RhinoCAM_GettingStartedGuide

RhinoCAM - Getting Started Guide

© 1997-2012, MecSoft Corporation 1

MecSoft Corporation www.mecsoft.com


http://www.mecsoft.com/



Contents

Welcome to RhinoCAM Getting Started Guide .............................................................. 14

About this Guide ................................................................................................... 14

Where to go for more help ..................................................................................... 14

Tutorial 1: Machining a Gasket ................................................................................... 15

Introduction ......................................................................................................... 16

Strategy to Machine the Gasket ........................................................................... 16

Main Programming Steps .................................................................................... 16

Preparing the part for Machining ............................................................................. 16

Loading the Part Model ....................................................................................... 16

Loading RhinoCAM – Machining Operations Browser ............................................... 17

Machining Operations Browser ................................................................................ 20

Machine Setup ................................................................................................... 20

Select Post Processor .......................................................................................... 21

Define Setup ..................................................................................................... 23

Create Stock Geometry ....................................................................................... 26

Align Part and Stock ........................................................................................... 28

Specify Material ................................................................................................. 30

Set Work Zero ................................................................................................... 31

Create Tools ......................................................................................................... 33

Create Machining Operations .................................................................................. 36

2 ½ Axis Profiling .................................................................................................. 36

Select Machining Features/Regions ....................................................................... 36

Select Cutting Tool ............................................................................................. 40

Set Feeds and Speeds ........................................................................................ 41

Clearance Geometry ........................................................................................... 42

Specify Cut Parameters ....................................................................................... 43

Cut Levels ......................................................................................................... 43

Entry/Exit ......................................................................................................... 45

Simulate Toolpath .............................................................................................. 47

Creating a 2 ½ Axis Profile for the Outer Region ....................................................... 49

Reports ................................................................................................................ 52

Shop Docs ......................................................................................................... 53

Post Processing ..................................................................................................... 54



Tutorial 2: Machining a Slotted Gear ........................................................................... 56

Introduction ......................................................................................................... 57

Strategy to Machine the Slotted Gear ................................................................... 57






Machine Setup ................................................................................................... 59


Define Setup ..................................................................................................... 61

Create Stock Geometry ....................................................................................... 64

Align Part and Stock ........................................................................................... 66

Specify Material ................................................................................................. 66

Set Work Zero ................................................................................................... 68

Create Tools ......................................................................................................... 70

Create Regions for Machining.................................................................................. 72

Create Machining Operations .................................................................................. 77

2 ½ Axis Profiling .................................................................................................. 77


Selecting the Tool .............................................................................................. 80

Set Feeds and Speeds ........................................................................................ 81

Clearance Geometry ........................................................................................... 82

Specify Cut Parameters ....................................................................................... 83

Cut Levels ......................................................................................................... 84

Entry/Exit ......................................................................................................... 85


Creating Engraving Operation ................................................................................. 89


Select Tool, Feeds & Speeds and Clearance ........................................................... 90

Specify Engraving Cut Parameters ........................................................................ 90


Post Processing .................................................................................................. 94

Tutorial 3: Machining a Shaft Base ............................................................................. 96



Introduction ......................................................................................................... 97

Strategy to Machine the Shaft Base ...................................................................... 97






Machine Setup ................................................................................................... 99


Define Setup ................................................................................................... 101

Create Stock Geometry ..................................................................................... 104

Align Part and Stock ......................................................................................... 106

Specify Material ............................................................................................... 107

Set Work Zero ................................................................................................. 109

Create Tools ....................................................................................................... 111

Create Machining Operations ................................................................................ 114

2 ½ Axis Facing .................................................................................................. 114

Select Machining Features/Regions ..................................................................... 115

Selecting the Tool ............................................................................................ 117

Set Feeds and Speeds ...................................................................................... 118

Clearance Geometry ......................................................................................... 119

Specify Cut Parameters ..................................................................................... 120

Cut Levels ....................................................................................................... 121

Simulate toolpath ............................................................................................. 122

Creating Facing Operation #2 ............................................................................... 123

Copying and Pasting a Machining Operation ......................................................... 123

Editing Machining Operation .............................................................................. 124

Specify Avoid Region ........................................................................................ 124

Change Cut Parameters and Cut Levels ............................................................... 126


2 ½ Axis Pocketing .............................................................................................. 129



Cut Levels ....................................................................................................... 132



Entry/Exit ....................................................................................................... 134


Hole Pocketing Operation ..................................................................................... 136

Create Predefined Machining Regions .................................................................. 136




Create Hole Pocketing Operation for the through holes ............................................ 144

Editing Machining Operation .............................................................................. 145


Create Engraving Operation .................................................................................. 148

Create Machining Region ................................................................................... 148

Select Engraving Operation ............................................................................... 150



Create Profiling Operation .................................................................................... 153

Select Machining Features ................................................................................. 153

Specify Parameters .......................................................................................... 153


Post Processing ................................................................................................ 156

Tutorial 4: V-Carving .............................................................................................. 157

Introduction ....................................................................................................... 158

Strategy to Machine the part ............................................................................. 158

Main Programming Steps .................................................................................. 158

Loading the Part Model ..................................................................................... 159

Loading RhinoCAM – Machining Operations Browser ............................................. 159

Machining Operations Browser .............................................................................. 159

Machine Setup ................................................................................................. 160

Select Post Processor ........................................................................................ 160

Define Setup ................................................................................................... 162




Set Work Zero ................................................................................................. 169



Create Tools ....................................................................................................... 171


V-Carving ........................................................................................................... 173





Specifying Cut Parameters ................................................................................ 176


Post Processing ................................................................................................ 179

Saving Operation to a Knowledgebase ................................................................ 179

Tutorial 5: Embossing ............................................................................................. 180

Introduction ....................................................................................................... 181






Machine Setup ................................................................................................. 182


Define Setup ................................................................................................... 184




Set Work Zero ................................................................................................. 191

Create Tools ....................................................................................................... 193


V-Carve Roughing ............................................................................................... 195




V-Carving Operation ............................................................................................ 200

Load Knowledge base .......................................................................................... 201

Edit V-Carving Operation ................................................................................... 202




Post Processing ................................................................................................ 205

Tutorial 6: Chamfering ............................................................................................ 206

Introduction ....................................................................................................... 207




Create Tools ....................................................................................................... 208

Create Machining Operation .................................................................................. 210

Chamfering ........................................................................................................ 211



Specifying Cut Parameters ................................................................................ 214

Reorder a Machining Operation .......................................................................... 215


Post Processing ................................................................................................ 216

Tutorial 7: 3 Axis Milling .......................................................................................... 217

Introduction ....................................................................................................... 218

Strategy to Machine the mold ............................................................................ 218


Preparing the part for Machining ........................................................................... 218




Machine Setup ................................................................................................. 220


Define Setup ................................................................................................... 221




Set Work Zero ................................................................................................. 229

Create Tools ....................................................................................................... 231


3 Axis Horizontal Roughing ................................................................................... 235



Select Tool ...................................................................................................... 236





3 axis Parallel Finishing ........................................................................................ 242



3 axis Horizontal Finishing .................................................................................... 245




Post Processing ................................................................................................ 249

Saving Operation to a Knowledgebase ................................................................ 249

Tutorial 8: Profiling with Bridges/Tabs ....................................................................... 250

Introduction ....................................................................................................... 251






Machine Setup ................................................................................................. 253


Define Setup ................................................................................................... 254




Set Work Zero ................................................................................................. 262

Create Tools ....................................................................................................... 264

Create Predefined Machining Regions ..................................................................... 266

Editing Bridge Points ........................................................................................ 268


2 ½ Axis Profiling ................................................................................................ 270






Post Processing ................................................................................................ 274

Tutorial 9: Hole Making ........................................................................................... 275

Introduction ....................................................................................................... 276






Machine Setup ................................................................................................. 277


Define Setup ................................................................................................... 279




Set Work Zero ................................................................................................. 286

Create Tools .................................................................................................... 287


Drilling ............................................................................................................... 289

Select Hole Features ......................................................................................... 290

Cut Parameters ................................................................................................ 293


Drill Operation #2 for 0.25” holes ......................................................................... 296

Edit Machining Operation .................................................................................. 296


Post Processing ................................................................................................ 299

Tutorial 10: Re-Machining a 3D Mold ........................................................................ 300

Introduction ....................................................................................................... 301

Strategy to Machine the mold ............................................................................ 301








Machine Setup ................................................................................................. 303


Define Setup ................................................................................................... 304




Load Knowledge base ....................................................................................... 312

Editing Machining Operations ............................................................................. 316


Create Pencil Tracing operation ............................................................................. 318


Advanced Cut Parameters .................................................................................... 321


Create Valley Re-Machining Operation ................................................................... 323

Specify Cut Control & Cut Parameters ................................................................. 324


Post Processing ................................................................................................ 327

Tutorial 11: Machining a Ring .................................................................................. 328

Introduction ....................................................................................................... 329

Strategy to Machine the ring ............................................................................. 329






Machine Setup ................................................................................................. 331


Define Setup ................................................................................................... 332




Set Work Zero ................................................................................................. 340

Set Rotary Center ............................................................................................... 342



Create Tools ....................................................................................................... 343


3 Axis Horizontal Roughing ................................................................................... 345

Select Tool ...................................................................................................... 346





Rotate table Operation ......................................................................................... 352

Create Roughing operation after table rotation ........................................................ 353


Create Rotate table operation #2 .......................................................................... 355

4 axis Parallel Finishing ........................................................................................ 357


Cut Parameters ................................................................................................ 359


Post Processing ................................................................................................ 362

Tutorial 12: Engraving on a Cylinder ......................................................................... 363

Introduction ....................................................................................................... 364

Strategy to engrave text on a cylinder ................................................................ 364





Machine Setup ................................................................................................. 365


Define Setup ................................................................................................... 367




Set Work Zero ................................................................................................. 375


Create Tools ....................................................................................................... 378




4 Axis Engraving ................................................................................................. 380


Select Tool ......................................................................................................... 382



Post Processing ................................................................................................ 386

Tutorial 13: Pocketing and Drilling on a Ring ............................................................. 387

Introduction ....................................................................................................... 388

Strategy to machine the part ............................................................................. 388





Machine Setup ................................................................................................. 390


Define Setup ................................................................................................... 391




Set Work Zero ................................................................................................. 399


Create Tools ....................................................................................................... 402


4 Axis Drilling ..................................................................................................... 405

Select Tool ...................................................................................................... 407

Set Clearance .................................................................................................. 409

Cut Parameters ................................................................................................ 409

Sorting ........................................................................................................... 411


4 Axis Pocketing.................................................................................................. 413


Select Tool ...................................................................................................... 415

Set Clearance .................................................................................................. 416

Cut Parameters ................................................................................................ 417



Cut Levels ....................................................................................................... 418


Post Processing ................................................................................................ 421

Tutorial 15: 5 Axis Surface based machining .............................................................. 422

Introduction ....................................................................................................... 423





Machine Setup .................................................................................................... 424




5 Axis Surface Normal Machining .......................................................................... 427

Machining Features .......................................................................................... 428

Select Tool ...................................................................................................... 430

Specify Clearance ............................................................................................. 431


Entry/Exit ....................................................................................................... 433

Gouge Check ................................................................................................... 434


5 Axis Swarf Machining ........................................................................................ 437

Machining Features .......................................................................................... 438

Select Tool ...................................................................................................... 442

Cut Parameters ................................................................................................ 443

Entry/Exit ....................................................................................................... 444

Gouge Check ................................................................................................... 445


Post Processing ................................................................................................ 447



Welcome to RhinoCAM Getting Started Guide

Welcome to RhinoCAM and thank you for choosing one of most powerful and easy to use

complete CAD/CAM packages on the market today.

RhinoCAM is a unique CAM product plug-in that runs inside of Rhinoceros. Plug-ins can be

considered as independent applications that can be loaded and unloaded on demand from

the host program, which in this case is Rhinoceros. This fully integrated RhinoCAM plug-in

seamlessly integrates Rhinoceros’s CAD functionality with toolpath generation and cutting

simulation/verification, in one package that is both easy and fun to use.

You can work with the native Rhinoceros design data as well as use any of the data types

that can be imported into Rhinoceros such as solids, surfaces and meshes. Then you can

use RhinoCAM with its wide selection of tools and toolpath strategies to create machining

operations and associated toolpaths. These toolpaths can then be simulated and verified,

and finally post-processed to the controller of your choice.

About this Guide

Welcome to the RhinoCAM getting started guide. This file contains various tutorials to help

you get started with learning RhinoCAM. Each tutorial lesson has two associated Rhinoceros

files that you can find located in the Tutorials folder under the installation folder of

RhinoCAM. The first file is a completed file that contains all of the completed toolpaths and

machining operations and represents the file that you should end up with after working

through the tutorial. The other file is a starter file that contains only the geometry. Use the

completed file as a reference. Copy the starter file and use this file to begin each tutorial.

Good luck and have fun!

Where to go for more help

Apart from the on-line help system you can download tutorials and projects from MecSoft

Corporation's web site at www.mecsoft.com. This will help you get started with using

RhinoCAM.

If you need additional help, or if you have any questions regarding RhinoCAM, you may

contact us via e-mail at [email protected]

MecSoft offers Online training as well as personalized full day training sessions. Please look

up our website or email us at [email protected] for further details

Please do continue to visit our home page to learn about the latest updates to RhinoCAM

and any other help material.

http://www.mecsoft.com/

mailto:[email protected]

mailto:[email protected]



Tutorial 1: Machining a Gasket



Introduction

This tutorial will illustrate machining of a simple prismatic part such as this gasket using 2-

1/2 milling operations. Even though we have created a 3-D representation of the gasket, it

will be seen later on that we can machine this using just 2-D curves.

The reason we are able to do this is because of the prismatic nature of this model.

The stepped instructions are accompanied by explanatory and introductory text. Reading

this text will help you understand the tutorial methodology and provide information about

additional options available.

Don’t forget to save your work periodically! You may want to save the file under a different

name so that the original file will be preserved.

Strategy to Machine the Gasket

We will machine the Gasket by using a 2-½ axis machining operation called Profiling.

The part will be machined out of a 10 x 6 x ¼ inch poplar wood sheet using a ½ inch

Flat End Mill.

The wooden sheet will be held to the machine table or the spoil sheet on the table

using double-sided tape.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

Create the Stock geometry

Set the Machine zero point with respect to the machine coordinates

Create / Select the tool used for machining

Set the feeds and speeds

Set the clearance plane for the non-cutting transfer moves of the cutter

Select the machining regions for containing the cutter to specific areas to cut

Select the machining operations and set the parameters

Generate the toolpath

Simulate the toolpath.

You may have to repeat either all or part of these steps for subsequent operations.

Preparing the part for Machining

The steps below shows loading and preparing the part for programming.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. You can

create parts within Rhinoceros, but it is more typical to import geometry created in another

CAD system.

To load a part:

1. Select File / Open from the Menu, or click the Open icon from the Standard bar.



2. From the Open dialog box, select the Gasket.3dm file from the Tutorials folder.

The imported part appears as shown below

Loading RhinoCAM – Machining Operations Browser

1. If RhinoCAM Machining Operations browser does not appear in Rhinoceros, select

RhinoCAM from the menu bar and click Machining Operations Browser. This is

also called MOps browser.

The MOps browser is now open and by default appears to the left of the viewport layout in

Rhinoceros.



2. Click RhinoCAM from the menu bar and select Machining Objects Browser. This is

also called MObs browser.

The MObs browser now appears next to MOps browser in Rhinoceros and is automatically

docked to the application by default.



You can drag the MObs browser on top of the MOps browser as shown below.

To drag the MObs browser, click on the title bar of the MObs browser and drag it over the

MOps browser.

Machining Objects browser (MObs) now appears under the Machining Operations browser

(MOps)



Machining Operations Browser

This tab allows you to define Machine Setup, Stock and create Machining Operations.

Machine Setup

1. Click Program tab under MOps browser and select Machine located under Machine

Setup group.



2. Under Machine Type, set Number of Axes to 3 Axis

3. Click OK. The machine type now appears under Machining Job in the browser area.

Select Post Processor

4. Select Post under Program tab to specify post processor options.



5. Set the current post processor based on your machine controller from available list of

posts. We will select Haas as the post processor for this exercise. Set the posted file

extension type to .nc



Note: By default post processor files are located under

C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2012\Posts

The program to send the posted output is set to notepad. This would preview the posted

code in a notepad.

Define Setup

This allows you to orient the Machine Coordinate System to have the part aligned in the

same way as it would be fixtured on the machine tool for cutting.

6. Double click on Setup 1 located under MOps browser.



Note: If Setup 1 does not exist, click Setup or Set CSYS Setup under the Program tab to

create one.

Standard configuration Expert, Professional and Premium configurations

The Machine Coordinate System (MCS) is displayed as a triad with Blue line

representing the Z-axis, Red representing X-axis and Green Representing the Y-axis.

MCS WCS

7. Set Align to World Coordinate System and click OK.



Machine Coordinate system is now in the same orientation as world coordinate

system.



Create Stock Geometry

In this step you will define the raw stock from which the designed part needs to be

machined.

8. Select Create Stock Model from Program tab.

9. Click Box Stock from the drop down list.

This brings up the Box Stock parameters.

10. Set the Length (L) = 10.0, Width (W) = 6.00 and Height (H) = 0.125. Leave the other parameters as default and Click OK.



The stock geometry is now created, and a semi-transparent stock box is displayed on

top of the part geometry.

If the stock geometry is not visible, Click Stock Visibility located at the bottom of the

Program tab.



Machining Job is now updated with the Machine Type, Post Processor and Stock information

in the MOps browser.

Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the part

geometry and use the stock box to specify the machine zero (home position).

11. Select Align Part and Stock Models under Program tab.

12. Set Z alignment to Top and XY alignment to Center. (This would align the stock to

the top of the part in Z and center in XY)



The stock is now aligned to the center of part geometry in XY and top in Z.



Specify Material

We will now set the material type for Stock geometry.

13. Select Define Stock Material under Program tab.

14. Set Material to Wood from the material drop down list and click OK.

The material texture is now applied to Stock geometry and displayed over the stock

model.



If the texture is not visible on stock geometry, Click Material Texture Visibility

located at the bottom of the Program tab.

Set Work Zero

This is used to define the workpiece origin. Work Zero translates the MCS origin from the

Setup to the desired location. This can be set to any location on the part or stock geometry.

15. Select Work Zero from Program tab located under Machining Operations group.



16. Select Set to Stock Box, the Zero Face to Highest Z, and Zero Position to South

West corner. This sets the machine home to the top of the stock material and the

southwest corner of the stock geometry.

The work zero is now translated to the Southwest corner and top of stock material.



Work Zero now appears under MOps browser.

Create Tools

To machine the above part we will now create a ½ inch (0.5”) Flat End Mill.

17. Select Tools tab under RhinoCAM – Machining Objects browser (MObs) and click

Create/Edit Tools.

18. Select the Tool Type to Flat Mill.



19. Set tool Name as FlatMill-0.5, Tool Diameter = 0.5. Under the Properties tab set

Material to HSS and Tool Number = 1.

20. Switch to Feeds and Speeds tab and click Load from File.



21. Set Stock Material to Wood and Tool Material to HSS. Click OK and the computed

cut feedrate and spindle speed is now applied to the feeds and speeds tab.



The computed feeds and speeds are transferred to the Feeds and Speeds tab.

22. Click Save as New Tool to save the tool. The tool is now created and listed under

Tools in Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the changes. You

can create additional tools by assigning a different name and specify the tool parameters.

The created tool is now listed under Tools tab in Machining Objects browser.

Note: To save Tools to library, Click Save Tool library under Tools tab in Machining

Objects Browser and specify folder location and file name in the Save as dialog box. Saving

Tool library as RhinoCAM Knowledge base file (*.vkb) saves feeds and speeds with tool properties.

Create Machining Operations

In this process, we will create 2 ½ Axis Profiling operation.

2 ½ Axis Profiling

1. Select 2Axis and choose Profiling from Program tab under Machining Operations

group.

This brings up the 2 ½ Axis Profiling operation dialog. We will go over the steps for

creating the profile operations for the inner features of the Gasket.

Select Machining Features/Regions



2. Click Select Drive /Containment Regions under Machining Features/ Regions tab.

The Profiling operation dialog is now minimized and allows selection of machining

features.

We will now select the surface edges of the 3 inside hole features.



3. Select the surface edge by clicking near the edge of each hole.

4. Repeat this step for the other 2 hole features.

5. Press enter or right mouse button click to end selection.

The 2 ½ Axis Profiling operation dialog comes back up displaying the selected Drive

regions. The selected regions are also highlighted on the part.



You can click on the Region list and corresponding surface edge curve is highlighted

on the part.



Select Cutting Tool

6. Switch to Tool tab under 2 ½ Axis Profiling operation.

7. Select Flat Mill-0.5 under Tools.

The 0.5” Flat End mill is now selected as the active tool and the Tool parameters are

displayed to the right of the Tools window.



Set Feeds and Speeds

8. Click Feeds & Speeds tab

9. Select Load from Tool. RhinoCAM will now get the feeds and speeds parameters

that was set when the tool was defined.



Clearance Geometry

10. Switch to Clearance tab.

11. Set the Clearance Plane Definition to Automatic and Cut Transfer Method to

Clearance Plane.

RhinoCAM will determine a safe Z height for the Entry & Exit when set to automatic.

Setting Cut Transfer to Clearance Plane would apply the automatic Z clearance

between transfers when the tool moves from a machining region to another.

When this dialog box is active, the clearance plane is shown on the model.



Specify Cut Parameters

12. Switch to Cut Parameters tab

13. Set the Stock = 0 and under cut start Side check Use Outside/Inside for Closed

Curves and select Inside. Alternatively you can also use Determine using 3D

model.

Cut Levels



14. Select the Cut Levels tab and set Location of Cut Geometry as At Top, specify the

Total Cut Depth = 0.125. The cut depth is always set as an absolute value. Set

Rough Depth = 0.125 and Rough Depth/Cut = 0.125.



Entry/Exit

15. Switch to Entry/Exit tab and set Entry and Exit Motions to None.

16. Click Generate. The 2½ Axis Profile toolpath is now generated and the operation is

listed under the RhinoCAM-MOps browser.

Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the

MOps browser.





Simulate Toolpath

The generated toolpath can now be simulated under the Simulate tab.

17. Switch to Simulate tab in RhinoCAM-MOps browser

18. Select 2 ½ Axis Profiling and click Play.

The cut material simulation is shown below.

Note: You can adjust the simulation speed by selecting Simulation Preferences that is

located under the Simulate tab.



To view simulation with texture mapping, toggle, Material Texture Visibility ON.

To exit the Simulation mode, Pause simulation first and then click Stop.



Creating a 2 ½ Axis Profile for the Outer Region

1. Switch to Program tab

2. Select the 2 ½ Axis Profiling operation under Setup 1,

3. Right mouse button click and left click on Copy.

4. Right mouse button click on 2 ½ Axis Profiling and left click on Paste.



This creates a copy of the profile operation.



5. Double click to edit the operation you just copied

6. Click Remove All under Machining Features/Region.

7. Click Select Drive/Containment Regions

8. Select the Surface edge on outer edge of the gasket

9. Right mouse button click or press enter on your keyboard to end selection.

10. Switch to Cut Parameters tab and change the Cut Start Side from Inside to

Outside under Use Outside/Inside for Closed Curves.

11. Leaving all other parameters with the same settings from the previous operation,

click Generate.

12. The 2 ½ Profiling toolpath is now regenerated with the changes.



13. Switch to Simulate tab, select the 2nd 2 ½ Axis Profiling operation under Setup and

click Play to run cut material simulation.

Reports


2. Select Setup 1, right mouse button click and left click on Information.

This provides the estimated machining time for operations created under Setup 1.

Note: You can also go over to Machining Job and right click and select information

determine the estimated machining time for all Setups.



Shop Docs

3. Shop documentation can be generated selecting Machining Job or Setup under the

Program tab. Right mouse button click and select Shop Documentation.

User can select from one of the 2 templates and generate shop documentation. This is

saved as an html file and can be printed and handed over to the operator in preparation for

the part to be machined on the CNC.



Post Processing

1. Select Setup 1 under Program tab, right mouse button click and select Post.

This would post all operations created under Setup 1.

The posted file name is set based on the rules specified under Set Post Options. By default,

when posting a Setup, Part file name + Setup name is used as the file name.

2. Click Post.



The posted file is now saved under the specified folder and can be viewed in a notepad.

The post by default is set to Haas as specified under the Post processor setup. You can

change the post processor by selecting a different one from the drop down menu in the list. The posted g code by default will be saved to the folder where the part file is located.

End of Tutorial 1!



Tutorial 2: Machining a Slotted Gear



Introduction

This tutorial will introduce the usage of 2 ½ axis profiling and Engraving Machining

operations in RhinoCAM. We will be using the Gear.3dm part file.

It should be noted that, even though the part file contains a 3-D geometry representing the

part, we could machine this entirely by using just 2-D curves due to the prismatic nature of

this model.






Strategy to Machine the Slotted Gear

We will machine the gear completely using 2 ½ axis-machining operations.

We will use the Profiling operation to cut the outer shape of the gear and the

Engraving operation to cut the slots. The engraving option is preferred in situations

where the cutter can be driven to create a slot that conforms to the shape of the tool

trajectory. This is because of the computational efficiency as well as the accuracy of

this method.

The part itself will be machined out of a 3 inch x 3 inch x ½ inch poplar wood sheet.



The part will be machined using a single ¼ inch flat end mill.




















CAD system.

To load a part:


2. From the Open dialog box, select the Gear.3dm file from the Tutorials folder.










Step by step instructions on loading MOps and MObs browser can be found under

Tutorial 1 - Loading RhinoCAM – Machining Operations Browser



Machine Setup


Setup group.















code in a notepad.

Define Setup







create one.




The WCS is displayed the same way as MCS with XYZ coordinates labeled on top of

it.

MCS WCS





system.





machined.


9. Click Part Box Stock from the drop down list.

This brings up the Part Box Stock parameters. The system calculates the bounding box

of the part model as the XYZ extents of geometry of the part model. The user can then

define offsets in any of the three coordinate directions to apply to the computed

bounding box. The system will expand the bounding box by the offset amount in each of

the coordinate directions. When the user clicks on the OK button, a stock model based

on the user definition will be created and displayed.

10. Set Offsets for X, Y and Z =0. Make sure to uncheck Ignore Wireframe Geometry

in Bounds Computation and click OK.

Note: Selecting Ignore Wireframe Geometry in Bounds Computation ignores all 2D

and 3D curve geometries present in the part from stock bounding box computation.






Program tab.



Machining Job is now updated with the Machine Type, Post Processor and Stock

information in the MOps browser.



geometry and use the stock box to specify the machine zero (home position). This step is

not necessary for this particular exercise as the part and stock models have the exact same

bounding box extents (3” x 3” x 0.25”)

Specify Material







model.





Set Work Zero




14. Select Set to Stock Box, the Zero Face to Highest Z, and Zero Position to North


northwest corner of the stock geometry.



The work zero is now translated to the Northwest corner and top of stock material.




Create Tools

To machine the above part we will now create a ¼ inch (0.25”) Flat End Mill.


Create/Edit Tools.




17. Set tool Name as FlatMill-0.25, Tool Diameter = 0.25, Flute Length = 1.0,

Shoulder Length = 1.5 and Tool Length = 2.0. Under the Properties tab set


18. Switch to Feeds & Speeds tab and use the following values for spindle speed,

feedrates and feedrate reduction factors.





Note: You can edit the tool properties and click Save Edits to Tool to save the changes.

You can create additional tools by assigning a different name and specify the tool

parameters.





Create Regions for Machining

In the steps below we will extract regions from the 3D model and create curves for

engraving.



1. Turn off Stock model visibility under RhinoCAM – MOps browser.

2. Select Layer Manager from the standard bar

3. Set Layer 01 as active layer by placing a check box next to Layer 01.

A new layer is selected just to have the curves created on a different layer from the

model layer. This would make it easier to view the curves as the new layer has a

different color from the default layer which contains the surface geometry.

4. From Curve menu Rhino Toolbar menu select Curve from Objects and Duplicate

Face Border.

The command bar will now prompt the user to select surfaces or faces for duplicate

border.

5. Select the top face (surface) of the part geometry. A selection list may be displayed

if you click near an edge. Browsing through the selection list will highlight the surface

that corresponds to the selection.



The curves from the top flat area are now extracted from the model and appear on

Layer 01.

6. Switch to the Top viewport or maximize the top view port.

7. From the Curve menu bar, select Circle -> Center, Radius.

8. Center of Circle: 1.5,1.5 and press enter

9. Specify Radius = 1.0 (or Diameter = 2.0) and press enter.

This creates a 2” diameter circle with center at 1.5, 1.5.



We will now create lines, which can be selected for engraving the slots on the gear.

10. Select Osnap from status bar and turn on Quad and Center snap. Turn off the

other snaps.

11. From the Curve menu select Line -> Single Line.

12. Start of Line: Snap to the Quad point of the circle and left click.

13. End of Line: Snap to center of arc



A line is now created at the center of the slot. We will now array the line across other

slots on the gear.

14. Select the line and go to Transform -> Array -> Polar

15. Use the following parameters

a. Center of polar array: 1.5,1.5

b. Number of items: 6

c. Angle to fill or first reference point: 360



The lines created as shown below.

Save your work by selecting File ->Save from the menu bar.



2 ½ Axis Profiling

1. Select Work Zero under Setup 1 and now select 2Axis and choose Profiling from

Program tab under Machining Operations group.


creating the profile operation.






features.

2. Select the inner circle first by using the left mouse click and then the outer circle.




The selected regions are now displayed under Machining Regions.



Selecting the Tool

4. Switch to Tool tab under 2 ½ Axis Profiling operation.



5. Select FlatMill-0.25 under Tools. The 0.25” Flat End mill is now selected as the active

tool and the Tool parameters are displayed to the right of the Tools window.







Clearance Geometry



Clearance Plane.








10. Switch to Cut Parameters tab

11. Set Stock = 0 and under cut start Side check Determine using 3D model.



Cut Levels

12. Select the Cut Levels tab and set Location of Cut Geometry as At Top, specify the

Total Cut Depth = 0.25. The cut depth is always set as an absolute value. Set

Rough Depth = 0.25 and Rough Depth/Cut = 0.125.



Entry/Exit

13. Switch to Entry/Exit tab and set Entry and Exit Motions to None.

14. Click Generate. The 2½ Axis Profile toolpath is now generated and the operation is


Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the

MOps browser.





Simulate Toolpath



16. Select 2 ½ Axis Profiling and click Play.

17. The cut material simulation is shown below.









Creating Engraving Operation

Now we will use engraving operation to cut the slots of the gear by driving the 0.25 inch

tool in the slot. This is an efficient way of machining slots by driving the cutter along the

center of the slot.

1. Switch to Program tab and select 2Axis and Engraving.


1. Under Machining Features/ Regions click on Remove All to deselect any regions

that could have been selected from the previous machining operation

2. Click Select Drive /Containment Regions under Machining Features/ Regions tab

and select the 6 lines on the slotted gear as shown below.

3. Right mouse click or press enter to complete the selection.

The selected lines are now listed under Machining Feature/Region tab.



Select Tool, Feeds & Speeds and Clearance

4. Switch to Tool tab and select FlatMill-0.25

5. Go to Feeds & Speeds tab and select Load from Tool.

6. Switch to Clearance Plane tab and set Clearance Plane Definition to Automatic

and Cut Transfer Method to Clearance Plane.

Specify Engraving Cut Parameters

7. Switch to Cut Parameters tab and use the following parameters

a. Cut Direction - Natural

b. Location of Cut Geometry as At Top

c. Total Cut Depth = 0.25. The cut depth is always set as an absolute value.

d. Rough Depth = 0.25 and Rough Depth/Cut = 0.125

e. Cut Traversal between Cut Levels (if any) - Zig



8. Click Generate.

The Engraving toolpath is now generated and the operation is listed below 2 ½ axis

Profiling under the RhinoCAM-MOps browser.



Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the MOps

browser.



Simulate Toolpath



10. Select Engraving and click Play.

The cut material simulation with material texture is shown below.







Post Processing


This would post all operations created under Setup 1.



The posted file name is set based on the rules specified under Set Post Options. By default,

when posting a Setup, Part file name + Setup name is used as the file name.

2. Click Post.




End of Tutorial 2!



Tutorial 3: Machining a Shaft Base



Introduction

This tutorial will illustrate machining of a prismatic part such as this Shaft Base using 2-1/2

milling operations. Even though we have created a 3-D representation of the part, it will be

seen later on that we can machine this using just 2-D curves. The reason we are able to do

this is because of the prismatic nature of this model. This tutorial will introduce the usage of

2 ½ axis machining for a simple one sided part. We will use profiling, pocketing and hole

pocketing operations.





name so that the original file will be preserved

Strategy to Machine the Shaft Base

We will machine the shaft base completely using 2 ½ axis-machining operations.

The starting material for the Shaft Base is aluminum and the size is 5.5 x 3.25 x

0.75 inches.

The stock will be held to the machine table using clamps.

The part will be machined using a ¼ inch flat end mill.

Determining the sequence of machining operations

o As the part thickness is 0.625” thick and the available stock is 0.75” the first

operation would involve reducing the thickness of the stock over the entire

area from 0.75 to 0.625. To carry out this operation we will use the 2 ½ axis

Facing operation as the toolpath extends past the region.

o The next step would involve machining the areas around and inside the boss.

We will use 2 ½ Axis Facing to machine around the boss and 2 ½ axis

Pocketing operation which is ideal removing material inside a specified region.

o We are now down to the level where the step holes need to be machined. As

the holes are circular we will use Hole Pocketing operation to machine the

holes to its depth in 2 separate operations.

o The 2 inner holes can be drilled using an engraving operation to its depth.

o Finally we will cut out the shape of the part from the rectangular using a

contour toolpath. This is accomplished using a 2 ½ axis Profiling operation

which separates the finished part from the stock material.




















CAD system.

To load a part:


2. From the Open dialog box, select the ShaftBase.3dm file from the Tutorials folder.













This tab allows you to define Machine Setup, Stock and create machining operations.

Machine Setup


Setup group.















code in a notepad.

Define Setup







create one.





it.

MCS WCS





system.





machined.




10. Set the Length (L) = 5.5, Width (W) = 3.25 and Height (H) = 0.75. Uncheck

Ignore Wireframe Geometry in Bounds Computation and Click OK.

Note: Selecting Ignore Wireframe Geometry in Bounds Computation ignores all 2D and 3D curve geometries present in the part from stock bounding box computation




top of the part geometry. If you have the material texture visibility on, the material

texture will be displayed on top of stock geometry.




Program tab.





12. Set Z alignment to Bottom and XY alignment to Center. Uncheck Ignore

Wireframe Geometry in Part Bounds Computation and Click OK. (This would

align the stock to the bottom of the part in Z and center in XY)



The stock is now aligned to the center of part geometry in XY and bottom in Z.

Specify Material





14. Set Material to ALUMINUM – 6061 from the material drop down list and click OK.


model.





Set Work Zero











MCS and WCS shown from Iso and Front views.

Create Tools

To machine the above part we will now create a ¼ inch (0.25”) Flat End Mill.


Create/Edit Tools.














You can create additional tools by assigning a different name and specify the tool

parameters.




Tool library as RhinoCAM Knowledge base file (*.vkb) saves feeds and speeds with tool

properties.




In this process, we will create 2 ½ Axis Facing operation.

2 ½ Axis Facing

1. Select Work Zero under Setup 1 and now select 2Axis and choose Facing from


This brings up the 2 ½ Axis Facing operation dialog. We will go over the steps for





2. Click Select Drive /Containment Regions from Drive Regions under Machining

Features/ Regions tab.

The Facing operation dialog is now minimized and allows selection of machining

features.

3. Select the rectangle by using the left mouse click.




The selected regions are now displayed under Drive Regions in Machining

Features/Regions tab.



Selecting the Tool

5. Switch to Tool tab under 2 ½ Axis Facing operation.

6. Select FlatMill-0.25 under Tools.

The 0.25” Flat End mill is now selected as the active tool and the Tool parameters

are displayed to the right of the Tools window.




7. Click Feeds and Speeds tab





Clearance Geometry



Clearance Plane.








11. Switch to Roughing tab

12. Under Global Parameters, set Tolerance = 0.001, Stock = 0, set Cut Pattern to

Island Offset Cuts, Cut Direction to Climb and Step Distance = 50 (% of tool

diameter).

13. Switch to Cut Levels tab



Cut Levels

14. Use the following parameters.

a. Location of Cut Geometry, select At Bottom or use Pick Top and set the

value = 0 (As the selected region at Z = -0.125”, we would need to start the

first cut from Z =0).

b. Under cut depth control, set Total Cut Depth = 0.125, Rough Depth =

0.125, and Rough Depth/Cut = 0.0625.

15. Switch to Entry/Exit tab and set Entry & Exit Parameters to None.

16. Click Generate. 2½ Axis Facing toolpath is now generated, and the operation is




Simulate toolpath

17. Switch to Simulate tab, Select 2 ½ Axis Facing, and click Play to run the

simulation.






Creating Facing Operation #2

We will now create a second facing operation to remove material around the boss area.

As we have already programmed a facing operation to remove excess material from the top

face of the stock, we will make a copy of the facing toolpath to program around the boss

feature. This would allow us to reuse some of the operation parameters.


Copying and Pasting a Machining Operation

2. Select 2 ½ Axis Facing operation created from the previous step, right mouse button

click, and select Copy.

3. Right mouse button click on the same operation and select Paste.



This creates a copy of the facing operation and lists it below the first facing operation as

shown below.

Editing Machining Operation

We will now edit the 2nd Facing operation under Setup.

4. Double click on the 2 ½ Axis Facing operation folder.

In the Machining Features/Regions tab, you will notice Drive Region1 as selected

machining region. This is the rectangle we used as region for creating the facing

operation in the previous step. With this being selected, we will now select the surface

edge on the boss of the part as Avoid region.

Specify Avoid Region

5. Click Avoid Regions tab under Machining Feature/Regions tab and Select

Avoid Regions.



6. Select the surface edge on the outer edge of the boss feature as show below.



7. Right mouse button click or press enter to end selection.

Selected Machining Region(s) now shows 1 avoid region added to selection. The

region highlight color for avoid region is different from drive region.

Leaving the Tool, Feeds and Speeds, Clearance parameters the same from the

previous operation, we will now specify cut parameters.

Change Cut Parameters and Cut Levels

8. Switch to Roughing tab

9. Change Step over Distance = 35 (% of tool diameter), select Corner Cleanup

10. Switch to Cut Levels tab and use the following parameters

a. Location of Cut Geometry use Pick Top = -0.125

b. Total Cut Depth = 0.375

c. Rough Depth = 0.375



d. Rough Depth/Cut = 0.125

11. Click Generate to compute the toolpath.

Select the facing operation to preview the toolpath. If the toolpath is not visible,

make sure to toggle toolpath visibility under the MOps browser.



Simulate toolpath

12. Switch to Simulate tab, select the second 2 ½ Axis Facing operation under Setup

and click Play to run the simulation.




2 ½ Axis Pocketing

We will now create a Pocketing operation to machine the area inside the boss feature.

1. Switch to Program tab and select 2Axis and Pocketing


2. Under Machining Features/ Regions tab click on Remove All to deselect any

regions that could have been selected from the previous machining operation.

3. Click Select Drive /Containment Regions under Machining Features/ Regions tab

and select the top inner edge on the boss feature.



4. Right mouse click or press enter to complete the selection.

The selected region is now listed as DriveRegion 1 under Drive Regions tab.

5. Switch to Tool tab and select FlatMill-0.25.

6. Select Feeds & Speeds tab and click Load from Tool

7. Switch to Clearance tab and set Clearance Plane Definition to Automatic and Cut

Transfer Method to Clearance Plane.

8. Go to Cut parameters tab




9. Set Tolerance = 0.001, Stock = 0, Cut Pattern to Offset Cuts, Cut Direction to

Climb and Step over distance = 25 (% Tool Diameter).




Cut Levels

11. Use the Following Parameters

a. Set Location of Cut Geometry as At Top (as the machining feature selected

is at the top of the pocket)

We will now determine the Total Cut Depth from the 3D model by snapping at 2

points.

b. Select pick depth button located to the right of Total Cut Depth. This allows

selection of 2 points for depth selection.

c. Turn on near point snap from Rhinoceros’s status bar.

d. Pick near the top edge of the boss feature as the first point and the bottom

edge of the floor of the pocket as the second point as shown below.

Fist Point Pick Second Point Pick

Total cut depth now determines the depth as 0.25.

e. Set Rough Depth = 0.25 and Rough Depth/Cut = 0.125



This would cut the pocket steps of 0.125” resulting in 2 cut levels.

Note: You can also specify the Total Cut Depth by entering the depth values under Total Cut Depth.



Entry/Exit

12. Switch to Entry/Exit tab and use the following settings

a. Approach Motion Length (L) = 0.025, Engage Motion use Path ramp and set

Angle (A) = 5 (degrees) and Height (H) = 0.125

b. Retract Motion use Linear, set Length (L) = 0.0625 and Angle (A) = 45

(degrees)

c. Select Apply entry/exit at all cut levels.

13. Switch to Advanced Cut Parameters tab, select Perform Arc Fitting and set

Fitting Tolerance = 0.002 and click Generate. 2½ Axis Pocketing toolpath is now

generated and is listed under the 2 ½ Axis Facing operation in the RhinoCAM-MOps

browser.

Note: You can rearrange operations in the MOps browser using drag and drop.



Simulate toolpath

14. Switch to Simulate tab, select 2 ½ Axis Pocketing operation under Setup and click

Play to run the simulation.




Note: To turn on/off the toolpath, stock model visibilities use the controls located at the

bottom of the MOps Browser.

Hole Pocketing Operation

In order to machine the 6 holes, we will now use 2 ½ axis hole pocketing operation.

Create Predefined Machining Regions



1. Click Regions tab under RhinoCAM Machining Objects Browser (MObs). If

MObs browser is not open, select RhinoCAM from Menu bar and click Machining

Objects browser.

2. Select Flat Area selection filters

3. Set the following options.

a. Select Ignore most region

b. Select Pick only Circles/Arcs



i. Select Use diameter filter and set Minimum Diameter = 0.5 and

Maximum Diameter = 0.5

c. Click OK.

4. Click on Select Flat Areas under Regions tab

5. Pick the flat area as shown below

Selecting the Flat Area creates regions around the 6 holes and the regions are now

available under the Regions tab as Flat Area Region 1 in the MObs browser.



We are now ready to create the Hole Pocketing operation for the 0.5” diameter stepped

holes.

6. Select the last operation (2 ½ Axis Pocketing) under Setup 1, from the Program

tab select 2Axis and Hole Pocketing.


7. Click Remove All under Machining Features/ Regions tab click to deselect any


8. Click Select Pre-Defined Regions under Machining Features/ Regions tab.

This opens up Select predefined Machining Region(s) dialog box.



9. Select Flat Area Region 1 and click OK.

Flat Area Region 1 is now added to Driver Regions under Machining Regions.

10. Switch to Tool tab under Hole Pocketing operation and select FlatMill-0.25

11. Select Feeds & Speeds tab and click Load from Tool.





13. Go to Cut parameters tab



a. Tolerance = 0.0001

b. Location of Cut Geometry = At Top

c. Hole Depth = 0.0625 and Uncheck use 3D mode to detect Depth

d. Hole Diameter = 0.5 and Uncheck Use Arc Diameter as Hole Diameter for all

selected holes

e. Set Cut Direction as Climb

f. Stepdown Distance (dZ) select Number of Levels set the value = 1

g. Check Do cleanup pass at each Z Level.

15. Switch to Entry/Exit tab and set the following parameters



a. Helix Diameter = 0.25

b. Helix Pitch, select Height = 0.025

c. Approach Distance = 0.025

d. Select Create full (360 degree) helixes only and Output each helix

individually.

16. Click Generate.

Hole Pocketing toolpath is now generated and is listed under 2 ½ Axis Pocketing

operation in the RhinoCAM-MOps browser.

Note: You can rearrange operations in the MOps browser using drag and drop.



Simulate toolpath

17. Switch to Simulate tab, select the Hole Pocketing operation under Setup and click




Create Hole Pocketing Operation for the through holes


2. Select Hole Pocketing operation created from the previous step, right mouse button

click, and select Copy.

3. Right mouse button click on the same operation and select Paste.

This creates a copy of the Hole Pocketing operation and lists it below the first Hole

operation as shown below.



Editing Machining Operation

We will now edit the 2nd Hole Pocketing operation under Setup.

4. Double click on the Hole Pocketing operation folder.

In the Machining Features/Regions tab, you will notice Flat Area Region1 as selected

machining region. This is the region we used for creating the hole pocketing operation

for the stepped holes in the previous step. As the through holes are concentric with the

step holes, we will use the same region and modify the cut parameters to program the

through holes.

5. Switch to cut parameters tab and use the following parameters


b. Location of Cut Geometry select Pick Top = -0.5625

You can also select the top using the Pick option and snap to the top edge of

the through hole using the near point object snap.



c. Hole Depth = 0.1875 and Uncheck use 3D mode to detect Depth

d. Hole Diameter = 0.315 and Uncheck Use Arc Diameter as Hole Diameter for

all selected holes

e. Set Cut Direction as Climb

f. Stepdown Distance (dZ) select Number of Levels set the value = 1

g. Check Do cleanup pass at each Z Level.

6. Switch to Entry / Exit tab and use the following parameters

a. Helix Diameter = 0.065 (Max Helix Diameter = Hole Diameter – Tool

Diameter)

b. Helix Pitch, select Height = 0.05

c. Approach Distance = 0.025



d. Select Create full (360 degree) helixes only and Output each helix

individually.

7. Click Generate. Hole Pocketing toolpath is now regenerated for the through holes.

Simulate toolpath

8. Switch to Simulate tab, select the second Hole Pocketing operation under Setup





Create Engraving Operation

We will now create engraving operation to drill the 2 center holes. The holes can also

be drilled using Drilling operation that is available under Hole Machining. In this

exercise, we will use Engraving to drill the holes using a 0.25” Flat Mill to avoid tool

change.

Create Machining Region

1. Select Layer Manager from the standard bar

2. Set Layer 01 as active layer by placing a check box next to Layer 01.



A new layer is selected just to have the curves created on a different layer from the

model layer. This would make it easier to view the curves as the new layer has a

different color from the default layer which contains the surface geometry.

3. Select Osnap from status bar and turn on Center Snap. Turn off the other snaps.

4. From Curve menu, select Point Object ->Single Point.

This prompts you to specify Location of Point object.

5. Move the cursor near the edge of the hole and when the cross hair on the cursor

detects the center, left click to create the point.

6. Repeat the above step to create a point for the other hole.

Snap to center for Left side hole Snap to center for Right side hole

The points created can now been seen on the part at the center of each of the 2 holes.



Select Engraving Operation

1. Select the last operation (Hole Pocketing) under Setup 1 and from Program tab

select 2 Axis and Engraving

2. Click Remove All under Drive Regions.

3. Select Drive /Containment Regions under Machining Features/ Regions tab.

The engraving operation dialog is now minimized and allows selection of machining

features.

4. Select the 2 points using left mouse click and then press enter or right mouse button

click to end selection.

Selected regions are now displayed under Machining Regions.

5. Switch to Tool tab under Engraving and select FlatMill-0.25

6. Click Feeds& Speeds tab and select Load from Tool.

7. Switch to the Clearance Tab and set the Clearance Plane Definition to Automatic


8. Go to Cut Parameters tab




b. Cut Direction as Natural



c. Location of Cut Geometry as At Top

d. Cut Depth Control

i. Total Cut Depth = 0.375,

ii. Rough Depth = 0.375,

iii. Rough Depth/Cut = 0.1875

e. Cut Traversal between Cut Levels (if any) as Zig

10. Set Entry and Exit to None under Entry/Exit tab.

11. Click Generate.

The engraving operation is now created and listed under Hole Pocketing operation.



Simulate toolpath

12. Switch to Simulate tab, select the Engraving operation under Setup and click Play

to run the simulation.




Create Profiling Operation

1. Select the last operation (Engraving) under Setup 1 and from Program tab select 2

Axis and Profiling

Select Machining Features

2. Click Remove All under Machining Features/ Regions tab click to deselect any


3. Click Select Drive /Containment Regions under Drive Regions tab.


features.

4. Select the outer edge on the top of shaft base as show below.

A selection list may be displayed when you click near an edge. Browsing through the

selection list will highlight the face edge that corresponds to the selection.


Specify Parameters


7. Click Feeds& Speeds tab and select Load from Tool.

8. Switch to the Clearance Tab and set the Clearance Plane Definition to Automatic



a. Set Tolerance = 0.001

b. Cut Direction as Climb

c. Cut Start Side, select Determine using 3D Model




a. Location of Cut Geometry as At Top

b. Cut Depth Control

i. Total Cut Depth = 0.25

ii. Rough Depth = 0.25




11. Set Entry and Exit Parameters to None under Entry/Exit tab.

12. Go to Advanced Cut Parameters tab, select Perform Arc Fitting and set Fitting

Tolerance = 0.002 and click Generate.

13. Profiling toolpath is now listed under Engraving operation in RhinoCAM-MOPs

browser.



Simulate toolpath

14. Switch to Simulate tab, select the 2 ½ Axis Profiling operation under Setup and

click Play to run the simulation.


Post Processing


This would post all operations created under Setup 1. The posted file name is set based

on the rules specified under Set Post Options. By default, when posting a Setup, Part file

name + Setup name is used as the file name.

2. Click Post.




End of Tutorial 3!



Tutorial 4: V-Carving



Introduction

This tutorial will illustrate machining a sign using V Carve operation. We can engrave the

sign using 2-D curves. This tutorial will introduce the usage of 2-½ axis V Carving using V

bit.

V carving refers to a cutting strategy employed by sign makers to create sharp corners. V

carving is performed using a tapered bit or conical tool (as shown below) usually known in

the industry as a V Bit.

The V-bit is made to rise from the cutting depth to the top of the surface at the corners in

such a way that the tapered sides of the cutter are always in contact with the corners. When

the cutter finally reaches the top surface, only the bottom tip of the tool will be in contact

with the corners, thereby creating clean and crisp cuts at the corners.






Strategy to Machine the part

V carving is performed using the 2 ½ axis machining operation.

The part itself will be machined out of a 10.75 inch x 4 inch x ½ inch poplar wood

sheet

The part would be machined using a single V-Groove bit.



















CAD system.

To load a part:


2. From the Open dialog box, select the V-Carve1.3dm file from the Tutorials folder.














Machine Setup


Setup group.















code in a notepad.

Define Setup





create one.





it.



MCS WCS



system.





machined.




10. Set the Length = 10.75, Width = 4.00 and Height = 0.5. Uncheck Ignore

Wireframe Geometry in Bounds Computation.





If you have the material texture visibility on, the material texture will be displayed

on top of stock geometry.







12. Set Z alignment to Top and XY alignment to Center. Uncheck Ignore Wireframe

Geometry in Part Bounds Computation and Click OK. (This would align the stock

to the Top of the part in Z and center in XY)




Specify Material







model.





Set Work Zero









This sets the MCS at the same location as WCS. Work Zero now appears under MOps

browser.



Create Tools

To machine the above part we will now create a 60 degree V-bit.


Create/Edit Tools.

18. Select the Tool Type to Vee Mill.

19. Set tool Name as VeeMill1, Taper Angle = 30, Tool Diameter = 0.5, Shoulder

Length = 0.5, Tool Length = 1, Under the Properties tab set Material to HSS and

Tool Number = 1.








You can create additional tools by assigning a different name and specify the tool parameters.





properties.


In this process, we will create 2 ½ Axis V-carving operation.



V-Carving

1. Select Work Zero under Setup 1 and now select 2Axis and choose V-Carving from


This brings up the V-Carving operation dialog. We will go over the steps for creating the

toolpath.



The V-carving operation dialog is now minimized and allows selection of machining

features.

3. Now, select the text by using the left mouse click, starting from left to right. Make

sure to get the inner curves on the letters ‘e’ and ‘o’. Each curve is separate (by

curves, not by letters) and must be selected separately.


The selected regions are now listed as Drive Regions under Machining Regions.



Selecting the Tool

5. Switch to Tool tab under V-Carving operation.

6. Select VeeMill1 under Tools.

The engraving tool is now selected as the active tool and the Tool parameters are






8. Select Load from Tool.

RhinoCAM will now get the feeds and speeds parameters that was set when the tool

was defined.

9. Switch to Clearance Tab



Clearance Geometry

10. Set Clearance Plane Definition to Absolute Z Value and specify Z value = 0.25 and

Cut Transfer Method to Clearance Plane.

Setting Cut Transfer to Clearance Plane would apply the Absolute Z value clearance


11. Switch to cut parameters tab.

Specifying Cut Parameters

12. Use the following Parameters




b. Cut Side as Inside

c. Location of Cut Geometry as At Top

d. Cut Depth Control




13. Click Generate.

The Engraving toolpath is now generated and the operation is listed under the

RhinoCAM-MOps browser.




browser.

Simulate toolpath

14. Switch to Simulate tab, select V-Carving operation under Setup and click Play to

run the simulation.




Post Processing





2. Click Post.




Saving Operation to a Knowledgebase

1. From the Program tab, select Knowledgebase and Save to KB

2. Specify a folder location, file name and click Save. The operation is now saved as

Knowledge Base Files (*.vkb) under the specified folder.

We will load the saved knowledge base in the next tutorial.

End of Tutorial 4!



Tutorial 5: Embossing



Introduction

This tutorial will illustrate machining a sign using engraving operations. We can engrave the

sign using 2-D curves. This tutorial will introduce the usage of V Carve Roughing with a Flat

End Mill and V Carving using V bit.

V carving refers to a cutting strategy employed by sign makers to create sharp corners. V

carving is performed using a tapered bit or conical tool (as shown below) usually known in

the industry as a V Bit.

The V-bit is made to rise from the cutting depth to the top of the surface at the corners in

such a way that the tapered sides of the cutter are always in contact with the corners. When

the cutter finally reaches the top surface, only the bottom tip of the tool will be in contact

with the corners, thereby creating clean and crisp cuts at the corners.







Embossing is performed using the 2 ½ axis machining operations.

The part itself will be machined out of a 21.5 inch x 4 inch x 1 inch poplar wood

sheet

The part would be machined using a Flat End Mill and a V-Groove bit.



















CAD system.

To load a part:


2. From the Open dialog box, select the Embossing1.3dm file from the Tutorials folder.












Machine Setup


Setup group.















code in a notepad.

Define Setup





create one.







it.

MCS WCS





system.



machined.





14. Set the Length = 21.5, Width = 4.00 and Height = 1.0. Uncheck Ignore

Wireframe Geometry in Bounds Computation.

















Specify Material







model.





Set Work Zero








browser.





Create Tools

To machine the above part we will now create a 1/8th inch (0.125”) Flat End Mill for V-Carve

Roughing operation and use a 60 degree V-bit for the V-Carve finishing operation.


Create/Edit Tools.

22. Select the Tool Type to FlatMill.

23. Set Tool Name as FlatMill-0.125, Tool Diameter = 0.125, Flute Length = 0.75,















properties.




In this process, we will create 2 ½ Axis V-carve Roughing and V-Carving operation.

V-Carve Roughing

1. Select Work Zero under Setup 1 and now select 2Axis and choose V-Carve

Roughing from Program tab under Machining Operations group.

This brings up the V-Carve Roughing operation dialog. We will go over the steps for

creating the toolpath.



The V-Carve Roughing operation dialog is now minimized and allows selection of

machining features.

3. Now, select the inner rectangle and the text by using the left mouse click, starting

from left to right. Make sure to get the inner curves on letter “R”, “o”, “A” and the

dot on letter “i”. Each curve is separate (by curves, not by letters) and must be

selected separately.





Specify Parameters

5. Switch to Tool tab under V-Carve Roughing operation and Select FlatMill-0.125.

6. Click on Feeds & Speeds tab and select Load from Tool.

7. Switch to Clearance tab and set Clearance Plane Definition to Absolute Z Value

and specify Z value = 0.25 and Cut Transfer Method to Clearance Plane.





b. Stock = 0

c. V-Carving Finish Tool Taper Angle = 30

d. Cut Pattern – Offset Cuts

e. Cut Direction – Mixed

f. Stepover Distance = 25 (% of tool diameter)

Note: V-Carve Finishing Tool Taper Angle represents the included angle of the V-bit that

would be used after the V-Carve Roughing operation. If you have a 60 degree V-Bit, the

Taper Angle would be 30 degrees.




a. Location of Cut Geometry as At Top

b. Cut Depth Control






10. Go to Entry/Exit tab and use the following parameters

a. Approach Motion = 0.025

b. Engage Motion , use Path, set Angle = 10 and Height = 0.05

c. Retract Motion use Linear, set Length = 0.0625 and Angle = 45

d. Departure Motion = 0.025. Select Apply entry/exit at all cut levels.

11. Click Generate. V-Carving toolpath is now generated and the operation is listed

under the RhinoCAM-MOps browser.


browser.



Simulate toolpath

12. Switch to Simulate tab, select V-Carve Roughing operation under Setup and click



We will now create a V-Carving operation to finish the sign using a 60 degree taper tool.

V-Carving Operation

As we created a V-carving operation on Tutorial – 4 and saved the operation to a knowledge

base, we will import the knowledge base file to this tutorial to program the part.



Load Knowledge base

1. From Machining Objects Browser, select K-Bases tab and click Load Knowledge Base

2. Browse to Tutorials folder to select V_Carve1_Completed.vkb

3. V-Carving operation now shows up under K-Bases tab in Machining Objects browser.



4. Drag and Drop V-Carving operation from Machining Objects browser onto Machining

Operations browser. Make sure to drag it below the V-Carve Roughing operation.

V-Carving operation now appears under Machining Operations browser and is ready for

editing and generating toolpath.

Edit V-Carving Operation

5. Double click on V-Carving folder to edit the operation.


This minimizes the V-Carving operation dialog.

7. Select the inner rectangle and the Text as shown below. Right mouse click to

complete the selection.





9. Switch to Tool tab, select VeeMill1 and click Edit/Create/Select Tool...

10. Change Tool Number under Properties tab to 2 and click Save Edits to Tool.



11. Click OK to close and return back to V-Carving operation.

12. Switch to Cut Parameters tab and set Total Cut Depth = 0.25, Rough Depth =

0.25 and Rough Depth/Cut = 0.05

13. Click Generate to compute toolpath.

Simulate toolpath

14. Switch to Simulate tab, select V-Carving operation under Setup and click Play to

run the simulation.




Post Processing





2. Click Post.



change the post processor by selecting a different one from the drop down menu in the list.

The posted g code by default will be saved to the folder where the part file is located.

End of Tutorial 5!



Tutorial 6: Chamfering



Introduction

This tutorial is intended to show an easy way to chamfer and smooth sharp corners by using

2 ½ axis Chamfering operation. A tapered tool is suitable for this purpose. In this example,

the chamfer is not modeled in the part. We plan to chamfer the edges of the part using a 30

degree taper tool that has a 0 radius at the tip.







Chamfering is performed using the 2 ½ axis machining operation.

The part would be machined using a single V-Groove bit.
















create parts within RhinoCAM, but it is more typical to import geometry created in another

CAD system.

To load a part:


2. From the Open dialog box, select the Chamfer.3dm file from the Tutorials folder.




Create Tools

To machine the above part we will now create a 60 degree Chamfer.


Create/Edit Tools.

4. Select the Tool Type to Chamfer Mill.

5. Set Tool Name as ChamferMill1, Taper Angle = 30, Flat Diameter = 0, Flute

Length = 0.4, Shoulder Length = 1, Tool Length = 1, Under the Properties tab

set Material to HSS and Tool Number = 2.



6. Switch to Feeds and Speeds tab and use the following values for spindle speed,












Create Machining Operation

In this process, we will create 2 ½ Chamfering operation.

1. Select the Program tab under RhinoCAM Machining Operations browser

You will notice the stock geometry has already been defined and includes a 2 ½ Axis

Facing operation programmed.



Chamfering

1. Select 2 ½ Axis Facing operation under Setup 1 and now select 2Axis and choose

Chamfering from Program tab under Machining Operations group.

This brings up the Chamfer operation dialog. We will go over the steps for creating the

toolpath.



that could have been selected from the previous machining operation

3. Click Select Drive /Containment Regions under Drive Regions tab.

The Chamfering operation dialog is now minimized and allows selection of machining

features.

4. Select the curve that follows the top edge of the spanner as shown below.




The selected lines are now listed under Machining Feature/Region tab.

Selecting the Tool

6. Switch to Tool tab under the Chamfer operation dialog.

7. Select ChamferMill1



8. Switch to Feeds & Speeds tab and select Load from Tool.

9. Select Clearance Tab and set Clearance Plane Definition to Absolute Z Value and

specify Z value = 0.25 and Cut Transfer Method to Clearance Plane.

Setting Cut Transfer to Clearance Plane would apply the Absolute Z value clearance




Specifying Cut Parameters

10. Switch to cut parameters tab.



b. Stock = 0

c. Chamfer Parameters



i. Select Geometry At Top

ii. Chamfer Width = 0.125

iii. Tooltip Clearance = 0

iv. Max Depth/Cut = 0.0625

d. Cut Direction as Mixed

e. Cut Start Side select Use Outside/Inside for Closed Curves and select

Outside

12. Set Entry & Exit parameters to None under Entry/Exit tab.

13. Click Generate. The Chamfer toolpath is now generated and the operation is listed

under the RhinoCAM-MOps browser.


browser.

Reorder a Machining Operation

If the chamfer operation is created above the 2 ½ axis Facing operation, you can reorder

the MOp using the steps below.

1. Minimize all MOps under Setup 1.

2. Select the Chamfering MOp and drag it over the 2 ½ axis Facing MOp. This would

move the Chamfer MOp below the Facing MOp.

Simulate toolpath

1. Switch to Simulate tab,

2. Simulate the Facing operation under Setup and click Play to run simulation.

3. Once this is completed, select V-Carving operation under Setup and click Play to

run the simulation.

Note: You can select Setup 1 and click Play to simulate all operations created under the

current Setup.




Post Processing





5. Click Post.




End of Tutorial 6!



Tutorial 7: 3 Axis Milling



Introduction

This tutorial will illustrate machining this Mold using 3 axis-milling operations. This tutorial

will introduce the usage of several 3-axis operations such as horizontal roughing, parallel

finishing, and horizontal finishing.






Strategy to Machine the mold

We will machine the mold completely using 3 axis-machining operations.

The part itself will be machined out of a 5.5 x 6.5 inch x 1.25-inch aluminum block.

The stock may be held to the machine table using clamps.

The part will be machined using 0.5” flat end mill, 0.25” & 0.125” ball end mills.

















CAD system.

To load a part:




2. From the Open dialog box, select the 3Axis_Example1.3dm file from the Tutorials folder.














Machine Setup


Setup group.













code in a notepad.

Define Setup





create one.







it.

MCS WCS





system.





machined.




10. Set the Length (L) = 5.5, Width (W) = 6.5 and Height (H) = 1.25.










Program tab.





12. Set Z alignment to Bottom and XY alignment to Center. (This would align the

stock to the bottom of the part in Z and center in XY)




Perspective view Front View



Specify Material





model.





Set Work Zero











Create Tools

To machine the above part we will now create the following tools

0.5 inch Flat End Mill

0.25 inch Ball Mill

0.125 inch Ball Mill


Create/Edit Tools.







23. Switch to Feeds & Speeds tab and click Load from File.



24. Set Stock Material to Aluminum-6061 and Tool Material to HSS. Click OK and the

computed cut feedrate and spindle speed is now applied to the feeds and speeds tab.

25. Set Feedrate reduction factors for Plunge between levels = 50 and First XY pass

= 50.


Tools in Library.



27. Select Tool type as Ball mill and specify the following parameters.

a. Name - BallMill-0.25, Tool Diameter = 0.25, Flute Length = 1.0,

Shoulder Length = 1.5, Tool Length = 2.0 and Shank Diameter = 0.25.

Under the Properties tab set Material to HSS and Tool Number = 2.




29. Set Stock Material to Aluminum-6061 and Tool Material to HSS, Tool Diameter =

0.25. Click OK and the computed cut feedrate and spindle speed is now applied to

the feeds and speeds tab.


Tools in Library.

31. Create another Ball Mill with the following parameters


Shoulder Length = 1.5, Tool Length = 2.0 and Shank Diameter = 0.125.


b. Click Save as New Tool.

The created tools are now listed under Tools tab in RhinoCAM Machining Objects

browser.




We will machine the mold using 3 different machining operations – Horizontal Roughing,

Parallel Finishing, and Horizontal Finishing.

The first step in machining the mold will be a roughing operation. This type of machining is

very efficient for removing large volumes of material and is typically performed with a large

tool. Roughing is typically followed by semi-finishing or finishing toolpaths

3 Axis Horizontal Roughing

1. Select Work Zero under Setup 1 and now select 3Axis or 3Axis Adv and choose

Horizontal Roughing from Program tab under Machining Operations group.

This brings up the 3 Axis Roughing operation dialog. We will go over the steps for


Machining Features/ Regions under 3 axis operations are used as containment regions.

For the roughing operation, we will skip the selection of machining features/regions.



Select Tool


The 0.5” Flat End mill is now selected as the active tool and the Tool parameters are





3. Go to Feeds & Speeds tab and click Load from Tool.

RhinoCAM will now get the feeds and speeds parameters that was set when the tool was

defined.



Clearance Geometry



Clearance Plane.








6. Select Cut Parameters tab

a. Set Intol = 0.005, Outol = 0.005

b. Stock = 0.025

c. Cut Pattern – Stock Offset,

d. Cut Direction – Mixed,

e. Stepover select % Tool Diameter = 40




a. Set Step Down Control (dZ) as % Tool Diameter = 40

b. Cut Levels Ordering – Depth First

c. Select Clear Flats under Cut Levels

8. Switch to the Engage/Retract tab and use the following parameters.

a. Select Path for Ramp motion and set Angle = 10 and Height = 0.1

b. Check Always engage in previously cut area if possible

c. Engage Retract in Air use Linear extension = 0.275

9. Click Generate.

Horizontal Roughing toolpath is now generated and the operation is listed under the





browser.

Simulate toolpath

10. Switch to Simulate tab, select Horizontal Roughing operation under Setup and





3 axis Parallel Finishing

We will now use 3 axis Parallel Finishing to pre-finish the part using a 0.25” Ball End Mill.

This is an efficient method of finishing or pre-finishing, typically used when part surfaces are

relatively flat. A 2D linear zigzag pattern is generated on the XY plane above the part

geometry. The tool moves along this cut pattern, following the contours of the part

geometry below.

1. Switch to Program tab and select 3Axis or 3Axis Adv and choose Parallel

Finishing from Program tab under Machining Operations group.

This brings up the Parallel Finishing operation dialog. We will go over the steps for


2. Switch to Tool tab under Parallel Finishing operation and select BallMill-0.25



3. Click Feeds & Speeds tab and select Load from Tool. RhinoCAM will now get the

feeds and speeds information that was set when the tool was defined.

4. Switch to Clearance Tab and set the Clearance Plane Definition to Automatic and



5. Click on Cut Parameters tab and set


b. Stock = 0

c. Cut Direction - Mixed

d. Stepover as % Tool Diameter = 15

6. Click Generate.



Parallel Finishing operation is now generated and listed under the Roughing

operation in RhinoCAM – MOps browser.


browser.

Simulate toolpath

7. Switch to Simulate tab, select Parallel Finishing operation under Setup and click





3 axis Horizontal Finishing

We will now create a Horizontal Finishing operation for machining steep area regions. This

method is used for pre-finishing or finishing in constant Z levels, typically used when the

part has large vertical surfaces and when Parallel Finishing will not yield satisfactory results.

1. Switch to Program tab and select 3Axis or 3Axis Adv and choose Horizontal

Finishing from Program tab under Machining Operations group.

This brings up the Horizontal Finishing operation dialog. We will go over the steps for



2. Click Select Drive/Containment Region from Machining Features/Regions tab.

Horizontal finishing operation dialog is now minimized and allows selection of

machining features.

3. Select the polyline from the edge of part as shown below.

A selection list is displayed when you click near an edge. Browsing through the

selection list will highlight the surface that corresponds to the selection.




The selected polylines is now listed as DriveRegion 1 under Drive Region in

Machining Features/Regions tab.

5. Switch to Tool tab under Horizontal Finishing operation and select BallMill-0.125






8. Click on Cut Parameters tab and set


b. Stock = 0

c. Cut Direction – Climb/Conventional




a. Set Stepdown as % Tool Diameter = 15


9. Set Entry & Exit parameters to none under Entry/Exit tab.



9. Click Generate.

Horizontal Finishing operation is now generated and listed under the Parallel

Finishing operation in RhinoCAM – MOps browser.


browser.

Simulate toolpath

10. Switch to Simulate tab, select Horizontal Finishing operation under Setup and





Post Processing





12. Click Post.





Saving Operation to a Knowledgebase

1. From the Program tab, select Knowledgebase and Save to KB

2. Specify a folder location, file name and click Save. The operation is now saved as

Knowledge Base Files (*.vkb) under the specified folder.

End of Tutorial 7!



Tutorial 8: Profiling with Bridges/Tabs



Introduction

This tutorial will illustrate creating and editing bridge points on a 2 ½ axis profiling

operation. The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide information

about additional options available.




We will machine the part using a 2-½ axis profiling operation.

We will define bridges so that the parts do not fall off the sheet once its cut to its full

depth.

The part will be machined out of a 10 x 10 x 1 inch poplar wood sheet using a 0.5

inch Flat End Mill.


using fixtures/clamps.
















CAD system.

To load a part:




2. From the Open dialog box, select the Profile_Tabs.3dm file from the Tutorials

folder.














Machine Setup


Setup group.













code in a notepad.

Define Setup





create one.







it.

MCS WCS





system.





machined.


13. Click Part Box Stock from the drop down list.

This brings up the Part Box Stock parameters. The system calculates the bounding box

of the part model as the XYZ extents of geometry of the part model. The user can then

define offsets in any of the three coordinate directions to apply to the computed

bounding box. The system will expand the bounding box by the offset amount in each of

the coordinate directions. When the user clicks on the OK button, a stock model based

on the user definition will be created and displayed.

14. Set Offsets for X =2, Y =2 and Z =1. Select Z offset Direction to –Z Only. Make

sure to uncheck Ignore Wireframe Geometry in Bounds Computation and click

OK.


and 3D curve geometries present in the part from stock bounding box computation.






Program tab.



Machining Job is now updated with the Machine Type, Post Processor and Stock

information in the MOps browser.













Specify Material





model.





Set Work Zero






southwest corner of the stock geometry. This sets the MCS at the same location as

WCS.






Create Tools

To machine the above part we will now create a ½ inch (0.5”) Flat End Mill.


Create/Edit Tools.


3. Set tool Name as FlatMill-0.5, Tool Diameter = 0.5. Under the Properties tab set





5. Set Stock Material to Wood and Tool Material to HSS. Click OK and the computed

cut feedrate and spindle speed is now applied to the feeds and speeds tab.



The computed feeds and speeds are transferred to the Feeds and Speeds tab.









Create Predefined Machining Regions

1. Click Regions tab under RhinoCAM Machining Objects Browser (MObs). If

MObs browser is not open, select RhinoCAM from Menu bar and click Machining

Objects browser.

2. Click Select Curves

3. Select the rounded rectangle from the view port. Press enter or right mouse button

click to end selection.



The selected curve is now defined as Curve Region1 and is displayed under Machining

Region Set 1 under Regions tab.

4. With Curve Region1 highlighted under Regions tab, click Automatic Bride Points

on Selection.

5. Set Number of Bridge Points = 4 under create equally spaced bridge points and

Click OK.



The bridge points are created and displayed on Curve Region 1

Editing Bridge Points

6. With Curve Region1 highlighted under Regions tab, click Edit Bridge Points in

Selections.

7. Left mouse button click on a bridge point and move it along the curve to change the

location of bridge point.



When the bridge point being is moved, the point appears in blue. Red represents the

original location of bridge point.

8. Left mouse button click on the desired location to place the bridge point.

9. Repeat steps 6 and 7 to move the other 3 bridge points.

We have now moved the bridge points for all 4 points.





2 ½ Axis Profiling

1. Select Work Zero under Setup 1 and now select 2Axis and choose Profiling from





2. Click Select Pre-Defined Regions under Machining Features/ Regions tab.



This opens up Select predefined Machining Region(s) dialog box.

3. Select Curve Region 1 and click OK.

Curve Region1 is now added to Driver Regions under Machining Regions.



4. Switch to Tool tab under Profiling operation and select FlatMill-0.5

5. Select Feeds & Speeds tab and click Load from Tool.







b. Stock = 0

c. Cut Direction = Climb

d. Cut Start Side select Use Outside/Inside for Closed Curves and select

Outside


a. Set Location of Cut Geometry – At Top






10. Switch to Entry/Exit tab and set Entry & Exit motions to None.

11. Go to Advanced Cut Parameters tab and under Bridges/Tabs

a. Select Create Bridges

b. Set Bridge Height = 0.125

c. Bridge Length = 2.0

12. Click Generate.



The 2½ Axis Profile toolpath is now generated and the operation is listed under the


Simulate toolpath

13. Switch to Simulate tab, select the 2 ½ Axis Profiling operation under Setup and


Post Processing





2. Click Post.





End of Tutorial 8!



Tutorial 9: Hole Making



Introduction

This tutorial will illustrate machining holes using Drilling operations. Even though we have

created a 3-D representation of the part, it will be seen later on that we can machine this

using just 2-D curves. The reason we are able to do this is because of the prismatic nature

of this model. The stepped instructions are accompanied by explanatory and introductory

text. Reading this text will help you understand the tutorial methodology and provide

information about additional options available. Don’t forget to save your work periodically!

You may want to save the file under a different name so that the original file will be

preserved.


We will machine part by using a Hole machining operation called Drilling.

The part will be machined out of a 7.25 x 8.5 x 0.75 inch poplar wood sheet using a

0.5” and 0.25” Standard Drill bit.


using clamps.















CAD system.

To load a part:


2. From the Open dialog box, select the Bitholder.3dm file from the Tutorials folder.














Machine Setup


Setup group.













code in a notepad.



Define Setup





create one.





it.

MCS WCS





system.





machined.




10. Set the Length = 7, Width = 8.5 and Height = 0.75.













12. Set Z alignment to Top and XY alignment to Center and click OK.




Specify Material







model.





Set Work Zero





West corner.


browser.



Create Tools

To drill the holes, we will create a 0.5” and 0.25” standard drills.


Create/Edit Tools.

2. Select the Tool Type to Drill.

3. Set tool Name as Drill-0.5, Tip Angle = 120, Tool Diameter = 0.5, Shank

Diameter = 0.5, Flute Length = 1.0, Shoulder Length = 1.5, Tool Length = 2,




4. Click Feeds & Speeds tab and use the following parameters.

5. Click Save as New Tool



6. Create another Drill tool using the following parameters

a. Set tool Name as Drill-0.25, Tip Angle = 120, Tool Diameter = 0.25,

Shank Diameter = 0.25, Flute Length = 1.0, Shoulder Length = 1.5,

Tool Length = 2, Under the Properties tab set Material to HSS and Tool

Number = 2.

b. Click Save as New Tool



Created tools are now listed under Tools tab in Machining Objects browser.



Tool library as RhinoCAM Knowledge base file (*.vkb) saves feeds and speeds with tool properties


In this process, we will create Standard Drill operation to drill the holes.

Drilling

1. Select Work Zero under Setup 1 and now select Holes and choose Drill from


This brings Drill operation dialog. We will go over the steps for creating the toolpath.



Select Hole Features

2. Click Select Holes on Flat Area under Hole Features tab.

Drill operation dialog is now minimized and allows selection of hole features.

3. Click on the top face of the part as shown below.



This automatically selects all hole features and displays the Drilling operation dialog back.



4. Now, select Use Diameter filter under and set Minimum Diameter = 0.5 and

Maximum Diameter = 0.5

This drops the holes that are outside the diameter range filter. The selected holes are

highlighted on the part.

5. Switch to Tool tab and select Drill-0.5

Drill-0.5 tool is now selected as the active tool and the Tool parameters are displayed to

the right of the Tools window.



defined.



Setting Cut Transfer to Clearance Plane would apply the Automatic clearance between

transfers when the tool moves from one hole feature to another.



Cut Parameters


a. Drill Type – Standard Drill

b. Drill Depth – 0.75

c. Select Add Tool tip to Drill Depth

d. Location of Cut Geometry – At Top

e. Approach Distance = 0.1

Note: Selecting Add Tool Tip to Drill Depth adds the taper height of the drill tool to the drill

depth to make it a through hole.



9. Switch to Sorting tab

a. Select Directional Sort,

b. Start Angle (A) = 0,

c. Secondary Sort Direction (S) – Low to High

d. Traverse Pattern - ZigZag

10. Click Generate.

Drill toolpath is now generated and the operation is listed under the RhinoCAM-MOps

browser.



Simulate toolpath

11. Switch to Simulate tab, select Standard Drill operation under Setup and click Play

to run the simulation.




Drill Operation #2 for 0.25” holes


2. Select Standard Drill under Setup 1

3. Right mouse button click and left click on Copy

4. Right mouse button click on Standard Drill and left click on Paste

This creates a copy of the Standard Drill operation and is listed below the first Standard Drill

operation.

Edit Machining Operation

5. Double click and edit the second Standard Drill operation under Setup.

6. Click Remove All under Hole Features tab

7. Click Select Holes on Flat Area and pick the top face of the part.



8. Select Use diameter filter and set Minimum Diameter = 0.25 and Maximum

Diameter = 0.25

This drops the holes that are outside the diameter range filter. The selected holes are

highlighted on the part.




Drill-0.25 tool is now selected as the active tool and the Tool parameters are displayed

to the right of the Tools window.

9. Leaving all other parameters with the same settings from the previous operation

click Generate. The toolpath is now regenerated for the 0.25” holes.

Simulate toolpath

10. Switch to Simulate tab, select the second Standard Drill operation under Setup





Post Processing





2. Click Post.





End of Tutorial 9!



Tutorial 10: Re-Machining a 3D Mold



Introduction

This tutorial will illustrate machining a Mold using advanced 3 axis-milling operations. This

tutorial will introduce the usage of advanced 3-axis operations such as pencil tracing &

valley re-machining. The stepped instructions are accompanied by explanatory and

introductory text.



Strategy to Machine the mold

We will machine the mold completely using 3 axis-machining operations.

The part itself will be machined out of a 5.5 x 4.45 inch x 1.25-inch aluminum block.

The stock may be held to the machine table using clamps.

The part will be machined using 0.5” flat end mill, 0.25” & 0.125” ball end mills.

















CAD system.

To load a part:




2. From the Open dialog box, select the 3Axis_Example2.3dm file from the

Tutorials folder.














Machine Setup


Setup group.













code in a notepad.

Define Setup





create one.







it.

MCS WCS





system.





machined.




10. Set the Length (L) = 5.5, Width (W) = 5 and Height (H) = 1.25.


and 3D curve geometries present in the part from stock bounding box computation









Program tab.





12. Set Z alignment to Bottom and XY alignment to Center. (This would align the

stock to the bottom of the part in Z and center in XY)







Specify Material





model.





Load Knowledge base

1. From Machining Objects Browser, select K-Bases tab and click Load Knowledge

Base

2. Browse to Tutorials folder to select 3Axis_Example1_Completed.vkb



3. Following machining operations are now loaded under K-Bases tab in Machining

Objects browser.

4. Drag and Drop Work Zero, Horizontal Roughing, Parallel Finishing and

Horizontal Finishing operations from Machining Objects browser onto Machining

Operations browser by selecting one operation at a time in a sequence as shown

below.





The dragged operations now appear under Machining Operations browser and are ready

for editing and generating toolpaths.

Notice that the machining operations are flagged in red indication the mops needs

regeneration.



Editing Machining Operations

5. Select Work Zero and Double click to edit the operation.

6. Click on Set to Stock Box, Zero Face – Highest Z and Zero Position – South

West, click Generate.

This sets the work zero to top of stock material and southwest corner.

7. Select Horizontal Roughing operation, right mouse button click and select

Regenerate.

8. Once the roughing has been generated, select Parallel Finishing operation, right

mouse button click and Regenerate.

9. Once the parallel finishing has been generated, select Horizontal Finishing and

double click to edit the operation.



10. Click Select Drive/Containment Region from Machining Features/Regions tab.

Horizontal finishing operation dialog is now minimized and allows selection of

machining features.

11. Select the polyline from the edge of part as shown below.

A selection list is displayed when you click near an edge. Browsing through the

selection list will highlight the surface that corresponds to the selection.




The selected polylines is now listed as DriveRegion 1 under Drive Region in

Machining Features/Regions tab.

13. Click Generate.

Simulate toolpath

14. Switch to Simulate tab, select Horizontal Finishing operation under Setup, right

mouse button click and select Simulate Until. This simulates to end all machining

operations.


Create Pencil Tracing operation

1. Switch to Program tab, select 3Axis Adv and choose Pencil Tracing from Program

tab under Machining Operations group.



2. Switch to Tool tab under Pencil Tracing operation and select BallMill-0.125






5. Select Cut Parameters tab. Use the following parameters



a. Intol = 0.001

b. Outol = 0.001

c. Stock = 0

d. Cut Direction – Climb

e. Select Do Multiple Cuts, specify Number of Cuts = 2

f. Stepover Control - % Tool Diameter = 20



Advanced Cut Parameters

6. Switch to Advanced Cut Parameters tab.

7. Set Limiting Steep Angle = 90 and Maximum included angle = 180

8. Click Generate.

Pencil Tracing operation is now generated and listed under the Horizontal Finishing




Simulate toolpath

9. Switch to Simulate tab, select Pencil Tracing operation under Setup, click and

select Play to run simulation.




Create Valley Re-Machining Operation

1. Switch to Program tab and select 3Axis Adv and choose Valley Re-Machining from


2. Switch to Tool tab under Valley Remachining operation and select BallMill-0.125







Specify Cut Control & Cut Parameters

5. Go to Cut Control tab and use the following parameters

a. Intol = 0.001

b. Outol = 0.001

c. Stock = 0

d. Under Reference Tool Parameters set Tool Diameter = 0.25



6. Click Cutting Parameters tab and use the following parameters

a. Select Split Cuts at Angle(A)

b. Cut Split Angle (A) = 45

c. Select Output Flat & Steep Cuts

d. Click on Flat Cut Parameters tab

i. Cut Pattern - Along

ii. Cut Direction – Mixed

iii. Stepover Control - % Tool Diameter = 20

e. Click Steep Cut Parameters tab

i. Cut Pattern - Horizontal

ii. Cut Direction – Mixed



iii. Stepover Control - % Tool Diameter = 20

7. Click Generate.

Valley Remachining operation is now generated and listed under the Pencil Tracing


Simulate toolpath

1. Switch to Simulate tab, select Valley Remachining operation under Setup, click

and select Play to run simulation.




Post Processing





2. Click Post.




End of Tutorial 10!



Tutorial 11: Machining a Ring



Introduction

This tutorial will illustrate machining this Ring using 4 axis-milling operations. We will use

index machining by creating a Table Rotate Operation for Roughing operation and finishing

using 4 axis parallel finishing. The stepped instructions are accompanied by explanatory and

introductory text. Reading this text will help you understand the tutorial methodology and

provide information about additional options available. Don’t forget to save your work

periodically! You may want to save the file under a different name so that the original file

will be preserved.

Strategy to Machine the ring

We will machine the ring completely using 4 axis-machining operations.

The part itself will be machined out of a cylindrical blank.

The stock will be held to the machine table using a rotary chuck.

The part will be machined using 0.125” and 0.0625” ball end mills.





Set rotary axis and rotary center













CAD system.

To load a part:




2. From the Open dialog box, select the Ring_Example1.3dm file from the Tutorials

folder.














Machine Setup


Setup group.

6. Under Machine Type, set

a. Number of Axes to 4 Axis

b. Configuration to Table.

7. 4th Axis Parameters - set Rotary Axis to X Axis












code in a notepad.

Define Setup







create one.




it.

MCS WCS





system.





machined.


14. Click Cylinder Stock from the drop down list.

This brings up the Cylinder Stock parameters.

15. Select Axis = X, click Copy Model Bounding Cylinder, set Radius = 0.56 and

Length = 0.866


and 3D curve geometries present in the part from stock bounding box computation






Perspective View Front View




Program tab.

You must switch the simulation model to Polygonal model to run 4 axis simulations.

Select CAM Preferences->Simulation Preferences located under MOps browser

and switch the simulation model to Polygonal if set to Voxel.





17. Set Z alignment to Center and XY alignment to Center. (This would align the stock

to the center of the part in Z and center in XY)



The stock is now aligned to the center of part geometry in XY and Z.




Specify Material



19. Set Material to PLASTIC - ABS from the material drop down list and click OK.


model.





Set Work Zero




21. Select Set to Stock Box, the Zero Face to Highest Z, and Zero Position to East.





Set Rotary Center

22. Edit Machine Setup under Program tab and set Rotary Center in Z = 0.15741.

This would set the rotary center to the center of the stock material in Z.

(As the Work Zero is set to top of Stock material Z = 0.71741 and the stock radius =

0.56, the rotary center would be 0.71741-0.56 = 0.15741)



Create Tools





Create/Edit Tools.

24. Select the Tool Type to Ball Mill.

20. Set Name - BallMill-0.125, Tool Diameter = 0.125, Flute Length = 0.75,

Shoulder Length = 1.0, Tool Length = 1.5, Shank Diameter = 0.125, Holder

Length = 0.5, Holder Diameter = 0.5. Under the Properties tab set Material to

HSS and Tool Number = 1.




22. Set Stock Material to PLASTIC-ABS and Tool Material to HSS, Tool Diameter =

0.125. Click OK and the computed cut feedrate and spindle speed is now applied to

the feeds and speeds tab.


Tools in Library.

33. Create another Ball Mill with the following parameters


Shoulder Length = 1.0, Tool Length = 1.5, Shank Diameter = 0.0625,

Holder Length = 0.5, Holder Diameter = 0.5. Under the Properties tab set


b. Click Save as New Tool.


browser.




We will machine the ring using roughing and finishing operations – Horizontal Roughing, 4th

Axis Parallel Finishing.

The first step in machining the ring will be a roughing operation. This type of machining is

very efficient for removing large volumes of material and is typically performed with a large

tool. Roughing is typically followed by semi-finishing or finishing toolpaths

3 Axis Horizontal Roughing

1. Select Work Zero under Setup 1 and now select 3Axis Adv and choose Horizontal

Roughing from Program tab under Machining Operations group.

This brings up the 3 Axis Roughing operation dialog. We will go over the steps for


Machining Features/ Regions under 3 axis operations are used as containment regions.

For the roughing operation, we will skip the selection of machining features/regions.



Select Tool

2. Switch to Tool tab and select BallMill-0.125

The 0.125” Ball mill is now selected as the active tool and the Tool parameters are displayed

to the right of the Tools window.






defined.



Clearance Geometry



Clearance Plane.








6. Select Cut Parameters tab

a. Set Intol = 0.001, Outol = 0.001

b. Stock = 0.01

c. Cut Pattern – Stock Offset,

d. Cut Direction – Mixed,

e. Stepover select % Tool Diameter = 25




a. Set Step Down Control (dZ) as % Tool Diameter = 35


c. Select Bottom (B) under Cut Levels and specify value = -0.6

This limits the toolpath to 0.6” from the top of the stock material.

8. Switch to the Engage/Retract tab and use the following parameters.

a. Select Path for Ramp motion and set Angle = 10 and Height = 0.05

b. Check Always engage in previously cut area if possible

9. Click Generate.

Horizontal Roughing toolpath is now generated and the operation is listed under the




Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the MOps browser.

Simulate toolpath

10. Switch to Simulate tab, select Horizontal Roughing operation under Setup and





Rotate table Operation

We will now create a rotate table operation and rotate it by 180 degrees. This would allow

us to program the part from rotated orientation.

1. Switch to Program tab and select Setup and Rotate Table Setup.

2. Set Table Rotation Angle =180 and click OK.



The MCS is now rotated by 180 degrees and a Rotate Table Setup operation is now

listed under the MOps browser.

Create Roughing operation after table rotation

3. Select the Horizontal Roughing operation created under Setup 1, right mouse and

select Copy.

4. Now click Setup2 (Rotate table operation), Right mouse button click and select

Paste.



This creates a copy of the Roughing operation under Setup2.

5. Right mouse button click on Horizontal Roughing operation under Setup 2 and select

Regenerate.

This generate the roughing toolpath for the bottom half of the ring model.



Simulate toolpath

6. Switch to Simulate tab, select Horizontal Roughing operation under Setup 2 and



Create Rotate table operation #2

We will now create another rotate table operation to rotate the table back to 0 and then

create finishing operation.



7. Switch to Program tab; click the last operation under Setup 2. Now select Setup

and Rotate Table Setup.

8. Set Table Rotation Angle =0 and click OK.

The MCS is now rotated back to 0 and a Rotate Table Setup operation is now listed

under the MOps browser.



4 axis Parallel Finishing

We will now use 4th Axis Finishing operation to finish the part using a 0.0625” Ball mill. In

this method, the tool is always normal to the axis of table rotation (continuous mode). The

tool motions can be parallel to or normal to the rotation axis.

1. Select Setup 3 under Machining Job and click 4Axis and choose Parallel Finishing

from Program tab under Machining Operations group.

If the rotary center is not set to the same location as the Machine Zero, a warning

message dialog would be displayed at all times when a 4 axis machining operation is

selected. Users can override this message by clicking OK in the dialog.



Note: You can select Do no show this dialog again to stop the warning message appearing

again when you create/edit a 4 axis machining operation.

This brings up the 4 Axis Parallel Finishing operation dialog. We will now go over the steps

for creating the toolpath.

Specify Parameters

2. Switch to Tool tab inside the 4 Axis Parallel Finishing operation dialog and select

BallMill-0.0625.



defined.



4. Switch to Clearance tab and set Clearance Cylinder Definition to Automatic and

Cut Transfer Method to Clearance Geometry.

Cut Parameters

5. Click Cut Parameters tab and use the following parameters

a. Intol and Outol = 0.001

b. Stock =0

c. Cut Pattern

i. Along Axis

ii. Zig Zag



iii. High to Low

d. Cut Axial Containment

i. Low Value = -0.8

ii. High Value = -0.1

iii. Start Angle = 0

iv. End Angle = 360

e. Stepover Control - % Tool Diameter = 10

6. Click Generate. 4th axis Parallel Finishing toolpath is now generated and listed under

Setup 3 in RhinoCAM – MOps browser.



Simulate toolpath

7. Switch to Simulate tab, select 4th Axis Parallel Finishing operation under Setup 3





Post Processing

1. Select Setup 1, hold the control key down and select Setup 2 and Setup 3 under

Program tab, right mouse button click and select Post.

This would post all operations created under Setup 1, Setup 2 & Setup 3. The posted file

name is set based on the rules specified under Set Post Options. By default, when

posting all in a file, the Part file name is used as the file name.

2. Click Post.




End of Tutorial 11!



Tutorial 12: Engraving on a Cylinder



Introduction

This tutorial will illustrate engraving text on a cylinder using a 4 Axis Engraving operation.






Strategy to engrave text on a cylinder

We will engrave the text using 4 axis-machining operations.



The part will be machined using 15deg V-Bit.

















CAD system.

To load a part:




2. From the Open dialog box, select the 4Axis_Engrave.3dm file from the Tutorials

folder.












Machine Setup


Setup group.




a. Number of Axes to 4 Axis

b. Configuration to Table.













code in a notepad.

Define Setup







create one.




it.

MCS WCS





system.





machined.




15. Select Axis = X, Radius = 1 and Length = 8










Program tab.















Specify Material







model.



Set Work Zero




21. Select Set to Stock Box, the Zero Face to Highest Z, and Zero Position to West.





Set Rotary Center

1. Edit Machine Setup under Program tab and set Rotary Center in Z = 0.


(As the Work Zero is set to top of Stock material Z = 1 and the stock radius = 1, the

rotary center would be at Z=0)



Create Tools

To machine the above part we will now create a 15 degree V-bit.


Create/Edit Tools.

2. Select the Tool Type to Vee Mill.

3. Set tool Name as VeeMill1, Taper Angle = 7.5, Tool Diameter = 0.25, Shoulder

Length = 1.0, Tool Length = 1.5, Shank Diameter = 0.2, Holder Length = 0.5,

Holder Diameter = 0.5 Under the Properties tab set Material to HSS and Tool

Number = 1.














We will engrave the text on the cylinder using 4 Axis Engraving. This method machines text

or logos by following the contours of the selected regions by projecting the text onto the

cylinder.



4 Axis Engraving

1. Select Work Zero under Setup 1 and click 4Axis and choose Engraving from







This brings up the 4 Axis Engraving operation dialog. We will now go over the steps for



2. Click Select Curves as Regions under Machining Features/Regions tab.



3. Now, select the text by using the left mouse click, starting from left to right. Make

sure to get the inner curves on the letters ‘R’, ‘o’ and ‘A’. Each curve is separate (by

curves, not by letters) and must be selected separately.




The selected regions are now displayed under Machining Regions tab.

Select Tool

5. Switch to Tool tab under 4th Axis Engraving and select VeeMill1



6. Click Feeds & Speeds tab and select Load from Tool.

7. Switch to Clearance tab and set Clearance Cylinder Definition to Automatic and

Cut Transfer Method to Clearance Geometry.


8. Click on Cut Parameters tab and use the following parameters


b. Select Project Curve(s) to Model

c. Step Down Control



i. Select Finishing Passes

ii. # of Passes = 2

iii. R Depth (Rf) = 0.05

9. Click Generate.

4 axis Engraving toolpath is now generated, and the Operation is listed under the




Simulate toolpath

10. Switch to Simulate tab, select 4th Axis Engraving operation under Setup 1 and





Post Processing





2. Click Post.




End of Tutorial 12!



Tutorial 13: Pocketing and Drilling on a Ring



Introduction

This tutorial is intended to describe the 4 axis pocketing and hole making operations.

Pocketing machines closed regions as if they were pockets - completely enclosed by inner

and outer regions. The tool cannot go beyond the outer region, and cannot go within inner

regions. This is unlike Facing, in which the outermost region is considered to enclose

material to be removed. Hole making operations are used to create holes in a part; the hole

types varying from simple drill holes, counter sunk holes, through holes to tapped and

bored holes. Here you will learn to drill simple holes.






Strategy to machine the part

We will machine the ring completely using 4 axis-machining operations.



The part will be machined using a 0.0625” Flat End Mill and 0.125” Standard Drill

















CAD system.

To load a part:




2. From the Open dialog box, select the 4Axis_Pocketing.3dm file from the

Tutorials folder.














Machine Setup


Setup group.


c. Number of Axes to 4 Axis

d. Configuration to Table.













code in a notepad.

Define Setup







create one.




it.

MCS WCS





system.





machined.




15. Select Axis = X, Radius = 2 and Length = 1










Program tab.















Specify Material



19. Set Material to ALUMINUM -6061 from the material drop down list and click OK.


model.





Set Work Zero


3. Select Set to Stock Box, the Zero Face to Highest Z, and Zero Position to East.





Set Rotary Center

4. Edit Machine Setup under Program tab and set Rotary Center in Z = 0.


(As the Work Zero is set to top of Stock material Z = 1 and the stock radius = 1, the

rotary center would be at Z=0)



Create Tools


0.125 inch Drill (Standard Drill)

0.0625 inch Flat Mill


Create/Edit Tools.

2. Select the Tool Type to Drill.

3. Set tool Name as Drill-0.125, Tip Angle = 120, Tool Diameter = 0.125, Shank

Diameter = 0.125, Flute Length = 0.75, Shoulder Length = 1.0, Tool Length =

1.25, Holder Length = 0.5, Holder Diameter = 0.5. Under the Properties tab set





5. Click Save as New Tool

We will now create the Flat Mill.



Shoulder Length = 0.75 and Tool Length = 1.0, Shank Diameter = 0.0625,

Holder Length = 0.5, Holder Diameter = 0.5. Under the Properties tab set





9. Click Save as New Tool.




browser.







We will the holes on the cylinder using 4 Axis Drilling. As in any other 4 axis operations, the

tool is positioned normal (perpendicular) to the rotary axis. Once the holes (regions) are

selected, the dialog boxes are similar to the 3 axis hole making operations. Sorting of holes

is also possible to optimize the tool motion.

4 Axis Drilling

1. Select Work Zero under Setup 1 and now select Holes and choose 4 Axis Drill

from Program tab under Machining Operations group.






This brings Drill operation dialog. We will go over the steps for creating the toolpath.

Select Hole Features

2. Click Select Drill Point/Circles under Hole Features tab.



Drill operation dialog is now minimized and allows selection of hole features.

3. From the menu bar in Rhinoceros, click Edit -> Select Objects and By Layer..

4. Select Layer 04 and click OK.

This adds the 12 drill holes to selection.

5. Press enter or right mouse button click to end selection



Select Tool






defined.



Set Clearance

8. Switch to Clearance tab and set Clearance Cylinder Definition to Stock Max R +

Dist = 0.25 and Cut Transfer Method to Clearance Geometry.

Setting Cut Transfer to Clearance Geometry would apply the Automatic clearance

between transfers when the tool moves from one hole feature to another.

Cut Parameters

9. Select Cut Parameters tab and use the following parameters

a. Drill Type – Standard Drill

b. Drill Depth – 0.1



c. Location of Cut Geometry – At Top

d. Approach Distance = 0.1



Sorting

10. Switch to Sorting tab

11. Select Minimum Distance Sort and set Start Point as Lower Left

12. Click Generate.

4 Axis Drill toolpath is now generated and the operation is listed under the RhinoCAM-

MOps browser.



Simulate toolpath

13. Switch to Simulate tab, select 4 Axis-Standard Drill operation under Setup and





4 Axis Pocketing

1. Select 4Axis and choose Pocketing from Program tab under Machining Operations

group.






This brings up the 4 Axis Engraving operation dialog. We will now go over the steps for






that could have been selected from the previous machining operation.

3. Click Select Curves as Regions under Machining Features/Regions tab.

4Axis Pocket operation dialog is now minimized and allows selection of curves.

4. From the menu bar in Rhinoceros, click Edit -> Select Object and By Layer...

5. Select Layer 02 and click OK.



This adds all curves on Layer 02 to selection.

6. Press enter or right mouse button click to end selection

Select Tool






defined.

Set Clearance

9. Switch to Clearance tab and set Clearance Cylinder Definition to Stock Max R +

Dist = 0.25 and Cut Transfer Method to Clearance Plane.



Setting Cut Transfer to Clearance Geometry would apply the Automatic clearance

between transfers when the tool moves from one region to another.

Cut Parameters

10. Select Cut Parameters tab and use the following parameters


b. Stock = 0

c. Cut Pattern – Offset Cuts

d. Cut Direction – Mixed

e. Start Point – Inside

f. Stepover Distance - % Tool Diameter = 25



g. Select Corner Cleanup


Cut Levels

12. Use the following settings

a. Set Location of Cut Geometry – At Top






e. Cut Level Ordering – Depth First

13. Click Generate. 4 Axis Pocketing operation is now generated and listed under 4Axis

Drilling operation in RhinoCAM – MOps browser.



Simulate toolpath

14. Switch to Simulate tab, select 4 Axis Pocketing operation under Setup and click





Post Processing





2. Click Post.




End of Tutorial 13!



Tutorial 15: 5 Axis Surface based machining



Introduction

This tutorial will illustrate machining of certain surfaces using 5 axis machining methods. In

this mode, tool path orientation is determined by surface normal direction.


We will machine the part using 3 and 5 axis-machining operations.

The part itself will be machined out of a precut blank.


The part will be machined using 0.5” Flat mill and 0.25” ball mill.



Define 5 axis machine configuration















CAD system.

To load a part:




2. From the Open dialog box, select the 5Axis_Example1.3dm file from the

Tutorials folder.

The part already has stock geometry defined and includes a 3 axis roughing

operation. We will now define the machine setup and create 5 axis machining operations.

Machine Setup


Setup group.

3. Under Machine Tool definition, select Load From File



4. Click the drop down list next to Current Machine Tool and select

5Ax_Okuma_MU400VA

Selecting a machine tool from the list displays the machine tool model in the view

port area and automatically loads the machine properties.

5. Click OK.



MOps browser now lists this information under Machining Job. The defined machine

tool can then be used to perform machine tool cut material simulation.




posts. We will select Okuma as the post processor for this exercise. Set the posted

file extension type to .nc




code in a notepad.

Specify Material

If the stock material has not already been defined,




model.




In this process we will first create a 5 axis Surface Normal Machining operation

5 Axis Surface Normal Machining

1. With the Horizontal Roughing operation under Program tab selected, click 5 Axis

and Surface Normal

This brings up the 5 Axis Surface Normal machining operation dialog. We will go over the steps for creating the toolpath.

In 5 Axis operations, the role of Part surfaces is non-existent. The user can define only

Drive and Check surfaces. The Drive surfaces determine the tool location and tool axis

in some cases while the Check surfaces define the surfaces to avoid. Drive surface is the

model geometry which is used for tool path generation; it is the surface you want to work

on and defines the shape to be milled. You can select multi surfaces.



Machining Features

2. Click Select Surface(s) to select Drive Surfaces under Machining Features tab

3. Select the top surface from the part as shown below.




The selected surface is now listed as Surface1 under Drive Surfaces. Selecting the surface displays the surface normal.

Make sure that the surface normal is oriented in proper direction. Tool path orientation is

determined by surface normal direction. So if you have generated the tool path on the

wrong side you can simply change the surface normal afterwards and regenerate your tool path again.

For the above surface, the surface normal orientation looks correct.



Select Tool

5. Click on Tool tab and select BALLMILL-0.25

6. Switch to Feeds & Speeds tab and select Load from Tool.


defined.

7. Go to Clearance tab



Specify Clearance

8. Use the following settings

a. Clearance Definition - Plane

b. Plane Orientation - Parallel to MCS XY

c. Plane Offset Distance – Automatic

d. Cut Transfer Method – Clearance Geometry

9. Click on Cut Parameters tab





a. Global Cut Parameters - Cut Tolerance = 0.001, Max Angle Change = 3,

Max Distance Change = 0.04 , Stock =0

b. Cut Pattern – Parallel to X

c. Cutting Traversal – Zig Zag

d. Stepover - % Tool Diameter = 15 e. Tool Axis Control – Lead/Lag Angle = 0, Tilt Angle = 0

11. Switch to Entry/Exit tab



Entry/Exit


a. Entry Motion type - Vertical Tangential Arc and Set Sweep Angle = 90,

Radius = 0.125

b. Exit Motion type - Vertical Tangential Arc and Set Sweep Angle = 90,

Radius = 0.125

c. Set Tool Axis Transition as Fixed for Entry & Exit motions.

13. Click on Gouge Check tab



Gouge Check

14. Select Perform Gouge Check for Tool Geometry against Check Geometry

15. Under Tool Geometry check Holder, Shaft and Tip. Set Holder Clearance =0.1

and Tool Shaft Clearance = 0.01

16. Gouge Check Strategy use Retract tool along tool axis

17. Under Check Geometry select Drive surfaces and Check surfaces

18. Click Add under Check Surfaces

This minimized the dialog and allows you to select surfaces.

19. Select the 4 side surfaces from the model as check surface geometry.




The 4 surfaces are now added as check surface geometries and listed under check surfaces.

21. Click Generate.

5 axis Surface Normal machining operation is now generated and listed under the Horizontal Roughing operation in RhinoCAM



Simulate toolpath


2. Toggle Machine Tool Visibility ON under simulate tab.

3. Select Horizontal Roughing operation under Setup and click Play to run

simulation.

4. Once this is completed, select 5 Axis Surface Normal Machining operation under

Setup and click Play to run the simulation.

Note: You can select Setup 1 and click Play to simulate all operations created under the

current Setup.

Turning off the machine tool visibility only shows cut material simulation.




5 Axis Swarf Machining

We will now create a 5 Axis Swarf machining toolpath to finish the side walls. The material

removal is performed by the sides of the cutter. The Swarf Milling strategy provides you

with a number of advantages during steep areas machining. With Swarf machining

performed by the sides of the tool, the contact area between the tool and the work-piece is

a line and therefore a better surface quality can be achieved with a minimum number of

cuts.

1. Switch to Program tab, select 5 Axis and Swarf



This brings up the 5 Axis Swarf machining operation dialog. We will go over the steps for creating the toolpath.

Machining Features

2. Click Remove All under Wall Surfaces to deselect any features that may have

been included from the previous operation.

3. Click Select Surface(s) under Wall Surfaces

This minimizes the dialog and allows selection of wall surfaces

4. Select the 4 side surfaces as shown below.




The selected surfaces now appear under wall surfaces. Selecting a surface from the

list, displays the surface normal direction.

6. Under Cut Pattern, select Parallel to Curves.

7. Click Select Curve(s) under Floor Curves



8. Select the face edge located at the bottom of each of the 4 wall surfaces as shown

below.




The surface edges are now listed under Floor curves in Machining Features tab.

Selecting a curve from the list highlights the edge on the surface.



Select Tool

10. Switch to Tool tab and select BallMILL-0.25


12. Click Clearance tab and use the following settings

a. Clearance Definition - Plane

b. Plane Orientation - Parallel to MCS XY

c. Plane Offset Distance – Automatic

d. Cut Transfer Method – Clearance Geometry




Cut Parameters


a. Global Cut Parameters - Cut Tolerance = 0.001, Max Angle Change = 3,

Max Distance Change = 0.04 , Stock =0

b. Cutting Traversal – Zig Zag

c. Cutting Area –

i. Select Determine by Number of Cuts

ii. Number of Cuts = 1

iii. Stepover Distance = 0.25, Start Margin = 0

d. Tool Axis Control – Lead/Lag Angle = 0, Tilt Angle = 90



15. Switch to Entry/Exit tab

Entry/Exit


a. Entry Motion type - Tangential Arc and Set Sweep Angle = 90, Radius =

0.125

b. Exit Motion type - Tangential Arc and Set Sweep Angle = 90, Radius =

0.125

c. Set Tool Axis Transition as Fixed for Entry & Exit motions.

17. Click Gouge Check tab



Gouge Check

18. Select Perform Gouge Check for Tool Geometry against Check Geometry

19. Under Tool Geometry check Holder, Shaft and Tip. Set Holder Clearance =0.1

and Tool Shaft Clearance = 0.01

20. Gouge Check Strategy use Retract tool along tool axis

21. Under Check Geometry select Drive surfaces and Check surfaces

22. Click Add under Check Surfaces

This minimized the dialog and allows you to select surfaces.

23. Select the top surface from the model as check surface geometry.




The surface is now added as check surface geometry and listed under check surfaces.

25. Click Generate.

5 axis Swarf machining operation is now generated and listed under the Surface Normal operation in RhinoCAM

Simulate toolpath


27. Toggle Machine Tool Visibility ON under simulate tab.



28. Select 5 Axis Swarf Machining operation under Setup and click Play to run

simulation.

Post Processing





2. Click Post.




End of Tutorial 14!

Documents

RhinoCAM_GettingStartedGuide