. You can scroll through the list or type
the first few letters of the keyword you are looking for. To open a highlighted entry in the index,
simply press Enter or select the Display button. Or, you can double-click on an entry to open that
topic.
• Search. Lets you search through every topic in the help file for a specific word or phrase. Type a
word or phrase (enclose the phrase in quotes to find that exact phrase), then select List Topics or
simply press Enter. Every help topic that contains that word or phrase is listed.

• Favorites. Lets you save a list of help topics that you commonly refer to. To add a topic to the
Favorites list, open the topic (from the Contents tab, the Index, or from a Search), place the
cursor in the Current Topic field and press Enter.
ESPRIT Help on t he Web

Get the most current information about ESPRIT, new product features and enhancements, latest
releases, post processors, advanced tips, and creative solutions. The ESPRITWeb is a family of four
websites dedicated to serving the needs of the ESPRIT community. Register for the ESPRITWeb at:
http://www.dptechnology.com/ew
• The ESPRITWeb home page is the central point for the ESPRIT online user community. It contains
up-to-date information on all ESPRIT products and includes links to all other ESPRIT online areas.
• WebBoard is a discussion group that provides you with an open forum for discussion on any
topic related to ESPRIT. Ask questions and share your ideas, solutions, and experiences with
other ESPRIT programmers.
• SupportWeb is a web-based three-step technical support system. Start by using the Frequently
Asked Questions (FAQs) to find a solution to your problem. If your initial FAQ search does not
answer your question, search the solution database for answers. Finally, if you have not found
your solution in either of these places, you can submit your question to our technical support
engineers directly from the web and subsequently via e-mail.
• FileLibrary is a web-based library of post processors, macros, and other data files useful to
ESPRIT programmers.
The ESPRITWeb is only available to registered ESPRIT users who have an active Software
Maintenance Contract (SMC).
For more information on SMC, go to http://www.dptechnology.com and click on the link to
Professional Services. We look forward to hearing your comments and suggestions on how we can
improve your website. Send your comments via e-mail to ESPRIT.news@dptechnology.com or even
better, post your message on the WebBoard discussion group.
General Windows® Help

From the Windows Start menu, select “Help and Support”. Microsoft provides general information
about the Windows operating system.

ESPRIT Support
The DP Technology web site provides a wide variety of information about the company and its
products.
You can access the web site at: http://www.dptechnology.com
For support issues, please send an e-mail to: support@dptechnology.com
Phone Suppor t
Contact your reseller first. Resellers of ESPRIT give specialized information related to the custom
solution they provided to you. This is the best place to start.
If you don’t have a reseller, contact the nearest DP Technology office.
Corporate Office Midwest USA Eastern USA
DP Technology Corp. DP Technology Corp. DP Technology Corp.
1150 Avenida Acaso 1001 E. Touhy Avenue 8535 Cliff Cameron Drive
Camarillo, CA 93012 Suite 300 Suite 112
Des Plaines, IL 60018 Charlotte, NC 28269
Toll Free: 800.627.8479 Toll Free: 800.627.8479 Toll Free: 800.627.8479
Tel: 805.388.6000 Tel: 847.297.8100 Tel: 704.594.9551
Fax: 805.388.3085 Fax: 847.297.8107 Fax: 704.594.9802
dptechnology.com
DP Europe DP Germany DP Italy

“Le Thèbes” Sommerleite 1 Via Iacopo Nardi 2
68 Allée de Mycénes D-96 148 Baunach 50132 Florence
34000 Montpellier Germany Italy
France
Tel: +33 4 67 64 99 40 Tel: +49 9 54 49 80 3 53 Tel: +39 055 2342286
Fax: +33 4 67 64 99 41 Fax: +49 9 54 49 80 3 54 Fax: +39 055 2347858
dptechnology.fr dptechnology.de dptechnology.it
DP Japan DP China
Level 28, Shinagawa InterCity 458 North Fu Te Road
Tower A Building No. 36, 1F
2-15-1 Konan, Minato-ku Waigaiqiao F. T. Z.
Tokyo 108-6028 Shanghai 200131
Japan China
Tel: +81 3 5485 1884 Tel: +86 21 5868 3696
Fax: +81 3 5469 1885 Fax: +86 21 5868 2803
dptechnology.jp dptechnology.cn

Sof t ware Maintenance Cont ract ( SMC )
Our goal is to build successful ESPRIT users. We believe the best way to do this is through the SMC
program. Participants receive...
• Unlimited phone support
• Continuous ESPRIT software and documentation upgrades
• ESPRIT de Corps Newsletter, our informative and technical newsletter
• Opportunity to participate in and gain from cutting edge field testing
• 24-hour web access to the DP Help Center and FTP site
For more details on the DP Technology SMC, please call 1+(805)388-6000.

ESPRIT Fundamentals
Before you begin the projects in this guide, you should The ESPRIT Work Environment.10
familiarize yourself with how to work with part files in
ESPRIT. As a native Windows-based application, the ESPRIT Opening and Storing Files in
interface and its menus and toolbars should look familiar to ESPRIT....................................................... 12
you.
Selecting Elements.......................... 14
This chapter explains how to work with ESPRIT part files as
well as how to open files from other CAD systems. You will Controlling the Display of
also learn about the ESPRIT work environment and how to Elements.................................................. 17
customize it to the way you work. In addition, you will gain
a working knowledge of how the ESPRIT KnowledgeBase Using Features.................................. 20
works.
ESPRIT Machining Technology.24
Note: Before beginning to use ESPRIT, you should have a
working knowledge of your computer’s operating system ESPRIT KnowledgeBase............... 26
and its conventions. You should know how to use a mouse
and standard menus and commands. To review these
techniques, refer to the documentation for Microsoft®
Windows®.
ESPRIT Fundamentals | 9
The ESPRIT Work Environment
Let’s take a quick look at the ESPRIT screen. Status Area
This window is displayed when you create a
The Status area, at the bottom of the ESPRIT
new file or open an existing one.
screen, provides dynamic information about
The ESPRIT window contains menus and the current work environment. As you select
default toolbars along the top of the screen, commands or move the cursor, the information
a graphic work area where you can view your is constantly updated.
work, and a status area along the bottom of
the screen that displays dynamic information Specialized Windows
about your part environment and the current
ESPRIT also provides two specialized windows
command or action.
that provide additional information about
the parts you are working on and provide an
Menus and Toolbars excellent way to manage your work.
You can select commands from the menus or
from toolbars. Use the Smart toolbar to quickly Project Manager
display and hide ESPRIT toolbars based on the The Project Manager consists of a set of
type of work you want to do. windows that list every operation, feature, and
cutting tool in the current session and lets you
manage, sort, and reorder these items. The
Tools window does not display for wire EDM
For example, if you want to create features, files. To view the Project Manager, press the
just activate the Features group of toolbars. F2 key or click Project Manager on the View
All other toolbars are automatically hidden. menu.
All visible toolbars activated from the Smart
toolbar will always be shown in the same Property Browser
position so you never have to hunt for a The Property Browser displays information
command. about any item selected in the graphic work
area or the Project Manager. You can view and
Graphic Work Area change individual properties for the selected
By default, the initial view orientation is set to item. To view the Property Browser, click
the Top view with the XYZ axes displayed. The Properties on the View menu or hold down the
X-axis is horizontal, Y is vertical, and Z points Alt key as you press Enter.
out towards you. To change to a different
view, use the View pulldown near the upper
right of the screen. To show or hide the XYZ
coordinates, select XYZ Axis on the View menu.
Prompt Area
The Prompt area is perhaps the most
important area on the ESPRIT screen. The
prompts tell you what to do next. Always pay
attention to what the prompt is telling you.
10 | Get Started with ESPRIT

Menus and Toolbars
Located at the top of the screen, menus and toolbars give you
quick access to the functions you can perform in ESPRIT.
The Graphic Work Area

Project The largest area of the screen,
Manager this is where your part is
Features displayed.
Tools
Operations
Property
Browser
The Prompt Area The Status Area

Located at the lower left of the Located at the lower right of the
screen, this area is where ESPRIT screen, this area provides dynamic
prompts to tell you what to do information about the current
next. work environment.
Opening and Storing Files in ESPRIT
When you start a new session in ESPRIT or familiar with ESPRIT, you can create templates
create a new file, you are given the choice of that make it easier and faster to work on similar
starting with a blank file or basing your new types of jobs.
work session on a predefined template. As a new user, select <Blank Document> and
click OK.
The display of the template dialog is controlled
by the “Display Template Dialog” option on the
Input page of the Options dialog, available on
the Tools menu. By default, the template dialog
displays.
For more information about how to create and
use template files, please refer to the ESPRIT
online help.
Creat ing New Files

Clicking the New command closes the current
The <Blank Document> option opens a new file file so that you can begin work on a new file.
that uses the ESPRIT defaults. A template file If changes have been made to the current file,
contains user-defined elements and settings for ESPRIT will prompt you to save those changes
the way you machine parts at your company. before the file is closed.
You can create templates that include regularly
used tools, machine setup configurations,
simulation settings, repeated geometry, and
KnowledgeBase settings. As you become more
The commands on the File menu or the icons on

the Standard toolbar (located near the upper
left of the ESPRIT screen) are used to manage
part files.

Opening E xist ing Files
ESPRIT lets you open native ESPRIT files (.esp extension), native 2D and 3D files from other CAD
systems such as SolidWorks or Pro/E, stereolithograhpy (STL) files, and translated files such as IGES
and STEP.
Since ESPRIT is based on the Parasolids kernel, it is adept at opening a variety of solid model files.
Use the Open command to open a previously saved file. Use the “Files of type” pulldown to list
only files with a specific extension. This makes it easier to browse for the file you want. If the file
you’re looking for has an unlisted extension, select “All Files”.
Note: The list of available file formats is based on the licensed options. For example, if your license
does not allow you to open Catia files, this option will not display in the “Files of Type” pulldown.
Opening CAD Files from Another System
You can import a CAD file or merge a CAD file into an existing ESPRIT file.
1. On the Standard toolbar, click Open or press Ctrl+O.
2. Click the Options button.
3. Select an option on the File Type pulldown to set the options for each type of CAD file.
Specific import options are provided for each type of CAD file. For example, if you are
importing a Parasolid, SolidWorks, or Solid Edge file, remember to select either “Import as
solid” or “Surfaces”. When “Wireframe” is checked, wireframe elements are created along
surface edges
4. After setting the options, click OK to return to the Open dialog box.
5. Select the file you want to import.
To make it easier to find the file you want, use the “Files of type” pulldown to select a file
extension.
6. If you want to preserve elements created in ESPRIT and merge the CAD file elements with
them, check the Merge option.
7. Click Open to import the CAD file into ESPRIT.
Saving Files
After working in ESPRIT, you’ll want to save your work so you can retrieve it later.
The Save command stores the current file as a native ESPRIT file or as another type of CAD format.
ESPRIT files are saved with a “.esp” file extension. If you want to convert the file to a different file
format, select the “Save as type” pulldown and then select a file extension.
Selecting Elements
One of the most important tasks in any CAD/CAM system is the
ability to select a variety of elements in the part file. A single
part file may include one or more solid models, wireframe
geometry, surfaces, and toolpath,
In addition, you must have the ability to select individual
components of an element, such as edges on a solid model or
the endpoint of a line.
Select ing Elements in t he Work Area

Elements in the work area can be selected individually, as a
group or by type of element.
• Use your mouse to select an individual element in the work
area.
• To select more than on element, hold down the Ctrl key as
you select elements or drag a selection box over a group of
elements.
• To select a group of connected elements, hold down the Shift
key as you select an element.
Use the Selection list to select elements by type. If Geometry
is chosen, you will only be able to select geometry elements
in the work area. When you are finished, remember to set the
Selection type back to All.
Selection List
The Group Command
If you want to select all elements that fit specific selection
criteria, you can use the Group command on the Edit menu.
The Group command lets you select all elements using the
following criteria:
• Element type
• Color
• Layer
• Work Plane
After you identify the selection criteria, click OK to automatically
select all elements that meet those criteria.
Group Dialog

Select ion Modes will highlight the next closest element. In this
example, you want to select the feature but
Four selection modes are provided in the status
a segment is highlighted instead. You would
area at the lower right of the screen:
click the right mouse button until the feature
• HI (highlight) mode
highlights.
• SNAP mode
• SUB-ELEMENTS mode
• INT (intersection) mode
• GRID mode
When a mode is grayed out, that means the

mode is disabled. Click on a mode to enable or
disable it.
HI Mode
When HI mode is enabled, ESPRIT always asks
you to confirm element selections. This allows
you to select from elements that are close to,
or even on top of, each other. For example, you
can use HI mode to select a solid model, an When the correct element is highlighted,
edge on that model, or feature created from a answer Yes by pressing the left mouse button.
solid model.
When HI mode is enabled, ESPRIT will prompt
“Is this the correct choice” and highlights an
element near the selection point.
If this is not the correct element, answer No

by pressing the right mouse button. ESPRIT
SNAP Mode select Options and then the Input tab). This
When SNAP mode is enabled, the cursor lets you select from a defined invisible array
recognizes the midpoints and endpoints of lines of screen locations in response to prompts for
and segments and the centerpoints of circles points, angles, distances, and so on.
and arcs as valid point selections. You may want to set the grid spacing to match
With SNAP enabled, the cursor changes to: your part drawing values.
when you hover over the end of a
segment or arc
Deselect ing Elements
To deselect all items simply click anywhere in a
when you hover near the midpoint of a
blank area of the work area.
segment or arc
when you hover over the centerpoint of Select ing Items in the
a circle or arc
Project Manager
SUB-ELEMENTS mode Features and machining operations can be
When SUB-ELEMENTS mode is enabled, you selected directly in the Project Manager. Most
can select the individual sub-elements of solid of the time, this is much easier than selecting
models or EDM features in the work area. For these items in the work area.
example, you can select the faces, faces loops, When a feature or operation is selected within
or edges of a solid model. You can also select the Project Manager, the same item highlights
the sub-elements of draft conic features. in the work area.
The selection of sub-elements is extremely
useful for selecting the individual faces on a
solid model that you want to machine. The
Grouping Properties command relies on the
selection of sub-elements to automatically
group faces for several types of features: Holes,
Draft Feature Recognition, Turning Profiles, and
FreeForm features.
INT Mode
When INT mode is enabled, the cursor
recognizes the intersections of segments, lines,
arcs, and circles as valid point selections.
With INT set on, the cursor changes
immediately to and remains as the INT
cursor until an intersection is chosen. The
cursor exits INT mode immediately after an
intersection is chosen.
GRID Mode
ESPRIT uses the grid configuration settings from
the Options dialog box (from the Tools menu,

Controlling the Display of Elements
ESPRIT provides a variety of methods that let
you control how your parts are displayed.
Shaded and Wireframe

Displays
For solids and surfaces, you can set the display
to shaded or wireframe mode.
Wireframe: Displays all solids, surfaces, and
geometry as wireframe.
Shaded Wire: Creates a shaded image with

wireframe. The display of the wireframe is light
source dependent. Wireframes will appear in
different colors and/or disappear depending on
the part orientation with respect to the light.
Silhouettes are not supported, only true edges.
Views
ESPRIT provides several standard view
orientations.
Shaded: Creates a shaded image. Has no effect

on geometry elements. You can also shade the
simulation of cutting operations.
When you change from one view plane to

another, the display in the work area rotates
to the new view orientation and the display
automatically zooms to fit all elements within
the screen. You can control the rotation
animation speed on the Workspace tab of the
Hidden Wireframe: Displays visible solids, Options dialog (available on the Tools menu).
surfaces, and geometry as wireframe You can also store your own view orientations,
depending on the orientation of the part. Pan, rotate or zoom the view to the orientation
Elements that would normally be hidden by a you prefer and then store the view for later
shaded view are not displayed. use.
Storing a View Zoom Previous: Zooms out to a smaller view
1. Click View Planes from the Layers and or jumps back to the previous view after using
Planes toolbar. Zoom.
2. Click the New... button. Zoom Dynamic: Dynamically zooms the view in
3. Type a name and click OK. or out depending on the direction of the mouse
movement. Moving the mouse forward causes
the view to zoom in; move the mouse back to
zoom out.
Rotate: To dynamically rotate your drawing
view in three dimensions about a selected
element, select Rotate View then hold down
the left mouse button over any line (including
the x, y, and z axes), segment, circle, arc, or
point and drag the mouse in the direction you
want to rotate the view.
Or, you can hold down the left mouse button
on an open space in the work area and drag the
mouse to freely rotate the view.
Pan: Shifts the view. Select Pan, then drag your
mouse in the direction you want to move the
view.
You can then choose that view at any time from
the pulldown list.
Panning, Zooming, and

Rotating
Commands on the View toolbar let you fit,
zoom, pan and rotate the display of your part in
the work area.
Redraw: Repaints the screen. Use Redraw

when graphics become temporarily obscured.
For example, if you delete an element that was
on top of another element, you may need to
redraw the screen.
Zoom to Fit All: Fits all visible graphic elements
in the screen. You can also press F6 to execute
this command.
Zoom: Magnifies a particular area. Select Zoom,
then drag a box over the area you want to
magnify.

Masks
The Masks command on the View menu lets you hide the display of specific element types.
Press Ctrl+M to display the dialog and uncheck any items you want to hide. All elements of that
type will be hidden in the work area. To display the elements again, check the item in the dialog.
Layers
Layers are very useful for controlling the display of different types of elements in a complex part
file. For example, you can set up different layers for machine components, the initial part stock
or casting, the finished part, roughing toolpaths and finishing toolpaths, or any other type of
geometry.
Once an item is placed on a particular layer, you can turn the layer on or off to hide or show the
different aspects of your part. Place elements of any type in a named layer, then turn that layer off
to hide all items in that layer. The elements are not deleted, just temporarily hidden. You can turn a
layer back on at any time.
Setting the Display of Items on Layers

1. Select Layers from the Layers and Planes toolbar.
2. Place a check next to the layers you want to show and uncheck layers you want to hide.
Note: Do not uncheck the active layer because this will cause all new elements you create to be
invisible.
Using Features
Features serve several purposes in ESPRIT. First, they describe the shape of the parts you want to
machine. ESPRIT uses standard manufacturing terms for features such as pocket, hole, profile, face,
and so on. In this way, a set of features can describe the shape of an entire part.
Features also contain machining properties that control where material removal should occur.
These properties include cutting depths, draft angles, cut direction, entry and exit points, and lead-
in/lead-out points to name a few.
When NC operations are created, ESPRIT typically prompts you to select a feature. You can select a
feature before or after the operation technology is defined. It is recommended that you select the
feature first because then the machining operation automatically adopts the machining properties
from the selected feature.
Features are created using the commands on the Features toolbar. To display the toolbar, click
Features on the Smart toolbar. A feature can be created from wireframe geometry, solid models,
surfaces, or NURB curves.
When a feature is created, it is classified as one of the following:
Chain Feature
An individual feature is considered to be a chain feature. A chain feature could be the boundary
around a part, a simple pocket, or a path constructed of wireframe geometry. A chain feature
defines the start location, direction, and end location for a cutting path.
Chain features are quite simple and are used when you want the cutter to follow a defined path.
Typically, these are contouring or profiling operations. In most cases, the tool can be centered on
the chain feature or offset to the right or left.
PTOP
A PTOP (point-to-point) feature defines a path connecting a series of holes or points.
PTOP features are typically used for drilling operations and can also be used for manual milling.
The tool will follow this path to drill each hole. PTOP features contain information about the depth
and diameter of holes along the path as well as information about chamfers and counterbores.
Feature
A collection of individual features that comprise an area to be machined is considered a feature.
Features are represented by a folder in the Feature Manager. A feature is typically a pocket
containing sub-pockets or islands or a part feature containing all features found within a part
boundary.

A feature that includes pockets, faces, holes and
profiles
A PTOP feature connecting a set of holes
A 3-dimensional chain feature
Feature Recognit ion

ESPRIT has the ability to recognize different types of features automatically. The Pocket, Face
Profiles and Holes commands will automatically recognize milled types of features such as pockets,
holes, faces, and boundaries. For wire EDM parts, the Draft Features command will automatically
recognize a part as a 2-axis or 4-axis feature.
When the Pocket or Face Profiles command is used, every feature within the selected boundary
or face is recognized. The Holes command will recognize every hole within a specified range of
diameters.
The ESPRIT KnowledgeBase extends this feature recognition ability by letting you create additional
classifications for features. For example, a chain feature can be further classified as a groove
profile. The advantage to this approach is that a specific machining process can be associated with
a specific type of feature. For example, that groove feature can be linked to a particular grooving
operation. This not only saves a considerable amount of time, it also improves the consistency and
reliability of your NC code.
Important: Your security module must be attached to your computer and you must have a valid
license in order to use the ESPRIT KnowledgeBase.
Default Par t Types
The ESPRIT KnowledgeBase includes several standard part types - milled, turned, mill/turn, or wire
EDM.
The KnowledgeBase can then be used to apply a specific type of machining based on which type
of part you are working on. For example, milling operations can be automatically applied to milled
features and EDM operations can be specified for specific wire EDM features.
Feature Manager
ESPRIT provides two very useful tools to help you manage
features: the Feature Manager and the Property Browser,
The Feature Manager lists every feature in the open part
file along with any associated machining operations.
The Feature Manager is a component of the Project
Manager. To display the Project Manager, press the F2 key
or select Project Manager from the View menu. The Project
Manager includes the Operations Manager, the Feature
Manager and the Tools Manager.
To view the Feature Manager, click on the Features tab.
Each time a feature is created, it is added to the Feature
Manager. When a feature is selected in the list, the
same feature highlights in the work area. As you create
machining operations, it is much easier to select a feature
from this list than in the work area, especially when a part
file contains multiple features.
Several operations can be associated with a single feature
and operations can be copied from one feature to another.

Proper t y Browser
The Property Browser displays all the properties of a selected item. These include general
properties such as color, layer, and element type plus any machining properties.
Features always have machining properties.
To display the Property Browser, hold down the Alt key as you press the Enter key (Alt+Enter) or
select Properties on the View menu.
To edit a feature property, click on the property’s value in the right column and make your change.
In this way, you can create a feature from 2D geometry and quickly give it 3D properties by adding
depth and draft angles.
Work Planes Assigned to Features

Each time a new feature is created, a work plane is assigned to it automatically. The assigned work
plane property affects the orientation of the tool for cutting operations placed on that feature. You
can view the work plane property in the Property Browser.
ESPRIT assigns only one work plane to each feature, regardless of the complexity of the feature.
If you try to delete a work plane associated with an existing feature, ESPRIT protects you from
accidentally deleting the work plane by displaying a warning that your action is not allowed.
ESPRIT Machining Technology
Use ESPRIT to create a wide variety of machining operations for milling, turning, mill/turn and wire
EDM.
Machining Modes
On the Machining menu, individual cutting operations are organized into three primary modes:
SolidMill, SolidTurn, and SolidWire. Selecting a command on one of these menus places you in that
mode. You can be in only one mode at a time. For example, if you have the SolidMill FreeForm
toolbar displayed and then open the SolidTurn toolbar, the SolidTurn toolbar replaces the SolidMill
FreeForm toolbar. Once a part has been programmed with a machining cycle, the mode in ESPRIT
is locked. Only one machining mode is allowed per file.
The current machining mode is displayed in the status area.
Technology Pages
When you select a machining command, the technology pages for that command are displayed.
Each technology page lets you choose the machining settings that control how that operation will
be performed.
You can save the technology settings for a particular operation by right-clicking inside the
technology page and selecting Save. To retrieve those stored settings later, right-click inside the
technology page and select Open.
Post Processing
After you create an operation, it is added to the Operations Manager in the Project Manager. You
can convert any or all of those operations to NC code.
To convert selected operations, open the Project Manager (press F2). Hold down the Ctrl key to
select individual operations or hold down the Shift key and then select the first and last of a block
of operations.
You can access the NC Code command in a number of ways:
• On the Common Machining toolbar, click NC Code
• Press the F9 key
• On the File menu, click NC Code
• Right-click inside the Operations page of the Project Manager and select NC Code from the menu
Important: To generate NC code, your security module must be attached to your computer and
you must have a valid license. You cannot save files or generate NC code if you are running ESPRIT
in “demo” mode.

Operation settings are logically Enter values directly or use the selection
grouped on separate tabs arrow to gather information from elements in
the work area
Right-click to
save, open or
reset technology
defaults
Click the pulldown Technology Pages

to view all available
options
Context-sensitive help is
available for all machining
commands
ESPRIT KnowledgeBase
The ESPRIT KnowledgeBase includes a
comprehensive database that lets you store
information about feeds, speeds, material,
cutting tools and standard machining
processes, providing you with optimum • KnowledgeBase Document Settings
feedrates and tools for machining your parts. • KnowledgeBase Settings
The information stored in the KnowledgeBase • Rebuild
can be accessed by anyone in the shop during • Rebuild Options
an ESPRIT session. • Process Manager
This guide primarily focuses on the following • KnowledgeBase Manager
KnowledgeBase commands on the Common
The KnowledgeBase Manager includes:
Machining toolbar:
• Cutting Tools Manager
• Speeds Feeds Manager
• Default part types
• KnowledgeBase Document Settings • Default technology
• KnowledgeBase Settings The separate KnowledgeBase Development
• Process Manager Environment includes:
For detailed information about the ESPRIT • All base options
KnowledgeBase, please read the ESPRIT online • Process Technology Manager
help. • Default Technology Manager
Important: To access the ESPRIT
KnowledgeBase, your security module must be
attached to your computer and you must have
a valid license. KnowledgeBase commands are
disabled if you are running ESPRIT in “demo”
mode.
The KnowledgeBase greatly expands the
productivity and automation capabilities
of ESPRIT. Use the KnowledgeBase to set
up and store your most commonly used
tools, materials, and parameter settings for
operation and tool pages. The KnowledgeBase
also offers dramatic improvements in the
efficiency, consistency and quality of machining
operations. Classify features by part type and
then use feature recognition to automatically
associate machining processes to a part.
As part of the base license of ESPRIT, the
following KnowledgeBase components are
included:

KnowledgeBase Document Set t ings
The KnowledgeBase Document Settings command lets you select the part type, part material, and
default technology settings used for cutting operations.
Part Type
ESPRIT provides several default part types for milling, turning, mill/turn and wire EDM. As you
create features, the Part Type determines the feature type associated with that feature based on
pre-defined rules. Feature types are typically associated with automated machining processes.
Part types are defined in the Part/Feature KB Manager.
Speed Feeds
The Speed Feeds settings for material and class determine the feedrate and speed for machining
operations. Materials are defined in the Speeds Feeds Manager.
Default Technology
The Default Technology determines the technology settings used for new cutting operations and
tools. Default technology is defined in the Default Technology Manager.
KnowledgeBase Document Settings
KnowledgeBase Set t ings
The KnowledgeBase Settings command is used to configure the colors displayed on technology
pages and for items linked to the KnowlegeBase in dialogs and the Property Browser. You can also
set up options for the Process Manager and global KnowledgeBase settings.
The option “Apply selected processes to all features” controls how a machining process is applied
to features when you use the Process Manager.
When this option is checked, the same process is applied to all the selected features. This is useful
when you want to machine several similar features at one time.
When “Apply selected processes to all features” is unchecked, you can select several features at
once and apply a separate machining process to each one.
The Reset Technology Last User Defaults button lets you reset all the technology page defaults to
the ESPRIT system defaults.
You can learn more about KnowledgeBase Options in the ESPRIT online help.
KnowledgeBase Settings

Process Manager
The Process Manager command lets you create and save a collection of machining operations as a
Machining Process (.prc) file for future use on similar projects. Or, you may want to use the Process
Manager simply as a convenient way to create and apply several operations to a feature at once.
When the KnowledgeBase is used to automatically link machining processes to features, you only
need to create features and then apply the associated process.
A machining process can be created to perform a complex set of operations. However, you can
also create machining processes to save time on relatively simple tasks. For example, if you always
create Center Drill, Drill, Countersink, and Tap cycles for certain types of holes, you can create a
single machining process that consists of all these drilling operations and then open and apply that
machining process whenever you need it. Or, if you commonly perform face milling and contouring
to most jobs, you can create a machining process with only Facing and Contouring operations.
The Process Manager has a toolbar of commands along the top of the dialog and three main list
areas: “Features”, “Process”, and “Process Steps”.
Process Manager
ct
1
je
o
Pr
Create Features
Features provide the basis for most machining operations in Create Milling Features...............32
ESPRIT. The machining properties contained within a feature
provide a single source of information about how to cut Create Turning Features.............39
the part regardless of which type or how many operations
Create Wire EDM Features....... 50
are associated with the feature. This allows for better
automation capabilities because the associated toolpaths are
automatically updated whenever a feature is modified.
In summary, features:
• Describe the shape of the part you want to cut
• Contain machining properties that control how the shape
is cut
• Allow you to automate machining processes
This project shows you how to create features for use with
milling, turning, and wire EDM operations.
Before you begin, please review how to select elements
using SNAP mode and HI mode in the “ESPRIT Fundamentals”
chapter.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Project 1: Create Features | 31

Create Milling Features
Milling features typically include features that have depth such as pockets, holes, and faces. These
features can be created from 2D or 3D wireframe geometry or created directly from a solid model.
In this project, you will import a solid model and quickly create an entire set of features by simply
selecting the top face of the part.
Face Profiles
The Face Profiles command lets you create a feature by selecting a face or individual face edges
on a solid model. The feature recognition capabilities in the Face Profiles command will create a
feature for the face boundary and additional features for any pockets, holes, or bosses associated
with the selected face.
Holes associated with the selected face are processed using the settings in the Feature Parameters
command. Face Profiles can handle compound holes such as chamfered, counterbored, and
countersunk. For complex holes you must use the Holes command on the Features toolbar. To
learn more about Hole features, please review the online help in ESPRIT.
Feature Parameters
The Feature Parameters command lets you define the parameters for how holes and pockets are
created when the Face Profiles or Pocket commands are used.
When the diameter of a hole lies within the minimum and maximum range, a Hole feature is
created. Drilling operations are typically applied to hole features. You can also choose to create a
single PTOP feature that connects all the holes when ESPRIT recognizes the features.
Otherwise, a pocket or a profile feature is created for any hole with a diameter outside the defined
range. Face Profiles will create a profile. Pocket will create a pocket. You can then apply a pocketing
or spiraling operation to mill these types of holes.
To learn how to machine the features in this lesson, complete the project called “Mill a Standard
Part”.

Open a Ty pical CAD File
1. On the Standard toolbar, click Open.
2. Locate the following file: Features\mill_part.x_b
3. Click Open.
Change t he Display in t he Work A rea

Before you begin working on this file, set up the display so that you can easily access the Feature
Manager, the Property Browser and the Features toolbar. You can perform the following steps in
any order.
Click View Shaded Wire Change view to Isometric
Press F2
to display
Project
Manager
Press
Alt+Enter
to display
Property
Browser
Enable HI Mode

Set t he Par t Ty pe in t he K nowledgeBase
It is important that you set up the document before you create any new features so that the
KnowledgeBase can assign the appropriate feature type as features are created.
1. On the Smart toolbar, click Common Machining and then click KnowledgeBase Document
Settings.
2. Set Part Type to Milled Part - Std Metric.
3. Click OK.
Define t he Parameter s for Hole Recognit ion

This part contains one set of holes with a countersink, another set with a counterbore and a
single large hole that should be milled instead of drilled. Since hole features are used for drilling
operations, you need to specify the maximum diameter allowed for a hole feature so that the
milled hole will be considered a pocket feature during feature recognition.
Step 1 Step 2
Click Features Click Feature Parameters
Step 3
Click Selection
Arrow
Step 4
Select the edge of
one of the larger
corner holes
Step 5
Click OK
When you click a selection arrow in any dialog, you can select an element in the work area and
ESPRIT will read the data directly from the part.

In this case, the new Max Diameter should be 21.48. From now on, hole features will be created for
any holes with a diameter between 0 and 21.48. Any hole with a larger diameter will be treated as
a milled feature.
Create an Ent ire Set of Features at One Time
Step 1
Click Face Profiles
Step 2
Select the top
face of the part
Step 3
Click OK
Let’s take a look at the new features in the Feature Manager.

Select any feature in the features list and then take
a look at its properties in the Property Browser. Pay
particular attention to the KnowledgeBase properties.
Notice that two hole features have been created, with
each one being recognized as either a Countersink or a
Counterbore feature type.
The three pocketed areas have been individually
recognized as either a Small Pocket, Medium Pocket, or
Slot.
The largest hole has been recognized as a milled hole.
Feature types in the KnowledgeBase are important
because specific machining processes can be linked to
each type.

Rename Features
It can be very useful to give meaningful names to features. They are easier to select later when
you create operations and are helpful to other people who use the file.
Step 1
In the Features list, select to
highlight the slot feature
Step 2
Right-click on the feature,
then click Rename on the
menu
Step 3
Type Slot and press Enter
to rename the feature
Step 4
In the Feature Manager, find the
highlighted feature shown and
rename it ‘Face Island’
Step 5
Optionally, rename the other
features as shown

Adjust t he Height of t he Face Island
When the feature around the island on the face was created, the
feature depth was determined by the height of the vertical walls.
You need to increase the height of the feature to make it parallel
with the top of the island.
1. In the Feature Manager, select the Face Island feature.
2. In the Property Browser, click the Depth value of -10 and change
it to -15.
You’re probably wondering why you need to enter a negative value
to increase the height of the feature. When a top face is selected,
Face Profiles assigns a positive depth pointing downward. For a
bottom face, a negative depth is assigned pointing upward.
Create a Hole Feature for t he Milled Hole

It is more efficient to pre-drill the milled hole before applying a spiraling operation. To do this,
you can create a simple Hole feature that matches the size of your largest drill.
Step 1
Click Holes
Step 2
Set the Max and Min
Diameter to 42
Step 3
Select the top face of
Step 4 the part
Click OK
You can now adjust the diameter of the hole feature to match your drill and the depth to match
the full depth of the part.
1. In the Feature Manager, select the new Hole feature.
2. In the Property Browser, change the Depth value from 23.1 to 38.1.
3. Change the Diameter value from 42 to 30.

Create Turning Features
Standard turning operations use chain features and PTOPs to define the cutter path. Mill/turn
operations also let you choose typical milling features such as face profiles and pockets.
For simple 2-axis work, you only need to create chain features on the inner and outer part profiles.
For multiple-axis work, you must create chain features on the upper and lower sides of the part
profile because they correspond to upper and lower turrets.
In this project, you will use the Turning Profile command to identify features for turning operations
and then use the Face Profile and Holes command to identify milling features for mill/turn
operations.
Turning Profiles
The Turning Profile command analyzes the shape of a selected solid model, surface, surface
composite, or STL model to find internal and external profiles. ESPRIT rotates the part around the
x-axis to find the OD profile, ID profile or projections of the front face or back face. The calculated
profile can be created as a chain feature or as individual geometric elements.
Chain Features
ESPRIT provides two general ways to create chain features. The Auto Chain command will create a
chain feature automatically from existing geometry. All of the geometry between the start and end
locations you select are added to the chain feature.
The Manual Chain command lets you create a chain feature by manually selecting existing
elements and, if SNAP mode is on, you can also select SNAP locations.
Chain features can also be created from surface curves, surface edges and text, but that does not
apply to this lesson.
To learn how to machine the features in this lesson, complete the project called “Turn an Advanced
Part”.

Open an ESPRIT File Cont aining a Mill / Turn Par t
2. Locate the following file: Features\turning_part.esp
3. Click Open.
Set Up t he K nowledgeBase
Settings.
2. Set Part Type to MillTurn Part - Std Metric.
3. Click OK.
Create Turning Profiles

In this lesson you will be extracting geometry from the part and creating multiple features. In
this type of situation, your job will be much easier if you place the different types of elements on
different layers so that you can turn off each layer as you finish each task.
This part file already includes layers for the part and the two types of features you will create:
chain features for turning operations and milled features for mill/turn operations.

Create OD and ID Profiles
First you will create a turned profile of the entire solid. ESPRIT gives you the choice of creating
the profile as geometry or as a feature. For this example, you will create geometry and then use
that geometry to create a chain feature that passes over the OD groove and a chain feature for
the ID at the back of the part. You do not want to cut the groove during the initial OD roughing
operation. The groove should be cut with a separate grooving operation. You will create a profile
of the OD groove in the next step.
Step 1
Set the layer to
Geometry
Step 2 Step 3
Click Features Click Turning
Profiles
Step 4
Step 5 Select the solid
Set Profile Type to Full model
Set Create to Geometry
Set Profile Location to Top
Click OK
You now have geometry that defines a complete profile of the part. Now you will create a chain
feature that passes over the groove area. First you need to turn off the ‘Part’ layer to make it easier
to see the geometry.

Step 6
Click Layers to display the
dialog
Step 7
Uncheck ‘Part’
Select ‘Chain Features’
Click Current
Close the Layers dialog
Step 8
Click Auto Chain
Step 9
Select the start
point of the feature
as shown
Step 11 Step 10
Select the end point of Select the segment to
the long segment the left to indicate the
feature direction

Step 12 Step 13
Select the end point Click Cycle Stop to
shown create the feature
Step 14
Click Auto Chain
Step 15 Step 16
Create a chain on the ID Click Cycle Stop
profile as shown
Step 17
Click Layers, then check ‘Part’ to
display the solid model again

Create t he OD Groove Profile
In addition to selecting the entire solid model, ESPRIT provides the ability to select individual
faces. You will create a profile feature of the OD groove by selecting only three faces. The feature
will be created below the turning axis because the groove will be cut with the lower turret.
Before you can select individual faces, you must allow the grouping of sub-elements. Otherwise,
the entire solid will always be grouped.
Step 1
In the Status area, make sure
SUB-ELEMENTS is active
Step 2
Click Turning Profiles
Step 3
Zoom in on the groove

Step 4
Using HI mode, select the face on the
chamfer as shown
Step 5
Select the other chamfer face and the
face between them
Step 6
Set Profile Type to OD
Set Create to Feature
Set Profile Location to Bottom
Click OK

Step 8
Click Layers, then uncheck ‘Part’ and
‘Geometry’ so you can see only the chain
features
Create a Face Profile Feature

In the following examples, you will learn how to create face profile features by selecting edges.
Since the milled areas around the circumference of the part are positioned at an angle, ESPRIT
will create a new work plane automatically when each feature is created. You can then view the
work plane property in the Property Browser.
1. In the Layers dialog, turn on the ‘Part’ layer to display the solid model and make Milling
Features the current layer.
2. Set the view plane to ‘Rotated’.
3. On the Features toolbar, click Face Profiles.
4. Select the edge loop shown below. You may need to right-click a few times to select the
correct loop.
5. Click OK.

6. Click Face Profiles again.
7. Select the two edges shown.
8. Use the Rotate command on the View toolbar to rotate the part and then select the third
edge as shown.
9. Click OK.
Notice that you do not need to select a closed loop of edges to create a face profile feature. You
have now created an open feature that can be milled with a contouring operation.
Because this feature is not parallel to the current work plane, ESPRIT has created a new work
plane and assigned it to the feature. You can see the new work plane on the work planes drop
down list.
Copy and Rot ate t he Face Profile Feature

Now that you have one of the face profile features, you can rotate copies of that feature around
the part to the other two locations.
1. On the View menu, click UVW Axis. Seeing the orientation of the axis will make it easier to
understand which plane you should use for the rotation. Elements are typically rotated around
the W axis of the current work plane, but you can also use a geometric element to define the
rotation axis.
2. Set the view plane to ‘Right’ and set the work plane to ‘YZX’.

3. Select the face profile feature you just created.
4. Press Ctrl+C to display the Copy dialog.

5. Set Transformation Type to Rotate, select Copy and set Number of Copies to 2.
6. Set Total Angle to 360 and press the Tab key. The Angle Between Copies value will be
automatically calculated as 120°. Make sure Use Origin for Rotation Axis is checked.
7. Click OK.
Create Hole and PTOP Features

The holes on this part are not planar so you cannot use the feature recognition capabilities in
ESPRIT. You can, however, create hole features by manually selecting each hole or by selecting
the face that contains the holes. First you will create features for the holes located around the
perimeter of the part, then you will create a PTOP feature for the drilled hole on the front face of
the part.
1. Set the view plane to ‘Isometric’ to get a better view of the part.
2. On the Features toolbar, click Holes to display the dialog.

Step 3
Set Max Diameter to 20
Set Min Diameter to 0
Step 4
Check ‘Connect all
holes with one Ptop’
Step 5
Check ‘Manual
Selection’
Step 6
Select the OD face that
contains the holes
Step 7
Click OK
Step 8
Click Manual PTOP
Step 9
Select the point at the
origin
Step 10
Click Cycle Stop

Create Wire EDM Features
ESPRIT provides features that are designed the draft angle for tapered walls, and corner
specifically for the needs of wire EDM styles such as sharp, conical or isometric based
operations. These features are used for no on the selected model. Any of these properties
other purpose than to make EDM programming can be easily changed after the feature is
as quick and easy as possible. created.
EDM features contain machining properties
such as taper, land height, and lead-in/lead- Ruled Features
out points. When an EDM feature is selected When ESPRIT recognizes a 4-axis part, a Ruled
for a machining operation, ESPRIT uses this feature is created. 4-axis EDM operations
information to automatically populate the require the use of a ruled feature. This type of
SolidWire technology pages. If you make any feature contains properties for the XY-profile,
changes to the feature, the machine technology the UV-profile, and synchronization (match)
will recognize those changes and update the lines between the two profiles.
appropriate settings upon rebuilding the To edit the match lines of a ruled feature, you
technology. must use the Add Match Line and Remove
Match Line commands on the Edit Features
Draf t Feature Recognit ion toolbar.
The Draft Features command will automatically
create the appropriate 2-axis or 4-axis wire Chain Features
EDM feature based on the type of geometry ESPRIT also allows the use of traditional chain
you select. For 2-axis geometry, ESPRIT will features for 2-axis wire EDM operations. The
create a Draft Conic feature. When 4-axis disadvantage to using chain features is that
geometry is selected, a Ruled feature is machining information such as depth, land
created. height, taper and so on must be defined on the
ESPRIT’s EDM feature recognition lets you machine technology pages each and every time
define rules in the Draft Features dialog that an operation is created. Another disadvantage
will automatically calculate the feature start to using chain features is that you cannot create
point, lead-in and lead-out points, corner advanced conics—including taper changes and
types, and taper angles. Open profiles and corner styles.
closed profiles can both be used in EDM feature Note: Chain features cannot be used for 4-axis
recognition. operations
Draf t Conic Features

When ESPRIT recognizes a 2-axis part, a Draft
Conic feature is created. You can select 2D or
3D geometry for a draft conic feature. When
2D geometry is selected, you can add 3D
properties through the Property Browser.
When 3D geometry is selected, you must have
an upper profile, a lower profile and at least
one element connecting the upper and lower
profiles. The feature will automatically include
properties for the land depth of vertical walls,

Create a 3 D EDM Feature from 2 D Geomet r y
2. Locate the following file: Features\EDM_part_2D.esp
3. Click Open.
Choose an EDM Machine Ty pe

Before you can use EDM feature recognition, ESPRIT must be in SolidWire mode. An easy way to
do this is to specify an EDM machine type for the work session. You can also activate SolidWire
mode by displaying the toolbar for SolidWire Gold or SolidWire Platinum.
1. On the Tools menu, click EDM Machine Types.
2. Select Sodick and click OK.
Note: You must actually select a machine type in the dialog to activate SolidWire mode. You
cannot simply open the dialog and then click OK. This prevents accidentally activating SolidWire
mode by simply opening the dialog.
Create a Draf t Conic Feature

You will now create an EDM draft feature from the simple 2D geometry in this file. After the
feature is created, you will use the Property Browser to add 3-dimensional properties like taper
and corner styles.
A fast way to select all the geometry in a profile is to hold down the Shift key as you select only
one element in the profile.
Note: Never use Ctrl+A to select geometry for an EDM feature. Ctrl+A will select all geometry
in the work area, including overlapping geometry or geometry that is not visible on the screen.
EDM feature recognition will fail when disconnected or inappropriate geometry is selected.

Step 1 Step 2
Hold down the Shift key Hold down the Ctrl key
and select an element in and select the thread
the profile point
Step 3
Click Draft Features
Step 4
Set Part Type to Punch
Set Approach Type to Middle
Set the UV plane height to 15
Approach Type is used to locate the element where the feature will start based on the location of
the thread point. In this example, the start point will be created at the midpoint of the element
closest to the thread point.
The lower edge of this profile is actually comprised of two separate line segments. ESPRIT gives
you the option to retain them as separate elements when the feature is created or combine them
into a single element.
In this project, a different draft angle will be applied to each segment so you will not want to
combine them.

Step 6
Click the Rules tab and set
Combine Elements to No
Step 7
Click OK to create the feature
Step 8
In the Feature Manager, select the new
feature
Step 9
In the Property Browser, click on the value
for Draft, change it to 10 and press Enter
Notice that the depth in the positive

Z direction is a negative value in the
Property Browser. This is to keep
consistency throughout the software
because, in the milling world, a positive
depth means moving the end mill in the
negative Z direction.

Customize t he Draf t Conic Feature
Now that the draft conic feature has a uniform depth, draft angle and corner styles, you will
begin to customize the feature by changing the properties of specific sub-elements. This is
accomplished by using the sub-element selector in the Property Browser.
The Sub-Element forward and back arrow buttons let you quickly move through and select
sub-elements in an EDM feature. The feature in this lesson has 10 sub-elements, which include
segments and arcs. As each sub-element is selected, the start and end locations are highlighted
in the work area.
Step 1
In the Feature Manager, select the draft
conic feature
Step 2
Use the sub-element arrow buttons to
select the upper right corner of the feature
Step 3
Change the Corner Radius Mode to
Isometric and press Enter to confirm

Step 4
In the same way, select the lower right
corner of the feature
Step 5
Change Corner Radius Mode to
Programmable and press Enter
Step 6
Change Program Radius to 2.0 and press
Enter
Step 7
Use the same techniques to update
the rest of the feature

Note: The color for sub-elements in a draft
conic feature is controlled in the Options dialog
(available on the Tools menu). This makes
it easier to see at a glance the difference
between each type of sub-element that makes
up a draft conic feature.
Change t he Taper of a Group of Draf t Conic Sub-Elements

Now that you have learned how to modify the properties of individual draft conic sub-elements,
you will practice modifying a group of sub-elements. In this example, you will make a taper
change to a group of sub-elements.
1. Open the following file: Features\EDM_part_subelements.esp
This draft conic feature currently has depth but no taper. You will add a 5° taper along the
bottom edge of the part.
2. In the Status area, make sure SUB-ELEMENTS mode is active.
3. On the View menu, click Mask and then uncheck Geometry. This will hide the display of all
geometry so that you won’t accidentally select geometry instead of feature subelements.
4. Make sure HI mode is active.
Note: When you use HI mode, ESPRIT will first highlight the entire feature. Right-click to respond
No, then respond Yes with a left-click when the sub-element highlights.

Step 5 Step 6
Select the first Hold down the Ctrl
sub-element key and select the
ending sub-element
Step 7
While holding down the Ctrl and
Shift keys simultaneously, select
any sub-element between the
first and last
Step 8
Click Taper Change
Step 9
Set Starting Taper and
Ending Taper to 5, then
click OK
When a taper is applied to sub-elements, the feature direction determines the location of the
starting taper. The selection of the first sub-element in a group has no effect. This becomes
apparent when a gradual taper is applied as you can see below.
Tip: Draft Conic features are always created in a counter-clockwise direction.

Create a Ruled Feature from a Solid Model
In this example, you will automatically select faces on the solid model to create a ruled feature.
You will select an edge along one face and use ESPRIT’s propagation capabilities to select all the
faces around the outside of the solid model. The face sharing the selected edge is grouped along
with the next face that shares the opposite edge. Each face that shares an opposite edge is then
propogated until all faces sharing opposite edges are added to the group.
Open the file: Features\EDM_part_4axis.esp
Step 1
Hold down the Shift key and
use HI mode to select an
edge
Step 2
Hold down the Ctrl key and
select the thread point

Step 3
Step 4
Set Part Type to Punch
Set Priority to Ruled Only
Set Approach Type to Single Direction
Set Angle to 60
Set the UV plane height to 30
Click OK

Step 5
Change the view to
Isometric
As you can see in the Property Browser, the ruled feature has properties for the XY profile, the UV
profile, and the match lines between them.

ct
2
je
o
Pr
Mill a Standard Part
ESPRIT has very strong capabilities in 2.5D milling, providing Remove Excess Material............ 62
both ease-of-use and a high level of control over every
aspect of a milling operation. Cut the Pockets and Slot.......... 70
The intent of this project is to teach you the process for Mill and Drill Holes........................77
creating standard milling operations using ESPRIT’s SolidMill
Traditional machining technology. Create a Shop Floor Report.... 82
ESPRIT gives you several options for accessing standard
milling commands.
• Menus and Toolbars. Traditional milling commands are
located on the SolidMill Traditional submenu on the
Machining menu. You can also use the SolidMill toolbar.
• Process Manager. You can also select SolidMill commands
from a single menu within the Process Manager. The
Process Manager lets you apply several machining
operations to a single feature at one time.
For this project, you will learn how to use the commands on
the SolidMill Traditional toolbar to create standard milling
operations and how to create a machining process using the
Process Manager.
CD.
Before you start this lesson, you can review and simulate the
cutting operations in the following file:
Milling - Standard\standard_milling_complete.esp.
Project 2: Mill a Standard Part | 61

Remove Excess Material
At the beginning of any milling job, it is critical Contouring
to remove as much excess stock as possible
The Contouring command creates cutting
before you begin cutting the finish passes.
passes that follow the shape of a selected
In this project, the part is cut from standard feature. You can center the tool on the feature
rectangular stock. The first thing you need to or offset it to the left or the right. You can enter
do is remove the excess material from the top an offset distance or use the radius of the tool.
and around the sides of the part.
The Contouring command lets you combine
To do this, you will first create a facing rough and finish passes in a single operation
operation to quickly remove as much stock as or you can create separate rough and finish
possible from the top of the part. Then you passes. When roughing and finishing passes
will create a 3D contour around the island on are combined in one Contouring operation,
the top face. You will finish by roughing and the same tool is used for both phases of the
finishing the outer profile of the part. operation. To use different tools, you must
create separate contouring operations.
Facing It is recommended that you use separate
The Facing command is ESPRIT has multiple operations for roughing and finishing.
options to make facing as fast and effective as
possible. You have full control over depths of Technology Files
cut, optimized cutting angle, stock allowance on Machining technology settings can be easily
floors and walls, and how far you want the tool saved as a separate file and used over and
to travel when it reaches the edge of the stock. over for the machining of similar parts. For this
The Facing operation also automatically creates project, you will load pre-existing technology
a final pass around any islands. This guarantees files that are located in the following folder:
a consistent amount of stock on floors and Getting Started\Milling - Standard\Technology
walls.
After loading the technology for an operation,
you can click on the various tabs to review
Wire Frame Milling the individual settings. For more detailed
The Wire Frame Milling command lets you information, click the Help button located at
create a basic 3D milling operation from simple the lower right corner of the technology page.
2D geometry. The profile of the shape you want
to cut is called the drive curve. This profile is
driven along a path called the basic curve. Each
curve must be created on a separate plane
and the end point of the drive curve must
lie along the basic curve. When constructing
the tool path, the drive curve will be placed
perpendicular to the basic curve at the start
point of the basic curve.

Open t he Par t File
1. Make sure HI mode is enabled.
2. Locate and open the following file: Milling - Standard\standard_milling.esp
3. On the Smart toolbar, click SolidMill Traditional - SolidMill Production to display the toolbar.
If you completed Project 1: Create Features, these milled features should look familiar to you.
Create a Facing Operat ion

For this facing operation, there is an island on the face that must be avoided. The Facing
command lets you select and avoid islands and pocketed areas when the Include Islands option
is set to Yes.This operation will start slightly below the selected feature and cut at incremental
depths of 8mm in a simple back and forth tool motion. A stock allowance of 0.5mm will remain
on the walls of the island after the operation is complete. No stock allowance will remain on the
floors.
Typically, you would select the feature first and then define the operation technology. Because
there is an island on the face, you must first define the facing technology and select the Include
Islands option. ESPRIT will then prompt you to select features for the boundary, any islands and
any pockets you want to avoid. You will select the stock profile feature and the island profille.
You want to face across the tops of the pockets on this part, so you will simply answer No when
ESPRIT prompts you to select pockets to avoid.

Step 1
Click Facing
Step 2
Right-click inside the
technology page and click
Open
Step 3
Open the file:
Milling - Standard\Technology\1-Facing.prc
Step 4
Click OK
Step 5
In the work area, select the
Stock Profile feature

Step 6
Select the Facing Island
feature
Step 7
This is the only island to
avoid, so right-click to
continue to the next step
Step 8
When prompted to select non-cross
pockets, right-click to answer No.
A non-cross pocket designates an open
area where the tool cannot rapid across.
Step 9
When prompted to select cross pockets,
right-click to answer No.
A cross pocket designates an open area
where the tool can rapid across.

Create a Wire Frame Milling Operat ion
For this operation, you will use two existing features. The Wireframe Drive Curve defines the
curved profile for the walls around the island on the face. The Wireframe Basic Curve feature is
located on the top face of the island and defines the path the profile will follow.
For Wire Frame Milling, you first define the machining technology and then select the features.
The Machine Along option controls which curve is used to control the direction of the cutting
passes. In this case, the tool will follow the direction of the basic curve.
Step 1
Click Wire Frame
Milling
Step 2
Open the file:
2-Wire Frame Milling.prc
Step 3
Click OK

Step 4
In the work area, select the Wireframe
Basic Curve feature located on the top
of the island
Step 5
Select the Wireframe Drive Curve
feature located on the island wall

Create Rough and Finish Contouring Operat ions
To cut the external profile of the part, you will first rough the profile with a 30mm end mill that
will leave 0.5mm stock on the walls and then finish with a 20mm end mill. Because the roughing
and finishing operations use very different settings, you will create two separate Contouring
operations.
Step 1 Step 2
Select the External Click Contouring
Profile feature
Step 3
Open the file:
3-Contouring Rough.prc
Step 4
Click OK

Step 5
With the feature still
selected, click Contouring
Step 6
Open the file:
4-Contouring Finish.prc
Step 7
Click OK

Cut the Pockets and Slot
The part in this project contains two pockets pocketing operations with full control over the
and a slot. ESPRIT offers two types of pocketing process.
operations that you will use to cut each pocket.
Rest Machining
Trochoidal Pocket ing The Rest Machining command is used to
The Trochoidal Pocketing command is used remove material in areas and corners that
to quickly rough parts at a constant material previous operations left behind. You can create
removal rate. Trochoidal Pocketing provides rest machining operations for several parent
multiple levels of control over tool motion operations at one time or you can create
pattern, feedrates, and cutter load. rest machining operations for all operations
Trochoid tool motion is well suited for high- associated with a single feature. The previous
speed machining (HSM) because it uses the operation becomes the “parent” operation
biggest possible curve based on the shape of and the rest machining operation applied to
the pocket, allowing for the fastest possible it becomes the “child” operation. The child
feedrates. Although developed for high- operation inherits many of the settings from
speed machining, Trochoidal Pocketing brings the parent operation, such as total depth,
benefits to any type of machine by providing a stock allowance, clearance settings, and so
more constant tool load and a better surface on. If a parent operation is modified, the
finish. rest machining operation is automatically
recalculated and updated.
The Trochoid tool motion pattern creates
a spiral in the largest area of the pocket to
Machining Processes
maintain a constant level of tool loading. When
the trochoid pattern reaches the maximum A machining process is a convenient way to
radius that will fit, the rest of the tool path create and apply several operations at once.
uses an adjustable curve that adapts to the The Process Manager lets you create any
shape of the pocket. number and type of machining operations and
apply them to any number of features.
Pocket ing Important: To use the Process Manager,
The Pocketing command removes material your security key must be attached to your
within a closed boundary. Within a single computer and you must have a valid license. If
pocketing operation, you have the option you are running ESPRIT in demo mode, use the
to create separately definable phases for commands on the SolidMill Traditional toolbar
roughing, wall finishing, and floor finishing to cut the pockets.
passes that each let you use a different tool.
For example, you can use a standard end mill
on the floors to provide the required finish and
use a ball or taper end mill on the walls. If you
do not want all of these phases combined in
a single operation, you can create each phase
independently. You can choose to create only
roughing passes, only wall finishing or floor
finishing passes, or a combination of your
choice. This gives you the flexibility to create

Set Up t he K nowledgeBase
Settings.
2. Set Part Type to Milled Part Std - Metric.
3. Set Default Technology to Default Technology - Inch / Metric.
4. Click OK.
5. Click KnowlegeBase Settings.
6. Make sure ‘Apply selected process to all features’ is checked and click OK.
Create a Process to Mill t he Medium Pocket

To mill the medium pocket, you will first remove as much material as possible as quickly as
possible with a Trochoidal Pocketing operation. A stock allowance of 0.5mm will remain on the
walls and floors of the pocket. A traditional Pocketing operation will then be applied to first
finish the walls and then the floors. To remove any material remaining in the corners, you will
then apply a Rest Machining operation. You will create a machining process to perform all three
operations.
Step 1 Step 2
Select the Medium Pocket A process already exists in the
feature and then click KnowledgeBase. Click New Process
Process Manager to create your own process.
Step 3
Select SolidMill Traditional -
Trochoidal Pocketing

Step 4
Open the file:
5-Pocket1 Trochoidal Pocketing.prc
and click OK
Step 5
Traditional Pocketing
Step 6
Open the file:
6-Pocket1 Finish Pocketing.prc
and click OK

Step 7
Rest Machining
Step 8
Open the file:
7-Pocket1 Rest Machining.prc
and click OK
Step 9
Click Apply
Do not click Exit yet

Create a Process to Mill t he S mall Pocket
The process to machine the small pocket is similar to the medium pocket, except that a Rest
Machining operation is not required.
Step 1 Step 2
Select the Small Click New
Pocket feature Process
Step 3
Trochoidal Pocketing
Step 4
Open the file:
8-Pocket2 Trochoidal Pocketing.prc
and click OK

Step 5
Traditional Pocketing
Step 6
Open the file:
9-Pocket2 Finish Pocketing.prc
and click OK
Step 7
Click Apply
Step 8
Click Exit

Cut t he S lot
To cut the slot, you will use a traditional Pocketing operation using a tool with a diameter the
same width as the slot. The tool will enter the material using a long ramping move and then cut
the slot with a single pass.
Step 1
Select the Slot
feature
Step 2 Step 3
Click SolidMill Click Pocketing
Traditional
Step 4
Open the file:
10-Slot with Ramping.prc
and click OK

Mill and Drill Holes
This part has different types of holes, including a milled hole. For this project, you will create
drilling and spiraling operations depending on the type and size of the hole.
Drilling
The Drilling command is applied to hole features or point-to-point (PTOP) features. The drilling
order is defined by the path of the PTOP feature. SolidMill Drilling supports several types of
drilling, including drill, tap, peck, and bore. The operation drills to a specified depth and you have
the option to include the length of the tool tip in the total depth value. You can also use SolidMill
Drilling to spot drill holes to the correct depth based on the diameter of the tool and the chamfer
diameter.
Spiraling
The Spiraling command creates spiral or helical cutting passes based on the selection of a circle
or a feature in the shape of a circle. A spiraling operation is typically used when you want to mill a
hole that is too large to drill.
Bot tom Up Spiraling

Spiraling passes can be created from the top down or from the bottom up. Bottom up spiraling
can be used to avoid having to rotate your part using index milling. Bottom up toolpath will be
automatically generated when the incremental depth is set to a negative value.
When using bottom up technology, the tool origin is very important. By default, all ESPRIT tools
have the origin set on the bottom. The bottom up technology does not shift the tool origin, so you
have to be aware of the tool thickness when creating your tool path. However, you can create a
custom tool where the tool origin is set on the top of the cutting tool edge.
Pre-Drill and Mill t he Milled Hole

The milled hole has an upper diameter of 42mm and a lower diameter of 50mm. You will cut this
hole in three steps. First, you will pre-drill the hole with a 30mm drill. Then, you will create a
Spiraling operation to mill the upper diameter to a depth of 30mm. You will then create a bottom
up Spiraling operation using a custom tool to mill the lower hole.

Step 1 Step 2
Select the Spiral Click Drilling
Rough feature
Step 3
Open the file:
11-Milled Hole Drilling.prc
and click OK
Step 4 Step 5
Select the Milled Click Spiraling
Hole Upper feature
Step 6
Open the file:
12-Milled Hole Spiraling.prc
and click OK

Step 7 Step 8
Select the Milled Hole Click Spiraling
Lower feature
Step 9
Open the file:
13-Milled Hole Bottom Up Spiraling.prc
and click OK

A pply E xist ing Processes to Drill t he Holes
The ESPRIT KnowledgeBase provides several standard machining processes. Based on the type
of feature you select, the ESPRIT KnowledgeBase will search for the most appropriate machining
process.
You will select the two hole features and use standard processes in the KnowledgeBase to drill
them. The KnowledgeBase will find one process for the countersink holes and another process
for the counterbore holes. The order in which you select the features controls the order of the
operations in the operations list.
To make sure the correct drilling process is created for each feature, you must use KnowledgeBase
Options to specify that you do not want the same process applied to all features. Otherwise, the
first process found will be applied to all the selected features.
1. On the Common Machining toolbar, click KnowledgeBase Settings.
2. Uncheck ‘Apply selected process to all features’.
3. Click OK.
Step 4 Step 5
Hold down the Ctrl key and select Click Process
the Countersink and Counterbore Manager
features
Step 6
Click Apply
Step 7
Click Exit

S imulate
Step 1 Step 2 Step 3

On the Smart toolbar, click Click Run to start the Click Stop to exit
Simulation simulation the simulation

Create a Shop Floor Report
The Report Generator creates HTML and PDF reports that detail the tools and operations for any of
your part files. The preformatted reports are an important NC post processing tool and invaluable
shop floor resource. They provide the machining details required to correctly set up a machine and
perform the required machining operations.
Reports contain information about the machine, the tools, the part, operations, and the NC
program. In addition, each page in the report displays a full-color image showing how the part
should look at each stage of the machining process.
Two types of standard reports are available: Summary and Detailed.
Summar y Repor t
Basic information about the machining process is provided on a single summary page. The
summary report contains a header with general information about the program and an operation
list with one row per operation. Each row displays the main information about the operation like
the operation name, the tool name, the tool ID, feeds and speed, and so on.
Detailed Repor t
This report provides the same summary page along with detailed pages for each operation and a
complete tool list. Click on an operation hyperlink in the summary page to access the operation
details. Click on a tool hyperlink to access the tool details. Operation report pages provide detailed
operation-specific information such as the tool details and available cutting parameters.
Default Folders for Repor t Files

By default, report files are saved to your user folder under the ESPRIT\Data\ReportGenerator\
Reports directory, but you can change it to any other location by clicking the Options button on the
Report Generator dialog.
Generated reports are saved to a subfolder in the distribution location. The subfolder is always
named the same as your part file. If you regenerate any report, all files in the subfolder, including
any output from a previous report, are deleted. If you intend to save any previous version of a
report, copy it from the distribution folder before you regenerate the report.
Important: To use the Report Generator, your security key must be attached to your computer
and you must have a valid license. If you are running ESPRIT in demo mode, the Create Reports...
command is not available on the File menu.

Step 1
On the File menu, click
Create Reports...
Step 2
Select Milling-Detailed, then click
Create Reports
It will take several moments to generate a detailed report of all the operations and tools used in
this part file. After the report is generated, Windows Explorer will launch and open to the folder
where the report files were generated.
Step 3
Right-click on OpSummary.htm
and click Open

Step 4
Click on a hyperlink to view the
operation or tool details

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Mill on a Rotary Axis
ESPRIT’s 4-axis wrap milling is used for cutting while the NC Cut Along a Contour..................... 86
machine axis rotates. Wrap milling is designed to be used
with a barrel stock rotating about an axis. For a standard Rough and Finish the Pocket...91
milling machine, the rotation axis can be parallel to the
Copy and Rotate Operations....94
x-axis (A-axis), y-axis (B-axis) or z-axis (C-axis). For a mill/turn
machine, the rotation axis is typically the C-axis.
Wrap milling should not be confused with index milling.
Indexing, or 4/5-axis milling, refers to the situation where the
NC machine axis (or axes) rotates to a new orientation, then
cuts after the NC machine stops rotating.
This project will show you how to set up rotary axes in
ESPRIT and create rotary milling operations to contour and
pocket the OD of a part. Wrap milling operations can also be
performed on the ID and the face of a part.
CD.
Milling - Rotary\rotary_milling_complete.esp.
Project 3: Mill on a Rotary Axis | 85

Cut Along a Contour
You will begin this project by creating a contouring pass on the OD of the part.
Wrap Contouring
The Wrap Contouring command lets you easily cut solids and 3-dimensional geometry while the
stock rotates on the NC machine. You can create as many contouring passes as needed — a single
finishing pass along the outline of the feature or multiple roughing passes offset incrementally
from the feature. You can also define separate stock allowance values for the walls and floors.
Entry and exit moves can be created while the stock is rotating or the tool can approach and exit
the part without rotary motion.
Wrap Contouring is used for milling on the OD or the ID of a part. To cut on the face, Rotary Face
Contouring is used.
Machine Setup for Rotar y Milling

To enable rotary milling, you need to define at least one rotary axis and set the angle limits for
the NC machine. Wrap milling operations can be defined on any rotary axis or combination of two
rotary axes. If available, the secondary axis will be used as the rotary axis. Otherwise, the primary
axis is used.
Creating a new rotary axis in ESPRIT is quite simple using the Machine Setup command on the
Common Machining menu.
Machine Setup lets you configure any type of 2-axis through 5-axis milling machine. You can define
separate linear motion in X, Y, and Z for your machine components as well as rotary movement in
A, B, and C. This allows you to customize the configuration of the machine in ESPRIT to match your
milling machine exactly and provide an accurate display of all machine motion, including rotary
and index milling, during simulation.

1. On the File menu, click Open.
2. Locate and open the following file: Milling - Rotary\rotary_milling.esp
This file contains all the features, cutting tools and machine parameters needed for this
project.
3. On the Smart toolbar, click Common Machining to display the toolbar.

Define Rot ar y A xes in Machine Setup
The NC machine for this project uses standard X, Y, and Z linear motion on the machine head.
The table has a rotary C-axis mounted on the A-axis.
Let’s take a look at the machine parameters in ESPRIT.

1. On the Common Machining toolbar, click Machine Setup.
2. Click the Assembly tab.

3. Open the assembly tree for Head and then open the tree for Axes. (Click the plus sign to open
a tree)
If you click on the X, Y, or Z axis you will see that they all have linear motion and that each has
its own axis vector that defines the direction of the axis.
4. Open the assembly tree for Table and then open Axes.
The order of the axes listed in Machine Setup is important. The first axis in the list is the
primary axis. The second axis is the secondary axis and so on. In this case, the C-axis is
mounted on the A-axis. Movement will first occur on the A-axis, followed by movement on the
C-axis.
Notice that the maximum rotation allowed for the A-axis is 90 degrees.
The maximum rotation allowed for the C-axis is a full 360 degrees.
5. Click OK to close the Machine Setup dialog.

Create a Wrap Contouring Operat ion
This operation will cut the contoured shoulder on the OD of the part with a single pass using a
25mm end mill. The diameter of the stock is 25mm. The entry and exit moves are performed
while the part is stationary. The lead-in and lead-out distances are both set to 20mm.
The Move Type setting on the Wrap Contouring technology page controls the position of the
tool during the cutting moves. In this case, the tool axis is positioned on the radial axis. Since the
wall you are cutting is parallel to the radial axis, you do not need to use the Preserve Radial Wall
option to prevent any possible gouging.
Step 1
Select the chain feature
around the contoured
shoulder
Step 2 Step 3
Click SolidMill Click Wrap
Traditional - Contouring
SolidMill Production

Step 4
Right-click inside the technology
page and click Open
Step 5
Open the file:
Milling - Rotary\Technology\1-WrapContouring.prc
Step 6
Click OK to create the
operation

Rough and Finish the Pocket
This part has four pockets on the OD. To save time, you will create operations to rough and finish
one of the pockets then simply copy those operations to the other three pockets.
Wrap Pocket ing

Wrap Pocketing lets you easily cut solids and 3-dimensional geometry while the stock rotates on
the NC machine. Roughing passes, wall finish passes and floor finish passes can be combined in a
single operation and each type of cutting pass allows the selection of a different tool. Tool path can
be produced on the OD or the ID of cylindrical stock and all tool paths are drawn in 3D for better
visualization.
With the exception of specific rotary options, the settings for Wrap Pocketing are identical to the
SolidMill Pocketing technology pages.
Wrap Pocketing is used for milling on the OD or the ID of a part. To cut on the face, Rotary Face
Pocketing is used.
Rough t he Pocket
You will first create an operation to rough the pocket using concentric cutting passes that start in
the middle of the pocket and move outward. A rough stock of 0.20 mm will remain on the walls
only. A second Wrap Pocketing operation will be used to finish the walls.
The roughing tool is defined in the General technology page and the cutting strategy is defined
on the Rough page.
Step 1 Step 2
Select the chain feature Click Wrap
around the pocket Pocketing

Step 3
Open the file:
2-WrapPocketing_Rough.prc
Step 4
Click OK
Finish t he Pocket Walls

Next, you will create an operation that only outputs a single wall finish pass using a 10mm
finishing tool. The tool and cutting strategy are defined on the Wall Finish technology page.
Step 1
With the chain feature
still selected, click Wrap
Pocketing

Step 2
Open the file:
3-WrapPocketing_Finish.prc
Step 3
Click OK

Copy and Rotate Operations
You now have rough and finish operations for one pocket. You will quickly copy those operations to
the other three pockets. In this case, the default UVW axis will be used as the rotation axis.
Step 1 Step 2
Hold down the Ctrl key On the Edit menu,
and select the two Wrap click Copy
Pocketing operations
Step 3
Set Transformation Type to
Rotate and click Copy
Step 4
Set Number of Copies to 3
and press the Tab key
Step 5
Check Use Origin for
Rotation Axis
Step 6
Click OK

S imulate

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Mill a Mold Core
The mold insert in this project is part of a mold assembly Remove Excess Material............ 98
used to manufacture a 2-button computer mouse. This
Pre-Finish All Surfaces............. 102
part will give you a good overview of surface roughing
and finishing techniques in ESPRIT. Not all surfaces of this Finish Near-Flat Surfaces.......106
sample part will be machined completely.
The intent of this project is to teach you the process for Finish the Blend Fillet..............108
milling complex surfaces. By the end of this lesson you will
know how to use the more advanced milling techniques
offered by ESPRIT that let you optimize your toolpaths and
cut your parts the way you want to.
CD.
Milling - Surfaces\mold_core_complete.esp.
Project 4: Mill a Mold Core | 97

When complex surfaces are milled, the maximum amount of stock material must be quickly
and evenly removed before the pre-finishing and finishing passes can begin. It is critical that the
roughed part have a constant stock so the finishing tools can cut as effectively as possible.
Variable-Z Roughing
Typical surface roughing operations use a standard cutting pattern, such as a back and forth
motion, to remove material at specified incremental depths. This can cause multiple tool
repositioning moves and a tool motion that does not follow the curves of the part.
The Variable-Z Roughing command creates an optimized roughing operation with cutting passes
that adapt to the shape of the part. At each incremental depth of the operation, ESPRIT calculates
the part boundaries so the tool follows a more intelligent pattern with fewer repositioning moves.
Trochoidal Tool Mot ion

Trochoidal tool motion lets you quickly rough parts at a constant material removal rate. Although
developed for high-speed machining, trochoidal roughing brings benefits to any type of machine
by providing a more constant tool load and a better surface finish.
Search Factor
Complex surfaces require complex toolpath. The Search Factor setting in ESPRIT lets you increase
the analysis of the part geometry to improve the accuracy of the toolpath.
Search Factor is applied to a part based on a grid calculated from the tool size, the tolerance, and
the step over specified on the operation technology page. The default value for Search Factor is
1. The operation searches for cutting passes based on the original calculated grid. Setting Search
Factor to 2 divides each grid in half (in effect doubling the number of grids), setting it to 3 divides
each grid in thirds, and so on.
For surfaces that require high precision machining, use a higher Search Factor value to allow for a
more precise scanning of your part.
Hiding Operations
When you program surfaces, the complexity of the different toolpaths can make it difficult to see
what you are doing on the screen. ESPRIT lets you hide the display of existing operations while
you are working and then display them again later. This makes it faster and easier to program your
parts by displaying only the operations you are currently working on.
In the Operations Manager, you can right-click on any operation and click Hide to hide the toolpath
or click Show to display a hidden toolpath. Hidden operations simulate and post like visible
operations.

2. Locate and open the following file: Milling - Surfaces\mold_core.esp
3. On the Smart toolbar, click SolidMill FreeForm to display the toolbar.
Create a Variable-Z Roughing Operat ion

This operation will use a Trochoid tool motion pattern. At each incremental depth of 2mm,
ESPRIT will create a spiral in the largest machinable area to maintain a constant level of tool
loading. When the spiral reaches the maximum radius that will fit, the rest of the tool path uses
an adjustable curve that adapts to the shape of the part. The Search Factor for this operation is
set to 2.
The feedrate for the trochoidal cutting movement is about one and a half times faster than the
feedrate used for the entry and exit moves. The feedrate for non-trochoidal moves is set on the
General technology page. The trochoidal feedrate is set on the Advanced page.

Step 1
Click Variable-Z
Roughing
Step 2
technology page and
click Open
Step 3
Open the file:
Milling - Surfaces\Technology\1-Variable-Z.prc
Step 4
Click OK
Step 5 Step 6
Select the solid model Click Cycle Stop to create the
operation

Step 7
Click the Operations tab
Step 8
Right-click on the roughing
operation and click Hide

Pre-Finish All Surfaces
The next step in this project is to pre-finish the surfaces. You will do this by creating two
operations: one to pre-finish all the near-vertical areas and one to pre-finish all the near-horizontal
areas.
Z-Level Finishing
The Z-Level Finishing command combines two types of machining strategies into a single operation
for the best possible surface finish on complex surfaces. Separate machining options are available
for vertical and horizontal cutting passes. The appropriate machining strategy is selected based
on a user-defined slope angle that indicates whether a surface should be considered vertical or
horizontal.
When you create a Z-Level Finishing operation, you have the option to machine the entire part or
you can selectively machine vertical or horizontal areas only. When you machine the entire part,
you can choose to cut the vertical and horizontal areas with different tools. Options for machining
vertical areas are located on the Z-Level Finish technology page, while options for machining
horizontal areas are located on the Floor Finish page. Feeds and speeds and entry/exit moves can
be defined independently for z-level and horizontal cutting passes.
Accelerat ion / Decelerat ion Distance

For high-speed machining, the Acceleration Distance and Deceleration Distance settings ensure
that the machine is at the specified feedrate when the tool reaches the part and starts cutting
material.
Entry and exit moves are affected by two feedrate settings: XY Feedrate and Entry Feedrate %.
Acceleration Distance and Deceleration Distance give you better control over how these feedrates
are applied over the entire length of the entry and exit movement so that the tool can be cutting at
the full XY feedrate before it reaches the part.
These distances are measured from the edge of the part along the entry or exit move.
Create Finishing Passes on Near-Ver t ical A reas

You will begin by pre-finishing all the near-vertical areas of the part, leaving a stock allowance
of 0.4mm. The entry and exit moves are both set to Tangent Radius, which will create a 10mm
radiused move tangent to the toolpath. The incremental depth for each z-level is 0.1mm.
Horizontal areas will not be cut.

Step 1
Click Z-Level Finishing
Step 2
Open the file:
2-Z-Level_Vertical.prc
Step 3
Click OK
Step 4
Answer Yes when prompted
to use the previously selected
surfaces
Step 5
Click Cycle Stop

Create Finishing Passes on Near-Horizont al A reas
This operation also uses Tangent Radius entry and exit moves except that the radius is now set to
3mm. The same stock allowance of 0.4mm is used. On the Floor Finish page, the Cut Horizontal
Areas is set to Only and the Max Slope Angle option is set to 15 degrees. This means that only
areas with a slope angle less than or equal to 15 degrees will be cut. When Cut Horizontal Areas
is set to Only, the settings on the Z-Level Finish page are disabled.
Step 1
Click Z-Level Finishing
Step 2
Open the file:
3-Z-Level_Horizontal.prc
Step 3
Click OK

Step 4
Answer Yes when
prompted to use the
default surfaces
Step 5
Click Cycle Stop
Step 6
Hide the display of the
two Z-Level Finishing
operations

Finish Near-Flat Surfaces
In order to provide a good mating surface with the other mold components, you need to finish the
flat areas of the mold insert.
Finishing
The SolidMill Finishing command creates finishing passes using either a specified step over distance
or an allowable scallop height from the tool you are using. When scallop height is specified, ESPRIT
calculates the distance of the step over between each cutting pass. Finishing offers a wide variety
of tool motion patterns that give you full control over how your toolpath is created.
Morphing Tool Mot ion

ESPRIT offers tool motion patterns that automatically adapt to the shape of an outer boundary and
an inner boundary. These tool motion patterns are called Morph and Morph Spiral. Morph moves
use bridge movements between cutting passes while Morph Spiral uses gradual spiral passes
between cutting passes.
These tool motion patterns typically require the selection of outer and inner boundary features.
With Morph In, the toolpath begins by following the shape of the outer profile and then gradually
adjusts to the shape of the inner profile. Morph Out produces the exact same toolpath except that
the toolpath begins with the inner profile.
Slope Machining
Several options are available that let you optimize the machining of localized areas within a part
based on a user-defined slope angle. There is no need to create additional toolpath boundaries.
In addition to creating a finishing operation for an entire part, individual areas of that part can be
defined as flat or steep based on the slope of the surface. Once these areas are identified, separate
operations can be created using different milling strategies.
Cut Near-Flat A reas

This operation will use the Morph Out tool motion pattern to cut all flat areas with a slope of less
than 10 degrees. To provide clearance, the cutting passes will be offset from any wall by 0.1mm.
There is no need to select inner and outer boundaries for the morph movement because ESPRIT
will automatically calculate the local boundaries around each flat area.
After the toolpath is created, please notice how the tool motion adapts to the shape of each flat
area.

Step 1
Click Finishing
Step 2
Open the file:
4-AreaFinish.prc
Step 3
Click OK
Step 4
Use the default
surfaces
Step 5
Click Cycle Stop

Step 6
Hide the finishing
operation
Finish the Blend Fillet

Next, you will create an operation to produce a smooth finish on the fillet around the mouse core.
This finishing operation will also use a morphing tool motion, except that this time you will use the
Morph Spiral In pattern to produce gradual spiraling passes. You will also need to select the outer
and inner boundaries since you will not be using slope machining to calculate the boundaries.
You will first define the machining technology and then ESPRIT will prompt you to select first the
outer boundary and then the inner boundary.

Step 1
Click Finishing
Step 2
Open the file:
5-FilletFinish.prc
Step 3
Click OK
Step 4
Select the chain feature for
the outer boundary

Step 5
Select the chain feature for the
inner boundary
Step 6
Use the default surfaces and
click Cycle Stop

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Mill 5-axis parts
Functions on the SolidMill Mold 5-Axis toolbar deliver Create 5-axis swarf operations...
fast, safe, and reliable programming for a variety of 5-axis 112
applications.
Create a 5-axis contouring
In this project, you will:
operation...............................................123
• Use 5-axis swarf milling operations to cut the tilted walls
on the inside and outside of a part by utilizing the side of Create 5-axis composite
the tool operations........................................... 127
• Create a 5-axis contouring operation to cut a profile on a
formed piece of sheet metal while keeping the tool axis
perpendicular to the model surfaces at all times
• Create five different 5-axis milling operations with the
Composite cycle by utilizing a variety of machining patterns
and tool orientations
Like other ESPRIT cycles, the SolidMill Mold 5-Axis cycles are
feature-based. All Mold 5-Axis cycles must be applied on a
FreeForm feature. The FreeForm feature defines WHAT is cut,
while the cycle defines HOW it will be cut.
CD.
completed files in the following folder:
Milling - 5-Axis
Project 5: Mill 5-axis parts | 111

Create 5-axis swarf operations
In this lesson, you will start by creating two FreeForm features that define the area to be
machined.
Then you will create two Ruled features that will guide the orientation of the tool during the cut.
The upper and lower profiles of the Ruled feature set the limits of the wall to be cut while the
match lines between the two profiles are used for the tool orientation.
The 5-Axis Swarf cycle utilizes the side of the tool to cut tilted walls. While the flank of the tool is
removing material along a wall, the bottom of the tool can be in the air or moving along the “floor”
of the part.
Open t he par t file

1. Open the file SwarfOperation.esp
Two chain features have already been created on the wireframe geometry. You will use these
chains to create a Ruled feature. But first, you will create two FreeForm features that define the
area to be machined.

Create a FreeForm feature on t he inside of t he par t
1. Click the Layers icon and select 5 ‘Solid’ to display the solid
model. Close the Layers dialog.
2. On the Smart toolbar, click SolidMill FreeForm.
3. Click FreeForm Feature.
4. Click Grouping Properties and set Face to Tangent Faces. Click
the Properties icon and set Maximum Tangent Angle Between
Faces to 2 and click OK.
5. Hold down the Shift key and select any face on the inside of the
part. All the inner tangent faces are added to the Part list in the
Project Manager.
6. In the Project Manager, click inside the Check list to activate it.
7. Select the solid model to add it as the check element.
8. Click OK to create the feature.

Create a FreeForm feature on t he outside of t he par t
1. Click FreeForm Feature again.
2. Hold down the Shift key and select a vertical edge on the outer wall of the part. All the outside
faces are grouped and added to the Part list.
3. Click inside the Check list and then select the solid model.
5. Close the Grouping Properties dialog.

Create a Ruled feature from wireframe geomet r y
1. Click Ruled Feature.
2. Set “Recognize From” to “Wire Frame Geometry”.
3. Click inside “Upper Chain” to activate it, then select the chain called “UpperProfile”.
4. Click inside “Lower Chain” and then select the chain called “LowerProfile”.
5. Click inside “Match Lines” and select all the segments that link the upper profile to the lower
profile.
6. Change “Name” to Inside1.
7. Set “Cutting Side” to Left and click OK.

Create a Ruled feature from solid faces
1. Again, click Ruled Feature.
2. Set “Recognize From” to “Solid Faces”.
3. Click inside “Faces” to activate it and then hold down the Shift key and select a vertical edge
on the outside of the part to propagate all the outer faces.
4. Click inside “Lower Edge” and select one of the edges at the bottom of the outer wall of the
part.
5. Change “Name” to “Outside2”.
6. Set “Cutting Side” to Left and click OK.

Create a 5 -A xis Swar f operat ion wit h floor sur faces
1. In the Feature Manager, select the feature “1 FreeForm”.
2. Click 5-Axis Swarf Milling.
3. On the General tab, select the tool EM6.
4. Click the Tool Path tab.

Set t he tool pat h parameter s
1. Set Tolerance to 0.1 and Stock Allowance to 0.
2. Click the selection arrow next to Ruled Feature and select the feature “Inside1”.
3. Set the following parameters:
• Cutting Side = Left
• Offset Tool Radius = Yes
• Stop At Floor = Yes
• Stock Allowance Floors = 0
• Single Cut = Yes
• Invert Tool Direction = No
• Loop Around Corners = No

Set t he approach t y pe
1. Click the Retract tab.
2. In the Approaches list, click Add New
Approach.
3. Add a Radius approach to the list.
4. Set Arc Angle to 45.
5. Set Arc Radius to 5.
6. Click OK to calculate the tool path.
S imulate
Simulate to verify the tool path.

Modif y t he tool pat h parameter s
1. Double-click on the Swarf operation in the Operation Manager and change the following
parameters:
• Single Cut = No
• Incremental Depth = 2
• Alternate Cut Direction = Yes
2. Click OK and simulate the new tool path.

Create a 5 -A xis Swar f operat ion wit hout floor sur faces
1. In the Feature Manager, select the feature “2 FreeForm”.
2. Click 5-Axis Swarf Milling.
6. Click the selection arrow next to Ruled Feature and select the feature “Outside2”.
• Offset Tool Radius = Yes
• Stop At Floor = No
• Bottom Wall Extension = 2
• Single Cut = No
• Incremental Depth = 2
• Alternate Cut Direction = No
• Adapt Orientation to Curvature = No
• Invert Tool Direction = No
• Loop Around Corners = Yes

Set t he approach t y pe
2. Add a Radius approach to the Approaches list.
3. Set Arc Angle to 90.
4. Set Arc Radius to 8.

Create a 5-axis contouring operation
In this lesson, you will create a continuous 5-axis contouring operation along a selected profile.
The profile must lie entirely on the surface to be machined (it must belong to the surface at least
within the machining tolerance). As the tool follows the profile, the tool axis is kept parallel with
the surface normal on the model.
For this lesson, you will use a chain feature as the drive profile for the tool. However, you can also
use a solid edge, solid loop, curve, segment, arc, line, or circle as a drive profile.

1. Open the file ContourOperation.esp
This file already contains a chain feature that you will use as the drive profile for the tool.

Create a 5 -A xis Contour operat ion
1. Click 5-Axis Contour Milling on the Mold 5-Axis toolbar.
2. Because a FreeForm feature was not selected first, ESPRIT starts the creation of a new
FreeForm feature.
3. Select the entire solid body and click OK.
5. Click the Tool Path tab

Define t he tool pat h parameter s
2. Click the selection arrow next to Drive Profile and select the feature “2 Chain”.
• Drive Feature on Edge = No
• Reverse Tool Direction = No
• Drive Profile Offset = 1 (equal to the tool radius)
• Penetration Distance = 1.5 (a distance bigger than the thickness of the sheet metal)
• Max Angle From Normal = 0

Define t he links
2. Add a Lateral approach to the Approaches
list.
3. Set Lateral Distance to 10.
4. Set Tool Length to 100.
6. Simulate.

Create 5-axis composite operations
The concept of the 5-Axis Composite cycle is that any 5-axis machining function, no matter
how complex, can be defined with a few simple steps. Instead of fragmenting advanced 5-axis
functionality into a dozen or more separate dedicated functions with a limited set of options, the
5-Axis Composite Milling cycle combines every possible way to machine a complex 5-axis part
while presenting the options in the logical steps for machining any type of part.
The 5-Axis Composite Milling function separates the desired shape of the tool path on the area
to be machined from the rules that govern the orientation of the tool axis during machining. In
this way, users can create their own customized tool path as a combination of available choices.
In other words, by choosing from the five different machining patterns and the four different tool
orientation strategies, you have twenty different ways to machine the part.
The tool path pattern defines the tool path flow along the part; the tool axis orientation defines
the orientation of the tool while machining. Users also have the ability to limit a 5-axis cycle to
4-axis motion by locking an axis.
In the following lessons you will learn to use each type of machining pattern on both milling and
mill/turn machines.

Create a composite operat ion from parallel planes
The Parallel Planes Intersection pattern creates curves by intersection of the part with a set of
parallel planes. The tool is then driven along those curves. The plane direction is set from an
existing work plane that must be previously saved. This work plane is used to control the direction
of the set of planes. The planes will be created in the direction of the W axis.
The position of the first plane in the set is defined by selecting a point or by entering X, Y, Z
coordinate values. The position of the last plane is set by a user-defined distance. The distance is
measured along the positive direction of the W axis. The user then enters the incremental distance
between each plane in the set. The step over of the calculated tool path depends on the distance
between the planes.

1. Open the file Composite_ParallelPlanes.esp
2. Start by creating a point at: X = 20, Y = 0, Z = 0.
This point will be used for the tool orientation.

Create a FreeForm feature
1. Click FreeForm Feature on the Mold 5-Axis toolbar.
2. Use the Shift key and grouping properties to group all the internal tangent faces of the part.
3. Select the solid model as the check element.

Create a 5 -A xis Composite operat ion
1. Select the FreeForm feature and click 5-Axis Composite on the Mold 5-Axis toolbar.
2. Select the tool UN10.

2. Set Machining Pattern to Parallel Planes Intersection.
• Tool Position = Contact Point On Curve
• Work Plane = YZX (this is an existing work plane in the document)
• Start Point X, Y, Z = 0,0,0
• Ending Distance = -80 (a negative ending distance will go in the opposite direction of the W
axis of the selected work plane)
• Pass Movement = One Way
• Change Pass Start Position = Yes
• Step Increment = 3

Define t he tool a xis orient at ion
1. Set Orientation Strategy to Through Point.
2. Click the selection arrow next to Through Point X, Y, Z and select the point in the work area.
• Toward Through Point = No
• In-Line Angle = 0
• Cross Angle = 0
• Angle Limitation = No Limit

Define t he links
2. Add a Vertical approach with a 60mm Vertical
Distance.
3. Add an Adaptive Cubic feed link and set the
Maximum Link Distance to 20mm.
S imulate
Simulate to verify the tool path.

Create a composite operat ion from planes along a cur ve
The Planes Intersection With Spine Curve pattern is similar to the Parallel Planes Intersection
pattern except that the set of planes are created perpendicular to a spine curve.
The spine profile can be a chain feature, an edge, a face loop, a curve, a segment, an arc or a
circle. The first plane in the set is located at a point along the curve. The point should belong to
the selected curve, but it does not necessarily need to be the initial point of the curve itself. The
last plane in the set is also located at a a point along the curve. Like the start point, the end point
should belong to the selected curve, but it does not necessarily need to be the ending point of the
curve itself.

1. Open the file Composite_PlanesWithSpineCurve.esp.
2. In the Feature Manager, select “1 FreeForm”.
3. Click 5-Axis Composite.
4. Select the tool BM20.

Define t he toolpat h parameter s
1. On the Tool Path tab, set Tolerance to 0.1 and Stock Allowance to 0.
2. Set Machining Pattern to Planes Intersection With Spine Curve.
• Tool Position = Contact Point On Curve
• Spine Profile = 1 Chain
• Start Point X, Y, Z = click the selection arrow and digitize the start point of 1 Chain. Then
change the X value to 2.
• End Point X, Y, Z = digitize the end point of 1 Chain
• Pass Movement = Optimized Direction
• Change Pass Start Position = No

1. Set Orientation Strategy to Perpendicular to
Drive Surface.
• Cross Angle = 0
• Angle Limitation = Fixed Angle With
• Reference Axis = X-Axis
• Fixed Angle = 75
The Angle Limitation setting is used to lock the
B-axis at -15 degrees. The Reference Axis is set to
X-Axis because the reference axis is in the global
XYZ system.
Define t he links
2. Add a Vertical approach with a Vertical Distance
of 10mm.
3. Add a Fluent Cubic feed link with:
• Maximum Link Distance = 10
• Start Arc Angle = 30
• Start Arc Radius = 5
• End Arc Angle = 30
• End Arc Radius = 5

Create a composite operat ion from a drive sur face
Parametric Pattern generates the tool path from the parametric curve of a selected drive surface.
When more than one surface is being cut, the curves are propagated side by side to the next
surfaces. The propagation tries to keep a fluid flow to the tool path. The drive surface must belong
to the model being cut.
After the drive surface is selected, the U and V cutting directions are displayed on the selected
drive surface. A white arrow shows the normal direction of the drive surface. The U direction is
displayed with a red arrow and the V direction is displayed with a green arrow.
The direction of the cut can be set to either the U direction or the V direction of the drive surface.
By default, the tool moves in the same direction as the arrow but an option is provided that lets
the user cut in the opposite direction.

1. Open the file Composite_ParametricPattern.esp.
2. Select the FreeForm feature.
4. On the General tab, select the tool BM20.

2. Set Machining Pattern to Parametric Pattern.
• Tool Position = Tool Center on Curve
• Drive Surface = click the selection arrow and digitize the face shown on the solid
• Cutting Direction = V Direction
• Reverse Cutting Direction = Yes
• Reverse Step Over Direction = Yes
• Pass Movement = Optimized Direction

Drive Surface.
• Cross Angle = 0
Define t he links
2. Add a Bridge feed link with:
• Maximum Link Distance =5
• Vertical Distance = 2

Create a composite operat ion from a projected sur face
Project Parametric Pattern is similar to Parametric Pattern except that an auxiliary surface that
does not belong to the model is used. The shape of the tool path is created by projection of the
parametric lines of the drive surface onto the model. The projection is normal to the drive surface.
After the drive surface is selected, the U and V cutting directions are displayed on the selected
drive surface as red and green arrows respectively. A white arrow shows the normal direction of
the drive surface.
The direction of projection is, by default, the opposite direction of the natural Normal direction of
the drive surface. That means that if the normal of the drive surface is pointing towards the model,
points will be projected in the opposite direction.
If the Normal direction arrow is pointing towards the model, check Reverse Projection Side to
make sure points are projected onto the model. The projection distance controls the maximum
distance that points are projected from the drive surface onto the model. The projection distance
can be used to prevent points from being projected onto undesired surfaces behind the target
surfaces.

1. Open the file Composite_ProjectParametric.esp.

2. Set Machining Pattern to Project Parametric Pattern.
• Tool Position = Contact Point on Curve
• Drive Surface = click the selection arrow and digitize 2 Nurb Surface
• Cutting Direction = V Direction
• Reverse Cutting Direction = Yes
• Reverse Step Over Direction = Yes
• Reverse Projection Side = Yes
• Projection Distance = 10
• Pass Movement = Zigzag

Drive Surface.
• Cross Angle = 0
Calculate t he toolpat h
2. Simulate.
Notice how the tool stays perpendicular to the drive surface and not to the model.

Create a composite operat ion with a constant of fset
The Contour Offset pattern uses a progressive offset of the boundary of the surfaces to be
machined. This produces a somewhat concentric tool path. The progressive offset can start on the
inside of the area to be machined, proceeding outward toward the external border, or it can start
at the external boundary and proceed inward toward the center of the area to be machined. If the
area to be machined contains islands, the offset can be calculated in an alternating inner-outer
order.

1. Open the file Composite_ContourOffset.esp.

2. Set Machining Pattern to Contour Offset.
• Tool Position = Contact Point on Curve
• Use Approach Point = No
• Pass Movement = Inside Out
4. Set the following tool axis orientation parameters:
• Orientation Strategy = Perpendicular to Drive Surface
• In-Line Angle =0
• Cross Angle =0

Define t he links
2. Add an Adaptive Cubic feed link with a Maximum
Link Distance of 5mm.

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Turn a Standard Part
A basic lathe permits movement within a single plane defined Remove Excess Material........... 146
by the Z and X axes—the Z axis being parallel to the stock and
the X axis perpendicular. In order for ESPRIT to accommodate Finish and Groove the OD....... 154
both standard milling and turning operations, the global axis
Finish and Thread the ID......... 157
labeled “X” is the spindle axis (the Z axis). The global axis
labeled “Y” is the lathe X axis. Perform the Cutoff........................ 161
The intent of this project is to teach you the process for
creating basic lathe operations using ESPRIT’s SolidTurn
machining technology.
CD.
Turning - Standard\turned_part_complete.esp.
Project 6: Turn a Standard Part | 145

The first step in any machining process is to You can define separate rough stock for the
remove as much excess material as quickly roughing passes and the finish pass.
as possible. It is equally important to leave a
uniform amount of rough stock so that finishing Drilling
operations can cut as efficiently as possible. The SolidTurn Drilling command creates a face
Variations in the amount of rough stock should centerline drilling operation to a specified
be avoided to prevent the tool from becoming depth in Z. SolidTurn Drilling gives you several
unexpectedly buried in excess material. A options for your drilling routines: drill, peck, tap
uniform amount of rough stock will also result and bore.
in a much better surface finish on the final part.
For off-centerline drilling or to drill on the OD
For this project, you will begin wih roughing of a part, you must have a live tool (a spinning
and drilling operations. tool) and you must use the Wrap Drilling
command on the SolidMillTurn menu. Mill/turn
Stock Automat ion operations are detailed in Project 6.
ESPRIT maintains awareness of the state
of lathe stock at any moment during the Process Manager
machining process. The current operation You will use the Process Manager to create a
calculates the stock material based on any separate process step for the face rough, the
previous turning operations or the initial OD rough, the OD pocketing and the center
stock defined in Machine Setup or Simulation. drill and then apply all four process steps with
After any turning operation is created, ESPRIT the click of a button. You can select as many
updates the knowledge of the stock. That features as you like in the Feature Manager and
knowledge can then be used to calculate the then use the Process Manager to create one
stock for any subsequent turning operations. or more operations for each feature. In this
The visibility of the turning stock on the screen project, you will create a single operation for
is controlled through the Masks dialog. Click each feature.
Masks on the View menu (or press Ctrl+M),
then check Lathe Stock on the Details tab. Important: To use the Process Manager,
your security key must be attached to your
Roughing computer and you must have a valid license. If
you are running ESPRIT in demo mode, use the
SolidTurn Roughing creates parallel cutting
SolidTurn toolbar to complete this project.
passes between the specified stock and a
selected chain feature. Roughing passes can be
created on the face, the OD, or ID of a part.
Technology Files
Machining technology settings can be easily
You can choose to create all rough cuts at a
saved as a separate file and used over and
specified depth except for the last pass, which
over for the machining of similar parts. For this
will follow the profile to cut the remainder of
project, you will load pre-existing technology
the material, or you can create evenly spaced
files that are located on the ESPRIT CD in the
roughing passes based on the distance between
following folder: Getting Started\Turning -
the stock and the selected feature.
Standard\Technology.
The Roughing command lets you create a finish
After loading the technology for an operation,
pass after the roughing passes are complete.
you can click on the various tabs to review

the individual settings. For more detailed information, click the Help button located at the lower
right corner of the technology page.

2. Locate and open the following file: Turning - Standard\turned_part.esp
This file already contains the features, cutting tools and lathe information you will need to
complete this project.
3. On the Smart toolbar, click Common Machining.
4. Click KnowledgeBase Settings.
5. Make sure ‘Apply selected process to all features’ is unchecked. You will be creating an
individual process step for each feature, so you don’t want the same process applied to all
features.
6. Click the ‘Reset Technology Last User Defaults’ button to reset all operation settings to the
system default.
7. Click OK.

Create a Process
This part will be roughed from 60mm bar stock. First, you will rough the face and then the OD,
leaving a uniform rough stock of 0.2 mm. You will finish by creating a drilling operation to remove
as much stock as possible from the ID.

On the View menu, On the Details tab, Close the Masks
click Masks select Lathe Stock dialog
Step 4
Hold down the Ctrl key as you
select the following features in
the Feature Manager:
1 Chain
2 Chain Step 5
7 Chain Click Process
1 PTOP Manager
Step 6
Select ‘1 Chain’ in the feature
list
Step 7
Select SolidTurn - Roughing

Step 8
Right-click anywhere inside the
technology page and click Open
Step 9
Open the following technology file:
Turning - Standard\Technology\1-Face Rough.prc
Notice that Type of Work is set to Face and Stock Type is set to Automation. Click the Rough tab
and observe the settings for Rough Passes. This operation uses a 2mm depth of cut with a uniform
amount of rough stock set to 0.2mm. The setting for Pullout Mode controls the direction of the
clearance cuts. In this case, the clearance cut will take place in the same direction as the cutting
pass for a distance of 2mm. On the Finish tab, notice that a finish pass will not be performed. The
OD will be finished later with a contouring operation.

Step 10
Face Rough process step
for the first chain feature
Step 11
Select ‘2 Chain’ in the
feature list, then select
SolidTurn - Roughing
Step 12
Right-click in the technology page and click Open
In the same Technology folder, open the file:
2-OD Rough.prc

The OD Rough operation uses the same roughing tool as the Face Rough operation. Type of Work is
now set to OD. On the Rough page, the same depths of cut and rough stock are used.
Step 13
Click OK to create the OD
Rough process step
Step 14
feature list, then select
SolidTurn - Roughing

Step 15
Open the file:
3-OD Rough Undercut.prc
and then click OK
This operation will be used to rough the undercut area on the OD using a constant depth of cut.
Notice on the Advanced tab that Undercutting Mode is set to Below. ESPRIT will recognize and cut
any undercut areas located below the tool while undercut areas in front of the tool will be ignored.
Step 16
Select the PTOP feature
in the list, then select
SolidTurn - Drilling
Step 17
Open the file:
4-ID Center Drill.prc
Step 18
Center Drill process
step

Step 19
Click Apply to generate all
four operations at once
Step 20
Click Exit to close the
Process Manager
You have now removed most of the excess material from this part.
If you click on the Operations tab in the Project Manager, you will see another view of the four
operations you just created. You do not need to be overly concerned about the order in which you
create operations, because they can be reordered easily in the Operations Manager with a simple
drag and drop.

Finish and Groove the OD
Now that you have roughed and pocketed the OD of the part, you will create a finishing pass along
the OD and then rough and finish the OD groove in a single operation.
Contouring
The SolidTurn Contouring command lets you create a finish pass along the face, OD or ID of a
part. You can choose to skip undercut areas where a material violation may occur or cut as much
material as possible with consideration for the size of the cavity and the side relief of the tool.
Grooving
The SolidTurn Grooving command gives you multiple options that let you control exactly how you
want to cut your grooves. A grooving operation can be applied to the face, OD or ID of a part.
You can create only roughing passes, only finishing passes, or both. When roughing and finishing
passes are combined, ESPRIT lets you define exactly when and where the finishing passes will be
created in relation to the roughing passes.
Step 1
Select the following
features: Step 2
3 Chain Click Process
8 Chain Manager
Step 3
features list
Step 4
Select SolidTurn - Grooving

Step 5
Open the file:
5-OD Groove.prc
Step 6
Click OK to create
the OD Groove
process step

Step 7
Select the ‘8 Chain’ feature,
then select SolidTurn -
Contouring
Step 8
Open the file:
6-OD Finish.prc
Step 9
Click OK
Step 10
Click Apply
Do not click Exit yet

Finish and Thread the ID
The OD of the part is now complete and you are ready to start working on the ID. You will first
rough and finish the ID in one step, then cut the ID groove and finish by creating a threading
operation.
Roughing and Finishing in One Step

When you roughed the OD of the part, you created only roughing passes. Now you will create a
single roughing operation that will create roughing passes for the ID, followed by a single finishing
pass. The same tool is used for all cutting passes.
Threading
The SolidTurn Threading command lets you create a threading operation on the face, OD or ID of a
part.
During simulation, the actual thread channels can be simulated by setting Simulate Threads to Full
Thread in the Simulation Parameters dialog.
Step 1
With the Process
Manager still open,
Select the feature:
4 Chain
Step 2
Select SolidTurn - Roughing

Step 3
Open the file:
7-ID Rough Finish.prc
Step 4
Click OK
Step 5
Click Apply

Step 6
Select ‘5 Chain’ in the Feature Manager, then select
SolidTurn - Grooving in the Process Manager
Step 7
Open the file:
8-ID Groove
Step 8
Click OK
Step 9
Click Apply
Step 10
Click Exit

Step 11
Click SolidTurn
Step 12 Step 13
Select ‘10 Chain’ Click Threading
Step 14
Open the file:
9-ID Thread
Step 15
Click OK

Perform the Cutoff
A cutoff operation is used to separate the part from the bar stock. It is a very simple operation,
with the tool moving only in the X direction along the specified chain feature.
Step 1 Step 2
Select the feature Click Cutoff
‘9 Chain’
Step 3
Select the Cutoff Tool
Step 4
Set Stock Type to
Automation

Step 5
Click the General tab
Step 6
Set the Entry and
Exit settings as
shown
Step 7
Click the Rough tab
Step 8
Set the Rough
Passes settings as
shown
Step 9
Click OK

S imulate
The details of the machine, including spindles and turrets, are already defined in Machine Setup.
You can now simulate the complete movement of the operations, the part and the machine if
you’d like to see how the operations you just created work together.
1. Click Simulation.
2. Click Run to start the simulation.
The operations are simulated in the same order as they are listed in the Operations Manager.
3. If you’d like to slow down the simulation, simply drag the speed control to the left. To pause
the simulation, click Pause. To show or hide the machine base, turrets, or spindles, click the
visibility icons.
4. When you are finished, click Stop.
Stop
Run
Speed

Shop Floor Repor ts
The ESPRIT Report Generator creates HTML and PDF reports that detail the operations and
tools used for any of your turning part files. The preformatted reports are an important NC post
processing tool and invaluable shop floor resource. They provide the machining details required to
correctly set up a machine and perform the required machining operations.
You can learn more about shop floor reports in the “Mill a Standard Part” project.

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Turn an Advanced Part
In the previous project, you learned how to turn a part on a Create a Balanced Rough.........166
basic lathe. Now, you will learn how to mill/turn a part on a
multi-axis lathe with two spindles and two turrets. Drill and Groove Simultaneously
169
A basic lathe permits movement within a single plane defined
by the Z and X axes. However, to perform livetool milling Mill/Turn a Face Profile........... 172
operations, additional axis combinations are required.
The first addition is a rotational axis along the stock, often Transfer the Part to a Sub-
referred to as the C axis. The next step is to add an axis Spindle....................................................174
normal to the ZX machining plane, often referred to as
Drill on a Rotary Axis................. 177
the Y axis. A rotational axis along the Y axis is called the B
axis. A specific machine tool manufacturer may refer to an Mill with the B-Axis..................... 178
additional axis by another name, but all mill/turn machines
support these axis combinations in one form or another.
creating multi-axis lathe operations. You will perform several
operations on the main spindle, then transfer the part to the
sub-spindle where you will complete the machining.
CD.
Turning - Advanced\advanced_turning_complete.esp.
Project 7: Turn an Advanced Part | 165

Create a Balanced Rough
The Balanced Roughing command uses two tools to let you rough a part about twice as fast as a
normal roughing operation. One tool stays behind the other and cuts at the next depth according
to the specified turret trailing distance.
Balanced Roughing also lets you perform pinch turning, where two tools cut simultaneously. The
main tool and the trailing tool cut at the same depth and at the same speed. Because the two tools
are cutting simultaneously, the feedrate can be doubled while maintaining the same tool load.

The part file for this project already contains the features, cutting tools and machine setup
information you will need to complete this project.
2. Locate and open the following file: Turning - Advanced\advanced_turned_part.esp
3. On the Smart toolbar, click SolidTurn.
If you completed the lessons in the “Create Features” project, this part should look familiar to
you.

Create a Balanced Roughing Operat ion
For this operation, two different tools are used; one for the upper turret and the other for the
lower turret. The tool on the lower turret will trail behind the first by 5mm. A 2mm depth of cut
is used and rough stock is set to zero.
After you load the Balanced Roughing technology file, take a look at the settings on the Strategy
page for the definition of the trailing turret and trailing tool. The settings for the roughing passes
and the trailing distance are defined on the Balance Rough page.
Step 1 Step 2
Open the Layers Press Ctrl+M and
dialog and turn off the check Lathe Stock on
Part layer the Details tab
Step 3 Step 4
Select the chain Click Balanced
feature for the Roughing
OD profile
Step 5
technology page and
click Open
Step 6
Open the file:
Turning - Advanced\Technology\1-Balanced Rough.prc
Step 7
Click OK

Two operations have been created, one for each
turret. You can click on each operation to highlight it in
the work area.
Add a S y nc Code
Next, you will add a sync code after these roughing operations to make sure that these
operations are completely finished before machining can begin on the next operation.
There are two methods for syncing operations. You can use the sync commands located at the
top of the Operations Manager or you can use drag and drop. For these operations, you will use
the sync commands. For the next set of operations, you will learn to use drag and drop. Then you
can decide which method you prefer.
Step 1 Step 3
Click the Operations tab to view the Click ‘Create Sync Below Selected
Operations Manager Operations’
Step 2
Select either of the Balanced
Roughing operations, then hold
down the Shift key as you select
the other operation

Drill and Groove Simultaneously
Next, you will use the top turret to perform a drilling operation as you groove the OD with the
lower turret. When simultaneous operations are created, only one spindle speed can be used.
Spindle priority must be specified for one of the operations so that ESPRIT knows which operation
controls the spindle speed.
Spindle priority should be designated for the operation with the longest cycle time to make sure
that only one spindle speed is used for the entire cycle. After the operations are created, you can
see which one has the longest cycle time by looking in the Property Browser or by launching a
simulation in real time mode.
Create a Drilling Operat ion wit h t he Upper Turret

For this operation, you will drill to a depth of 40mm. For this reason, the Drill Type on the Drill
technology page is set to Peck with a peck increment of 5mm.
Step 1 Step 2
Select the PTOP feature on Click Drilling
the face of the part
Step 3
Open the file:
2-Face Drilling.prc
Step 4
Click OK

Create a Grooving Operat ion wit h t he Lower Turret
For this operation, you will be cutting the groove below the center line. For this reason, the
X Clearance Absolute value for the entry and exit moves must be negative. You can view the
Entry and Exit settings on the General page. On the Groove page, you will see that this grooving
operation includes roughing passes that leave 0.2mm rough stock followed by a final finishing
pass.
Note: The Drilling and the Grooving operations both have Spindle Priority set to Off. You will
complete the operations and then use the Spindle Priority command in the Operations Manager
to set the Spindle Priority.
Step 1 Step 2
Select the chain Click Grooving
feature for the lower
groove
Step 3
Open the file:
3-OD Groove.prc
Step 4
Click OK
Set t he S pindle Priorit y and S y nc t he Operat ions

You can set Spindle Priority on the machining technology pages or you can set it in the
Operations Manager. Unless you know for certain that one operation will have a longer cycle
time than the other, it is better to first create the operations, compare the cycle times in the
Property Browser and then set the spindle priority for the longest operation in the Operations
Manager.
You also need to add sync codes after the drilling and grooving operations. The next operation is
a milling operation so all turning operations must be complete before you can start milling.

Step 1
In the Operations Manager, select the
Grooving operation. The cycle time is
displayed in the Property Browser.
Step 2
Click Spindle Priority
To show you which operation has spindle

priority, the name of the grooving operation
is highlighted in yellow and the background
is a dark gray.
Step 3
Select near the bottom of the Drilling
operation
Step 4
Hold down the mouse button as you
drag the cursor to the bottom of the
Grooving operation. You should see a
bright red line below both operations.
Step 5
Release the mouse to create a sync
code below the selected operations
Note: Selecting above or below an operation has an affect on where the sync code is created.
When you select above an operation, the sync code is added above that operation. A bright red
line above or below the selected operation highlights where the sync code will be located.

Mill/Turn a Face Profile
The profile feature on the face of the part needs to be milled. For milling a face on a rotary axis,
you can use the Rotary Face commands on the SolidMillTurn menu. Whether the tool is positioned
above or below the center line for a rotary face milling operataion depends on the X Axis Limit in
Machine Setup.
For the next operation, the tool is positioned below the center line. The illustration below shows
the settings used in Machine Setup to accomplish this.
Set a negative axis limit in X to position the tool below the center line. A positive limit positions the
tool above the center line. Machine Setup is available on the Common Machining menu.
Create a Rot ar y Face Operat ion

The technology settings for Rotary Face Contouring are identical to the standard Contouring
command on the SolidMill Traditional menu, except that the NC output combines rotary motion
with tool motion.
For this operation, the tool is positioned below the center line with a lead-in/lead-out distance
of 10mm. You can view the entry and exit move settings on the Common page. The flat areas on
this profile are cut with a single roughing pass that leaves no rough stock. The profile is cut with a
combination of tool movement and rotary movement of the part.

Step 1
Click SolidMillTurn
Step 2 Step 3
Select the profile Click Rotary Face
feature on the face of Contouring
the part
Step 4
Open the file:
4-Wrap Face Contouring.prc
Step 5
Click OK
Step 6
Add a sync code after the milling
operation and the last sync code
Note: A sync code can be added to a

machining operation, another sync code
or to a tool

Transfer the Part to a Sub-Spindle
Next, you need to transfer the part from the main spindle to the sub-spindle to that you can
perform additional operations on the back of the part. To do this, you must first instruct the
machine to pick up the part with the sub-spindle, pull the bar stock forward and then perform a
cut off to separate the part from the bar stock.
The bar feed distance should be calculated as follows:
Bar Feed Distance = Final Part Length (A) + Cut Off Tool Width (B) + Back Stock Allowance (C1) +
Front Stock Allowance (C2)
After the cut off, the front face of the bar is positioned at the same location as the front face of
the bar at the beginning of the program. This makes it possible to loop the program in order to cut
several parts using the automatic bar feeder of the machine.
Create a Pickup Operat ion wit h t he Sub-S pindle

You will now instruct the sub-spindle to pickup the part on the front face using a designated
pickup point.

Step 1 Step 2
Click SolidTurn Click Pickup
Step 3
Open the file:
5-Pickup.prc
Click OK
Step 4
Select the reference
point on the face of the
part
Create a Bar Feed Operat ion

Next, the sub-spindle needs to pull the bar stock forward so that the cutoff can be performed.
The calculated distance for this bar feed operation is 84mm.
• Part Length = 80mm
• Front and Back Stock Allowance = 0
• Tool Width = 4mm
You then need to specify a point from which this distance will be measured. You will select the
same reference point on the face of the part that you used for the pickup operation.
Step 1
Click Bar Feed
Step 2
Open the file:
6-Barfeed by Spindle.prc
Click OK
Step 3
Select the reference point
on the face of the part

Create a Cutof f Operat ion
Finally, you will use a cutoff tool on the upper turret to perform the cutoff. You then need to add
a sync code to make sure all operations are complete before you begin the operations on the
sub‑spindle.
Step 1 Step 2
Select the chain Click Cutoff
feature at the
back of the part
Step 3
Open the file: 7-Cutoff.prc
Click OK
Step 4
Add a sync code after
the Cut Off Cycle

Drill on a Rotary Axis
You will now use the Wrap Drilling command to create a rotary drilling operation on the
sub‑spindle. Wrap drilling operations are created from PTOP features. You can create wrap drilling
operations on the diameter of the stock or on an end face. The drill points should be located
directly where they will be drilled. These holes will be drilled to a depth of 10mm.
Step 1
Click SolidMillTurn
Step 2
Select the PTOP feature Step 3
for the holes on the OD of Click Wrap
the part Drilling
Step 4
Open the file:
8-Wrap Drilling.prc
and click OK

Mill with the B-Axis
You will now mill the profile features that are located on the OD of the part. Since the three milled
areas are the same, you will create a contouring operation for one of them, then copy and rotate
that operation to the other two.
Note: The orientation of the B-axis is automatic in ESPRIT. The tool axis is always positioned
parallel with the feature work plane.
Create a Mill / Turn Contouring Operat ion

This operation will use the top turret of the sub-spindle and will cut directly to the feature depth
with a single roughing pass.
Step 1
Select the profile
feature on the OD Step 2
of the part Click Contouring
Step 3
Open the file:
9-Baxis Milling.prc
Click OK
A sync must be added after the wrap drilling operation and before the B-axis contouring operation.
Wrap Drilling rotates the part as it drills. The B-axis contouring operation requires that the part
remain stationary while only the tool moves.
Adding a sync code after a tool change saves time because the tool for the contouring operation
will be loaded on the top turret while the drilling operation is being performed on the lower turret.

Step 4
Add a sync code after the Wrap
Drilling operation and the 10mm
end mill tool
Step 5
Change the view orientation to
‘Right’
Step 6
Select the B-axis Milling
Operation
Step 7
Press Ctrl+C
Step 8
Set the dialog as shown and
click OK to copy and rotate the
operation

S imulate
The details of the machine, including spindles and turrets, are already defined in Machine Setup.
You can now simulate the complete movement of the operations, the part and the machine if
you’d like to see how the operations you just created work together.
1. Click Simulation.
2. Click Run to start the simulation.
3. If you’d like to slow down the simulation, simply drag the speed control to the left. To pause
the simulation, click Pause. To show or hide the machine base, turrets, or spindles, click the
visibility icons.
4. When you are finished, click Stop.

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Wire EDM a Die Plate
ESPRIT offers a complete tool set for your make/model Create Draft Conic Features..182
of EDM machine. Each manufacturer’s unique cutting
technology and methodologies are integrated into specialized Contour the Die Openings........ 191
technology pages. This gives you full control over the
Sort EDM Operations..................198
advanced features and unique functionality of the leading
machines on the market. Simulate the Slug Removal..... 201
Before creating SolidWire operations, you must first let
ESPRIT know which type of wire EDM machine you are using.
The machine type you choose determines the options that
are available on the operation technology pages.
creating 2-axis wire EDM operations using ESPRIT’s SolidWire
Gold machining technology.
CD.
Wire EDM\die_plate_complete.esp.
Project 8: Wire EDM a Die Plate | 181

Create Draft Conic Features
When you have a large number of shapes to cut, you can save time by creating features as a group
and then applying a machining operation to all of them at once.
2-A xis Contouring

Contouring operations are used to remove material along tapered and vertical walls (lands).
SolidWire Contouring operations can be applied to features with closed or open shapes. Draft
conic features as well as chain features can be used for 2-axis contouring.
A chain feature defines a simple 2-dimensional path for the wire to travel along. Workpiece
thickness, land depth, taper and corner styles must all be defined in the cutting operation. A draft
conic feature represents a 3-dimensional shape that already contains information about tapers,
land depth, corner types, and so on.
Feature Groups
Although you can create wire EDM operations one at a time, it is much faster and easier to select a
group of similar features and apply the same operation to the entire group at one time.
When several features are selected first and then a technology applied, ESPRIT will automatically
create a folder in the Feature Manager that contains all the selected features, a ‘parent’ operation,
and a ‘child’ operation for each feature.
Each child operation has the exact same technology settings as the parent operation. If you change
the parent operation, the child operations will be updated automatically.
You can also treat the child operations as independent operations by changing some of the
technology settings. However, if any of those settings are updated later in the parent operation,
the parent will override the children.
Shop Floor Repor ts

The ESPRIT Report Generator creates HTML and PDF reports that detail the operations for any of
your wire EDM part files. The preformatted reports are an important NC post processing tool and
invaluable shop floor resource. They provide the machining details required to correctly set up a
machine and perform the required machining operations.
You can learn more about shop floor reports in the “Mill a Standard Part” project.

The part file for this project contains a solid model of a die plate.
2. Open the following file: Wire EDM\die_plate.esp
3. Change the view to Shaded.
This part has several types of die openings. There is a group of 10mm diameter holes, a triangular
opening with a 2° taper and several rectangular openings with a land depth of 2mm and a 1° taper.
Set t he EDM Machine Ty pe

It is important to define the type of EDM machine you are using so that ESPRIT will display the
correct machining technology pages.
1. On the Tools menu, click EDM Machine Types...
2. Make sure Generic is selected and click OK.

Create Draf t Conic Features
You will create draft conic features for the die openings and the holes. Instead of creating
features one at a time for the die openings, you can create all the features at once using
ESPRIT’s face propagation capabilities. After the features are created, you will create Contouring
operations to cut all the holes and then all the rectangular openings. Then you will create a
Contouring operation for the triangular opening.
Draft Conic features are ideal in the following situation:
• You want to create features from 3-dimensional geometry.
• The geometry has tapers, tapers and lands, or advanced conics.

On the Smart toolbar, Change to an Select the solid
click Features Isometric view model

First you will use Draft Feature Recognition to create the hole features. Draft Feature Recognition
will automatically recognize any holes in the solid model and create specialized features with the
thread point automatically placed at the center of each hole. You will also automatically place the
new features into a feature group.
Step 4
Step 5
Set Part Type to Hole
Step 6
Click the selection arrow next to
Maximum Diameter
Step 7
Select an edge of one of the holes to
automatically load the value on the
technology page

Step 8
Click the Rules tab
Step 9
Set Group to Folder to Yes
Step 10
Click OK
Note: Full descriptions of the draft feature dialog settings are available in ESPRIT Help (press F1).
The Feature Recognition Report dialog displays a message that the positions of the thread points
was calculated by ESPRIT. The display of this dialog is controlled on the Rules page with the ‘Display
Error Messages’ setting.
Step 11
Click OK

The hole features are added to a folder in the Feature Manager. The features are named according
to the selection for Part Type to make them easier to identify later.

Next you will select all the faces that belong to the die openings using the Tangent Faces option
in the Grouping Properties dialog. All faces will be selected that are tangent to the first face you
select.
When you hold down the Shift key, you can select a solid or a single solid face and ESPRIT will
automatically select faces based on the settings in the Grouping Properties dialog. When you hold
down the Ctrl key as well, you can continue to add more elements to the group.
Step 1 Step 2
Click Grouping Set Face to
Properties Tangent Faces
Step 3
Hold down the Shift key and
the Ctrl key as you select a face
from each opening
Next you will select all the thread points. These points will be used to define the lead-in/lead-out
and start points for each feature.

Step 4
Set the Selection Filter to Point
Step 5
Hold down the Ctrl key as you
draw a selection box around all
the points
Step 6
Step 7
Set Part Type to Die
Set Approach Type to Normal
Set UV to 20
Step 8
Click the Rules tab
Step 9
Set Group to Folder to Yes
Step 10
Click OK

You have just created 7 features in one step. The feaures are created in the same order as the faces
were selected.
Step 11
Set the Selection Filter
back to All

Contour the Die Openings
First you will create a single contouring operation and apply that operation to all the holes.
Step 1
Click SolidWire
Step 2 Step 3
Select all the Click Contouring
features in the Hole
Group
Since most of the machining information is extracted directly from the selected features, you only
need to define the cutting strategy on the Contour page and how many cutting passes to create on
the Contour page.

Step 4
Make sure Strategy is set to [Rough][Skim]
Step 5
Click the Contour tab and set Strategy to Rough
and 1 Skim, then click OK

You will again create a Contouring operation to cut all the rectangular openings. Then you will
create a Contouring operation for the triangular opening.
Step 1
Drag the feature for the triangular
opening to the XYZ coordinate to
move it out of the Die Group

Step 2 Step 3
Select all the features Click
in the Die Group Contouring
Step 4
Set Strategy to [Rough][Skim]

Step 5
Click the Contour tab
Step 6
Set the Primary Cut Strategy to
Rough
Step 7
Set the Land Cut Strategy to
Rough and 2 Skims
Step 8
Click OK

Step 9 Step 10
Select the triangular Click Contouring
feature
Step 11
Make sure Strategy is set to [Rough][Skim]
Notice that this time there is no reference plane for the
land height

Step 12 Step 13
Click the Contour tab Set the Primary Cut Strategy to Rough and 1 Skim
Notice that the Land Cut Settings are disabled
Click OK

Sort EDM Operations
SolidWire operations are added to the Operations Manager in the same order as they are created.
This is typically not the optimum order in which you will want to cut the final part.
The Advanced Operations Sorting command gives you plenty of options for sorting operations to
optimize cutting time. You can sort operations by type of cut or by cavity and then optimize the
cutting path between operations.
The operations you created in this project are currently sorted by feature.
You will use Advanced Operations Sorting to sort the operations by type so that all the roughs are
performed first, the cutoffs second and the skims last. Then you will practice optimizing the cutting
path using different optimization methods.
Note: You can also manually reorder individual SolidWire operations by dragging and dropping
them anywhere in the Operations Manager.

Step 1
Click Advanced Operation Sorting
Step 2
Set Sort By to [Rough][Cut-Off][Skim]
Step 3
Set the Path Optimization Routine to Shortest
Path, then click the selection arrow and select
the lower left feature as shown
Step 4
Click Apply to see the results

Step 5
Set Routine to Zigzag and Zigzag Type to
Horizontal
Step 6
Set Band Width to 10 and then click Apply to
see the results
Step 7
Click OK

Simulate the Slug Removal
When SolidWire operations are simulated, you have the option to display the slug removal
automatically while the operations simulate or you can wait until the simulation is complete and
then remove the slugs manually. For this project, you will manually remove the slugs.
Create t he Simulat ion Stock

Before you start the simulation, you will create a solid that represents the initial stock for this
part. You will do this by creating a chain feature of the outer profile and then use the Simulation
Parameter command to extrude that profile to create the simulation stock.
To automatically select all the connected segments that form the profile of the part, you will hold
down the Shift key during the selection process.
Step 1
Hold down the Shift key and select a
segment in the outer profile

Step 2 Step 3
Click Features Click Auto Chain
Step 4 Step 5
Click Simulation Click Simulation
Parameters
Step 6
Uncheck Automatic Slug
Removal

Step 7
Click the Solids tab
Step 8
Set Type to Stock
Set Create From to Extrusion
Step 9
Set Z+ to 0 and Z- to 20
Click the Selection Arrow and
then select the chain feature
Step 10
Click Add
Step 11
Click OK

S imulate
Step 1
Click Run to simulate all the
cutting operations
Step 2
Click Slug Removal
Step 3
Select different stock items in the list and click
Move Down or Move Up
ESPRIT will prevent you from moving the tapered Step 4
stock above the block because this is not possible Click Stop to exit the
simulation

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Wire EDM a 4-Axis Part
What distinguishes 4-axis wire EDM from 2-axis is that the

shapes of the top profile and bottom profile can be different,
which requires a constantly changing taper as the wire moves
around the part.
In ESPRIT, consistency is maintained between 2-axis and
4-axis wire EDM machining technology to make it extremely
easy to transition from standard 2-axis EDM operations to
more complex 4‑axis machining.
This project will show you how easy it is to apply the
knowledge you already learned in Project 7: Wire EDM a Die
Plate to 4-axis wire EDM operations.
CD.
Wire EDM\advanced_4axis_complete.esp
Project 9: Wire EDM a 4-Axis Part | 205

Contour a Multi-Axis Part
For this project, you will quickly create a ruled feature from an imported solid model and just as
easily apply a 4-Axis Contouring operation to that feature.
4 -A xis Contouring
The 4-Axis Contouring command on the SolidWire Platinum menu is very similar to the Contouring
command on the SolidWire Gold menu, except that you will be cutting separate UV and XY profiles.
The biggest difference between 2-axis and 4-axis contouring in ESPRIT is that you cannot use chain
features for 4-axis cutting operations. ESPRIT provides a specialized EDM feature called a Ruled
feature for 4-axis wire EDM operations. Ruled features are described in greater detail in Project 1:
Create Features.
Cut O f fs
ESPRIT lets you perform a cut-off in two steps. When cutting a punch, a large cut-off distance
is sometimes necessary in order to retain rigidity and stability of the punch while roughing
and skimming. However, a smaller glue distance is required to allow the operator to make
arrangements for the punch that will fall free. Using a secondary cut off frees the operator from
standing at the machine while a large glue stop is being cut.

2. Open the file: Wire EDM\advanced_4axis.esp
If you completed Project 1: Create Features this part should look familiar to you.
3. Click SolidWire.
4. On the Tools menu, click EDM Machine Types...
5. Select Generic and click OK.
Create a 4 -A xis Contouring operat ion

The machining properties for this feature contain most of the information ESPRIT needs to create
a 4-axis contouring operation. You simply need to define the order for cutting passes and how
many rough and skim passes to create.
ESPRIT offers standard machining strategies for dies and punches that provide a quick and easy
mechanism to generate highly efficient machining, especially important when you are cutting
multiple work pieces or work pieces that require multiple cuts. The Punch strategy will perform
all the rough cuts first, followed by all the skim cuts, finishing with the cut-offs.
You will specify one rough cut, two skim cuts, a primary cut off and a secondary cut off. The two
skim cuts will also be applied to the cut off.

Step 1 Step 2
Select the Ruled feature Click 4-Axis Contouring
Step 3
Set Direction to CW
Set Strategy to
[Rough] [Skim] [Cut-Off]
Step 4
Set Retract Length to 2.0
Step 5
Click the Contour tab
Step 6
Set Strategy to Rough and 2 Skims
Step 7
Set the offsets as follows:
Rough: 0.19
Skim 1: 0.125
Skim 2: 0.106

Step 8
Click the Cut Off tab
Step 9
Set the Cut-Off settings as
shown
Step 10
Click OK


ESPRIT 2009 Get Started Guide

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ESPRIT 2009 Get Started Guide

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Get Started

Welcome to ESPRIT 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Welcome to ESPRIT 2009 | 1

2 | Get Started with ESPRIT 2009

Install ESPRIT from t he CD

Welcome to ESPRIT 2009 | 3

Other ESPRIT 2009 menu items:

4 | Get Started with ESPRIT 2009

Welcome to ESPRIT 2009 | 5

ESPRIT Help on t he Web

General Windows® Help

6 | Get Started with ESPRIT 2009

DP Europe DP Germany DP Italy

Welcome to ESPRIT 2009 | 7

8 | Get Started with ESPRIT 2009

10 | Get Started with ESPRIT

The Graphic Work Area

The Prompt Area The Status Area

Creat ing New Files

The commands on the File menu or the icons on

12 | Get Started with ESPRIT

Select ing Elements in t he Work Area

14 | Get Started with ESPRIT

When a mode is grayed out, that means the

If this is not the correct element, answer No

16 | Get Started with ESPRIT

Shaded and Wireframe

Shaded Wire: Creates a shaded image with

Shaded: Creates a shaded image. Has no effect

When you change from one view plane to

Panning, Zooming, and

Redraw: Repaints the screen. Use Redraw

18 | Get Started with ESPRIT

Setting the Display of Items on Layers

20 | Get Started with ESPRIT

A PTOP feature connecting a set of holes

A 3-dimensional chain feature

Feature Recognit ion

22 | Get Started with ESPRIT

Work Planes Assigned to Features

24 | Get Started with ESPRIT

Click the pulldown Technology Pages

26 | Get Started with ESPRIT

KnowledgeBase Document Settings

28 | Get Started with ESPRIT

Project 1: Create Features | 31

32 | Get Started with ESPRIT 2009

Change t he Display in t he Work A rea

Click View Shaded Wire Change view to Isometric

Project 1: Create Features | 33

Define t he Parameter s for Hole Recognit ion

34 | Get Started with ESPRIT 2009

Create an Ent ire Set of Features at One Time

Let’s take a look at the new features in the Feature Manager.

Project 1: Create Features | 35

36 | Get Started with ESPRIT 2009

Project 1: Create Features | 37

Create a Hole Feature for t he Milled Hole

38 | Get Started with ESPRIT 2009

Project 1: Create Features | 39

Create Turning Profiles

40 | Get Started with ESPRIT 2009