Alp - Trg116 3D Machining Strategies 2014 R2 V5.0 PDF

Alp_Trg116
3D Machining Strategies
Copyright
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Page 2 of 70 ALP_TRG116
Contents
Conventions used in this guide ................................................................... 6
Recommended Operating Systems and Hardware for Alphacam ................ 7
Supported Operating Systems 7
Alphacam Minimum Specifications 7
Introduction ............................................................................................... 8
Objective 8
3D Machining Strategies ............................................................................ 8
Roughing Strategies 8
Finish Machining Strategies 8
First Dialogue 9
Front End Dialogue (Essential) 9
Front End Dialogue (Standard) 9
Front End Dialogue (Advanced) 9
Front End Dialogue (Ultimate) 9
3D Z Contour Roughing .............................................................................10
Z Contour Roughing Dialogue 1 10
Strategy Type 11
Close Open Pockets (contour option) 12
Smoothing Radius (waveform option) 12
Back Pass Retract (waveform option) 12
Use Max Feed on Back Pass (waveform option) 12
Cutting Type 13
Links 13
Link Type 13
XY Standoff 13
Feed When Plunging 13
Avoid Rollover 14
High Speed Cornering 14
Take Account Previous Machining 14
Use Geometry Boundaries Instead of Material 14
Material Selection 14
Material Top and Bottom 15
Include Flat Areas as Additional Z Levels 15
Intermediate Slices 16
Approach Type 16
Slope Angle 16
Maximum Plunge Depth 16
Trochoidal for Full-Width Moves 17
Adaptive Feed Rates 18
Z contour Roughing Tutorial Example ........................................................19
3D Finish Machining Strategies .................................................................20
Multi-Processing of 3D Machining Operations 20
Finish Machining Strategy Options 21
3D Solid Machining Accuracy 22
Width of Cut 22
Cusp Height 22
Chart showing the relationship between Cusp Height, Tool Diameter and Width of Cut 23
Version 5 A0 Page 3 of 70
Chord Tolerance along Cut 24

Facet Tolerance 24
Lead In/Out Links 24
Contact Angles 25
Corners 25
Parameter Line Machining (surfaces only) ................................................. 26
Horizontal Z Contours ............................................................................... 27
Horizontal Z Contours Dialogues 27
Rest Finish 27
Dialogue Descriptions 28
Advanced Dialogue Descriptions 29
Parallel ..................................................................................................... 31
Advanced Tab 32
Perpendicular Lace 33
Up Down Mill 33
Projected Contours ................................................................................... 34
Radial ....................................................................................................... 35
Spiral ........................................................................................................ 36
Rest Machining ......................................................................................... 37
Drive Curves ............................................................................................. 38
Using Geometries 38
Using Toolpaths 39
Flat Area ................................................................................................... 40
Helical Z ................................................................................................... 41
Cylindrically Parallel ................................................................................. 42
Cylindrical Profiling................................................................................... 43
Constant Cusp........................................................................................... 44
General 44
Advanced 45
Z (Enhanced Undercuts) ............................................................................. 46
Tool paths generated with Horizontal Z 46
Tool Paths Generated with Z (Enhanced Undercuts) 46
3D Finish Machining tutorial example. ...................................................... 47
Finish Machining Outline 47
Model Examples ........................................................................................ 48
Bracket 48
Curved Recess 49
Helical Z 49
Male Form 1 50
Mould Insert 50
Mould 1 51
Mould 2 51
Mould 3 52
Mould 4 52
Panel + Shape 53
Part Machined with lollipop cutter 53
Pipe 54
Pocketed Plate 54
Tool Axis Conversion ................................................................................. 55
Convert 3D work plane tool path to Vertical 56
Convert 2 Axis tool path in work plane to Vertical 57
4 Axis XZ or YZ Rotation 58
Through Axis 58
Parallel tool paths 58
Helical Z tool paths in work plane 59
5 Axis 60
XZ Rotation Confine with Boundary 60
Normal to Curve or Curves 61
XY Rotation Tool at Fixed Tilt Angle 62
Project through Point 63
Project through Axis 64
Confine with Boundary 65
Project through Guide Curves 66
Cut Spline or Polyline ................................................................................ 67
4 Axis Cut With side of tool 69
Conventions used in this guide

To enable you to use the information in this guide effectively, you need to understand the used in
the guide to represent different types of information.
• Buttons on the screen are represented as the button text in square brackets.
For example: Click on [Ok].
• Keys on the keyboard are represented as bold lettering in between <> characters.
For example: Press <Enter.>
• Menu options are represented as a path with the main menu in UPPER case with sub menus
Capitalised and separated with an arrow.
For example: Select FILE > Open
• Field names are represented as bold text. And the value to be entered will be represented by
Narrow Bold Text.
For example: Enter the value 50 in the Offset field. Or
When prompted for the X & Y values type 100,50 <Enter>
 This is a note. It contains useful or additional information.
 This is a reference. It directs you to another part of the user guide.
This is a thought box. It is generally used in exercises and contains a question for
you to consider.
 This is a highlighted note to emphasise information
This is a warning, it contains information that you must not ignore.
 This is a tip. It is generally used in exercises and offers further advice.
1 This is the first line a number list item

this is the second line of the numbered item
2 This is the second item of the numbered instructions, which you must
3 Follow in sequence.
• This is a list
• of items, in which
• The order is not important.
Recommended Operating Systems and Hardware for Alphacam

Supported Operating Systems
• Operating System
Windows Vista (Vista Business or Vista Ultimate recommended), Windows 7 (Professional or
Ultimate recommended),Windows 8 Professional and Windows 8 Enterprise
• Alphacam will install and run on the ‘Home’ editions of the above operating systems.
However, this is not recommended and we cannot guarantee to fix any Alphacam issues
specifically related to these operating systems.
Alphacam is not supported on Windows 7 Starter Edition.
• Alphacam will install and run on 64-bit versions of these operating systems, where
applicable (note however that Alphacam is a 32-bit application).
• nVidia or ATI Open GL Graphics Card with 512Mb dedicated memory
 We recommend you keep up to date with the with the latest service packs for the
supported operating systems and drivers for your hardware base.
Windows NT, 95,98,ME and XP are not supported operating systems

Alphacam Minimum Specifications
The latest minimum speciation can be found at
www.alphacam.com/systemrequirements
This minimum specification is to run Alphacam Essential you will need to considerably increase the
specification if you are working with solid models and producing the nc code for 3D 3, 4, or 5 axis
simultaneous machining strategies.
Your minimum specifications should be the fastest processor with the most memory and the
biggest video card that your budget will allow.
If using Autodesk Inventor please check the current Inventor requirements at
www.autodesk.com
Introduction
Objective
The purpose of this training course is to enable you to apply machining strategies to either: Solids +
Surfaces or Surfaces, applied as 3, 4 and 5 Axis machining conditions.
The machine tool and software module level capabilities will place restrictions on the position and
orientation of the model and the machining strategies that can be used.
Alphacam Modules include 3D Solid Machining strategies that create roughing and finishing tool
paths to optimise the productivity of CNC machine tools while, at the same time, ensuring the
highest quality machining of Solid models and Surfaces.
Roughing Strategies
Material Roughing Z Contour Roughing
Finish Machining Strategies
Parameter Lines
(Only applicable to
Surface Machining)
Horizontal Z Contours
Parallel.
Projected Contours
Radial
Spiral
Rest Machining
Drive Curves
Flat Area
Helical Z
Cylindrical Parallel
Cylindrical Profiling
Constant Cusp
Z (Enhanced Undercuts)
First Dialogue
The front end Dialogue box and number of options will differ dependent upon 3D machining type
and the module level being used.
The Essential module only has one 3D Solid machining strategy.
The Standard module only has three 3D Machining strategies.
Front End Dialogue (Essential)
There is no front end Dialogue in Essential the first prompt is for you to select the containment
boundary, followed by the parallel machining dialogues.
Front End Dialogue (Standard)
Front End Dialogue (Advanced)
Front End Dialogue (Ultimate)
 The Ultimate level of the software allows surfaces and polylines to be profiled in 4 –
5 axes simultaneously.
3D Z Contour Roughing
The first machining strategy that is normally used is 3D Z Contour roughing.
The 3D Z Contour Roughing can only by actioned as a 3 axis strategy.
However the 3 axis tool paths are generated with respect to the currently active work plane when
the strategy is applied.
Multi planer machining can only be created within the limitations of your machine
tool.
Z Contour Roughing Dialogue 1
Strategy Type
Contour Linear
Spiral Waveform
 Note that in some circumstances the Spiral setting will be overridden and a
concentric tool path created. This may occur for large step over values, E.G.,
where a spiral tool path would leave pegs of uncut material in corners.
 The Waveform roughing strategy is a high speed machining technique that

maintains a constant tool cutting load by ensuring the tool engagement into the
material is consistent. The tool path moves in a smooth path to avoid sharp
changes in direction which maintains the machine tool’s velocity.
Close Open Pockets (contour option)

If unchecked, the tool will work from the outer edge inwards. If checked, all open pockets will be
treated as closed pockets and the tool will start in the middle and work outwards.
Smoothing Radius (waveform option)

This controls the radius of tangential arcs between the linear moves that join the tool path when
approaching into a corner.
 By default, the smoothing radius is set to 25% of the tool diameter or equal to the
minimum radius, whichever is greater. If specified, the radius must be at least equal
to the minimum radius and no greater than the tool diameter
Back Pass Retract (waveform option)
A large axial depth of cut can cause the tool to flex, so when disengaged on the
back pass, the tool end could remove a small amount of material under the
pendulum affect. This will blunt the bottom of the tool and generate unwanted heat
in the component.
The Back pass Retract is used to raise the tool by a small amount in the Z axis to avoid dragging
the tool across the part surface on the back passes.
The tool starts to lift from the cut Z depth at the point where the tool disengages from the material
and lifts over 5 degrees of travel, at which point the tool will switch high feed rate, if specified. The
tool will descend back towards the Z cut depth 5 degrees before the tool re-engages.
Use Max Feed on Back Pass (waveform option)
If checked, this option to use the maximum allowed feed rate on the back pass, where the tool is
disengaged from the material over a large distance, i.e. where the tool is not cutting.
Max Feed is specified by $753 or PostConfigure.FeedMax in the post processor.
The high feed rate becomes active 5 degrees past the point where the tool disengages from the
material. Then, at 5 degrees before the tool re-engages the tool path switches back to the cutting
feed rate.
Cutting Type
The cutter can move along a profile on the left or right side. This, combined with the spindle
direction, gives the type of cutting to be either Climb or Conventional.
• Climb Tool cuts on the left of the profile (i.e. material is on the right).
• Conventional Tool cuts on right of the profile
• Optimised Cycle is optimised to reduce link moves.

The tool may cut on the left or right side.
Links
Link Method
• Always Ramp There is a retract for the link (rapid) move.

(The height of the retract is set by ‘Link Type’).
• Always Stay At The tool stays at the same depth and there is no retract. This does
not apply to links that clear geometry, for these links there is always a
Depth
retract, to avoid gouging.
• Optimised The faster of the two methods above is automatically selected
Link Type
When there is to be a retract for the link, this setting controls the retract height.
• Optimised – This setting only applies to moves within the same machined out volume (as
in a pocket in a boss in a pocket). For links that move between two separate volumes
(two separate pockets for example), the tool always retracts to the Clearance height.
These moves will be at the maximum feed rate specified in the post processor.
• Clearance – For the link the tool always retracts to the Clearance height.
XY Standoff
This allows you to specify the distance between the stock and the tool when approaching
from outside.
Feed When Plunging
When checked, the tool will use the feedrate when moving down in the Z axis during the
cycle. This is a safe option when the amount of stock material is unknown. When
unchecked, the tool will rapid to the safe distance above the model then feed into position.
Avoid Rollover
Check this to eliminate the tool roll-round on the outer corners of open pocket geometry.
This is mainly for use with wireframe and prismatic type solid geometry.
High Speed Cornering

This setting only affects non-final passes; when checked, a radius is introduced into sharp
tool path corners. This is the default. This will lower machine stresses, reduce tool path
length, maintain tool speed and reduced cycle time. It will, however, generate more NC
code. When unchecked, all tool path corners have an angle from the profile, however sharp
Checked… Unchecked…
Take Account Previous Machining

When checked, the cycle uses looks for and avoids any areas of the part which have been
previously machined at the same cutting depths.
Use Geometry Boundaries Instead of Material

When checked, the user is asked to select a closed geometry path which represents the
tool path boundary. When unchecked, the existing material geometry, as defined by the
Set Material command, is used.
Material Selection
• Current The primary setting for initial machining, ticking this option will
use the only material available once selected or a currently
Material
active material from a previous operation.
• Select Allows the use of materials from previous operations to be

selected as the new working envelope for the roughing cycle
Material(s)
• Use Allows for the addition of extra controlling 2D geometric

boundaries to contain the roughing cycle.
Boundaries
Material Top and Bottom

These options automatically take their settings from the primary material value and all work
done on the part is between these values if the Auto option is ticked.
Un-ticking Auto allows the user to limit the upper and lower Z machining levels by altering
the second set of options that show.
Include Flat Areas as Additional Z Levels
Check this to ensure that there is a cutting pass at the height of any flat region. This
prevents material being left un-machined at the bottom of pockets or the top if pillars, for
example.
Without this option checked, the last (lowest) pass occurs when there is not sufficient depth
remaining for another full cut (as specified by the Cut Increment).
It is recommended to leave the option unchecked when working with large surface parts
with no flat areas to increase processing speed.
Intermediate Slices
Intermediate cuts may be used to reduce the size of the step left by the roughing cycle.
Only the step region is machined by intermediate cuts. Intermediate cuts will always be cut from
bottom to top within each cut increment to reduce unnecessary cutting. This method roughs and
semi-roughs the part in one cycle while allowing the tool to cut to its maximum depth for the main
increments.
Max Depth per Cut
Specifies the depth of each successive cut (for intermediate cuts).
Percentage Feed
The feederate for intermediate slices is specified as a percentage of the cutting feederate.
Approach Type
Offers you the ability to start the cycle from pre-drilled hole(s) and set a preference for Ramp or
Helical approach.
• Automatic The cycle automatically applies an appropriate ramp method.
• Pre-Drilled Holes Specify a pre-defined drill point as the point of entry. The tool will
plunge down the nearest hole to the start point in a region. When no
valid point is available the tool will ramp instead. The tool will rapid
down the hole to the desired depth unless it is within the safe distance
of the pre-drill point where it will feed to depth from the safe distance
above the point. If Feed When Plunging is checked, the tool will feed
down the hole at the Down Feed value.
• Helix The cycle will always attempt to place a helical approach in pocket
areas before any other approach type.
• Ramp The cycle will always attempt to place a ramp approach in pocket
areas before any other approach type.
Slope Angle
The Slope angle sets the angle of the ramp move into the stock material. The maximum
ramp angle is calculated from the Maximum Plunge Depth and Centre Cut modifiers. This
value will automatically be used if it is found to be less than the specified Ramp Angle. If the
modifier is left blank the calculated ramp angle will be used.
Maximum Plunge Depth
The Maximum plunge depth specifies the maximum distance in the Z-axis that the tool can
plunge into the material. The value will be used to check that the ramp move does not
exceed this value.
If Maximum Plunge Depth is set to 0 the tool cannot plunge or ramp. Therefore, the cycle
can only machine external areas or pocket areas that have pre-drilled holes.
Trochoidal for Full-Width Moves

Full Width Cut Move = Cut move which exceeds the specified Width of Cut.
This potentially overloads the tool, so Alphacam detects when a cut would be full width and
offers this option. Note that in a narrow channel there may not be room for a trochoidal cut,
in which case the channel is excluded from the cycle.
The chord Tolerance is used in determining the mesh size used in determining what features are
seen to be machined. If the roughing cycle appears to miss sections it is usually because the chord
tolerance is too large.
Adaptive Feed Rates

Adaptive feed rates adjust the feed rate to even out loading on the tool so are not applicable when
using the waveform cutting strategy.
For example in a narrow channel the loading could be higher as the actual step over increases
above the specified Step over value; in this case the feed rate would be reduced. Conversely for
smaller cuts at less than the specified %Step over, the feed rate would be increased to reduce
machining times.
 The adjustment is only made to XY feeds; it is not applied to any Z feeds.

The Minimum Feed rate is the % of the original specified feed rate to be used in a full width cut
(where the effective step over = 100%). At intermediate effective step over’s, the feed rate is
adjusted proportionally.
For example, if the increment % is 10 for a specified cut feed of 5500 and the specified step over is
50% of the tool dia. i.e. 10, then, if the actual step over is 12 i.e. 60% of the tool dia., the feed rate
would be reduced by 10% to 4950. If the step over was 16 i.e. 80% of the tool dia., then the feed
rate would be reduced by 30% to 3850. If the step over was 20 i.e. 100% of the tool dia., then the
feed rate would be reduced by 50% to 2750.
The Maximum Feed rate is the % of the original specified feed rate to be used as the effective step
over reduces towards 0.
For example, if the increment % is 10 for a specified cut feed of 5500 and the specified step over is
50% of the tool dia. i.e. 10, then, if the actual step over is 8 i.e. 40% of the tool dia., the feed rate
would be increased by 20% to 6600. If the step over was 6 i.e. 30% of the tool dia., then the feed
rate would be increased by 40% to 7700. If the step over was 1 i.e. 5% of the tool dia., then the
feed rate would be increased by 95% to 10725.
The feed rate can only be adjusted to certain values. This Feed rate Increment is the size of the
steps between these values, as a percentage of the original feed rate.
Specifying low values helps produce tighter control over the feed rate, but with
potentially more CNC code and slower processing. Specifying high values helps
reduce the CNC code and speed processing, but with less accurate control over
the feed rate
 The Step over is specified as a width of cut value in the Z contour roughing
Dialogue the system internally uses the width of cut and the tool diameter to
calculate the relevant percentages.
Z contour Roughing Tutorial Example

Input the Twisted Handrail.pmod from the ALP_TRG116 3D Machining
Strategies\Examples\Solids folder
This is to be machined with Ø25 diameter flat tool with cutting length of 125mm.
The component is machined from the Top and 2 sides using residual material to eliminate air cuts.
Using 3D > Auto Set Material with a top at Z+10mm, a bottom Z value of -200mm and an
allowance in X & Y of 10mm.
The reason for a Z-200 figure is to represent an oversize piece of material which allows the part to
be lifted above the table of holding fixture.
1. Z Contour Rough from the top restricting the cut depth to 150mm.
Enter 2mm in XY&Z allowances for roughing.
2. Run the solid simulation
3. Create STL from Solid simulation using the small “Save” disc icon on the Simulation Project
Manager page.
4. Turn off the Materials and the Operation.
5. Create a Bounding Work Volume around the Handrail model only.
6. Slice Through the Work Volume to create a new Work Plane on the front of the part.
7. Import STL from the Solid Simulation.
8. Z Contour Rough from work plane using the Selected Material option and selecting the
imported STL as material. Change the depth restriction to -75
9. Run the solid simulation
10. Create STL from Solid simulation as previous..
11. Turn off the Materials and the Operation
12. Using 2 Lines For X&Y, create a new Work Plane from the rear face of the Work Volume
13. Repeat the Process from 7 through to 9 but alter the depth restriction to -55.
14. Run the simulation
You will need to use Rapid Manager to control how the machine gets the tool to
the relevant machining face.
3D Finish Machining Strategies

There are several different types of finish machining strategies because one strategy does not suit
all cutting conditions.
It is not uncommon to have to use several different machining strategies on one

part. These machining strategies are usually applied using containment
boundaries.
The decision as to which of the machining strategies to use for which of the different 3D features is
sometimes not obvious, as several different strategies may give the desired result. Each feature
being machined has to be looked at with respect to how you can; access the feature, the nature of
the feature, the nature of the surface finish to be achieved, and also the nature of the tool marks you
or your customer would be satisfied with.
Multi-Processing of 3D Machining Operations

In the FILE > Configure > General dialogue box is the ability to turn on Background Processing
when working with 3D machining cycles. This functionality permits the use of unused processor
capacity in your pc to be applied to the complex calculations required when creating and editing 3D
machining cycles.
During the calculation period the operation that is being worked on will display the “Processing”
tag to indicate that it is being worked on.
More than one item can be processed at a time and you can also Abort the calculations if you feel
that you have made an error or wish to adjust any settings.
Allowing Background Processing frees up the waiting time that you would have had to leave
Alphacam alone, so that you can continue to add further operations or geometry items.
Finish Machining Strategy Options

Parameter Lines
(Only applicable to Surface
Machining)
Parallel.
Projected Contours
Radial
Spiral
Rest Machining
Drive Curves
Flat Area
Helical Z
Cylindrical Parallel
Constant Cusp
The finish machining strategies Dialogue options will differ depending upon the level of software
module and current post processor.
3D Solid Machining Accuracy

Width of Cut
This is normally used for roughing and is the step over distance between the centre line of each
pass of the cutter.
Cusp Height
This is normal used for finish machining with a ball end tool.
Alphacam will calculate the position of each cut to produce the cusp height set. If you ask for a very
small cusp height, in an attempt to produce a mirror finish, the NC program will be very a big,
calculation which will be slow, and machining will take a long time. A sensible practical value for
metric work is between 0.1 and 0.02.
Chart showing the relationship between Cusp Height, Tool Diameter and Width of Cut
Values in mm
Tool Width Width Width Width Width

Dia. 0.2 0.4 0.6 0.8 1.0
2 0.00501 0.0202 0.04606 0.08348 0.13397
4 0.0025 0.01003 0.02263 0.04041 0.06351
6 0.00167 0.00667 0.01504 0.02679 0.04196
8 0.00125 0.005 0.01127 0.02005 0.03137
10 0.001 0.004 0.00901 0.01603 0.02506
12 0.00083 0.00333 0.0075 0.01335 0.02087
20 0.0005 0.002 0.0045 0.008 0.01251
Cusp Height
Tool Width Width Width Width Width

Dia. 1.2 1.4 1.6 1.8 2.0
2 0.2 0.28586 0.4 0.56411 1.0
4 0.09212 0.1265 0.16697 0.21394 0.26795
6 0.06061 0.08281 0.10863 0.13818 0.17157
8 0.04526 0.06173 0.08082 0.10256 0.12702
10 0.03613 0.04924 0.06441 0.08167 0.10102
12 0.03008 0.04097 0.05257 0.06788 0.08392
20 0.01802 0.02453 0.03205 0.04058 0.05013
Cusp Height
Chord Tolerance along Cut

All 3D machining is output as straight line moves in X Y and Z, and this figure determines how many
straight lines are output to represent a curved cutting move. A very small chord tolerance will
produce very large NC programs, without much effect on the surface accuracy. A sensible practical
value for metric work is between 0.1 and 0.02
Facet Tolerance
This is a function of the Chord Tolerance and should not be changed from 0.25 unless producing
mirrored surfaces.
Lead In/Out Links
The lead and links between cuts can be configured controlling the path extension length, the
ramping angle and length and the radius size between the path extension and ramp.
Bi-directional paths can also be joined with arc type moves to give paths for high speed machining.
The Lead-In/Out and Links check box Specify Moves between Paths switches on the lead in and
out options
1. Extension Length: the amount of overrun from the edge of the surface.
2. Ramp Length: the length of the extension ramp
3. Arc Radius: the arc radius between the Extension and the Ramp.
4. Ramp Angle: the angle between the Extension and the Ramp.
5. Join Paths with Arc: if not checked a straight line is used.
Contact Angles
The Contact angles, accessed via the advanced tab on a number of cycles, provide control of which
surfaces/faces are cut for each operation.
Corners
The tool normally rolls around any external corner and maintains contact in some cases, this can
cause the corner to be eroded. To avoid this, use one of the corner control methods.
Round Straight Loop High Speed

Round: Tool radius rollover that maintains tool contact with the corner (Default).
Straight: Replaces the rollover with a sharp corner. The tool path extends past the corner
until it intersects with the next section.
Loop: Replaces the round with a external loop move
High Speed: Replaces the rollover with a sharp corner. The tool path extends past the corner
until it intersects with the next section, where it is then blended with a radius of
75% of the tool radius to maintain tool path tangency and will help the machine
tool maintain its velocity.
Loop Radius: Specifies the radius of the loop move
Parameter Line Machining (surfaces only)

This machining strategy is unique to surface machining as solids do not have parameter lines. The
parameter lines are the lines drawn when the surface is not shaded; the density of these lines
determines the accuracy of the surface and is defined by the edge tolerance when the surface was
created.
The surface finish achieved is dependent upon the machining step over in the strategy.
This method is best when used for machining one surface only, but two or more surfaces can be
machined if the parameter lines are in the same (or very similar) directions on all the surfaces.
You have the option to use boundaries, to define the areas to be machined. These will be treated as
Hard or Soft Boundaries and the tool will be kept inside or outside or allowed to move until the tool
centre line is on the boundary.
The tools cutting direction is set to move in one of the directions shown by the parameter lines on
the screen depending upon your selection.
Gouge Checking requires prodigious calculations, and you should not ask for gouge checking if it
obviously is not necessary.
Check for Gouging on Current Surface: Check this box only if the surface being machined has
undulations or folds which create valleys into which the tool will not fit. This check is only applicable
for the Parameter Line method.
The first finish machining Dialogue allows you to set the machining strategy; the second Dialogue
sets the tooling and depth parameters and the third Dialogue (shown below) allows you to
determine the surface finish achieved.
The selection criteria are:

Boundaries, Surfaces to Cut, Surfaces to check, first point (where to start cutting), Second point (to
give direction).
The Pipe examples shown shows the cuts parallel with the parameter lines for each half.
This method creates paths that are at constant Z Levels. The distance between the levels is
controlled by either Width of Cut or Cusp Height. The Upper Z Level and Lower Z Level can also be
set to limit the machining to within the reach of the tool. You can machine any amount of surfaces.
There are options to machine all of the selected surfaces or contain the machining within
boundaries which can be any shape. These will be treated as Hard or Soft Boundaries and the tool
will be kept inside or outside or allowed to move until the tool centre line is on the boundary.
The cutting direction can be controlled to give Climb Conventional or Optimised cutting, giving
clockwise, anti-clockwise or bi-directional tracking around the profiles. The links between the
subsequent Z Levels can be controlled to obtain a smooth transition and even helically ramp from
one level to the next by checking the Join Paths with Arcs option. The cutting order can be
controlled when several Islands or pockets are identified at different levels, ensuring that the tool
will cut all areas at each level or cut all levels at each area first to reduce lift off and any excess
rapids. There is also an option to reverse the order of the Z levels and cut from the lower Z level to
the upper. This can be achieved by checking Bottom to Top.
Horizontal Z Contours Dialogues
This machining strategy has three tabs, General, Advanced and Rest Finish
Rest Finish
Previous Tool – Allow for rest machining to be done automatically after the flat area machining has
been done.
Dialogue Descriptions
Mill Type –
The Optimised option results in an optimised, bidirectional tool path. The Conventional and Climb
options can be used if consistent (single) direction cuts are desired.
Connect Aircut Length –
The minimum distance allowed for rapid moves between cuts within the cycle. Rapids moves with
lengths less than this distance will be converted to feed moves, keeping the tool at the cut depth.
Helical –
This option applies to closed contours only. Instead of the depth increasing in a step after each Z
level pass, the depth increases continuously throughout the pass. For each complete pass, the
depth increases by the cut increment. There is a final pass at the finish depth with no Z movement.
Bottom to Top –
If checked, the machining will start at the lowest level first and work upwards, rather than starting at
the top and work downwards.
Tool can under-cut –
This option allows undercuts to be applied. This is only available if an undercutting tool is selected
(e.g., Lollipop). Note that this option should be left unchecked unless it is known that undercuts will
actually be applied as this will help minimize processing time. Also note that with this option
checked, the Rest Finish settings are unavailable.
Include Flat Areas as additional Z Levels –
This option allows you to specify that an additional cutting pass is created at the height of any “flat”
region. This ensures that material is not left un-machined at the bottom of pockets, for example.
Prismatic Geometry –
This option detects areas of prismatic geometry, such as cylindrical islands, cones, and rectangular
pockets. This geometry is then used to produce arcs and line moves. On some parts, this can
drastically reduce the size of the NC code output but will increase processing time.
Cut Between Z Levels –
With the Auto option checked, the Upper Z and Lower Z values are automatically populated from
the extents as determined from within the active drawing.
If Auto is unchecked, the Upper Z and Lower Z values can be explicitly specified.
If Clip to Depth is checked, the tool path is clipped at the point at which the tool is in contact with
the part.
If Clip to Depth is unchecked, the tool path continues to the extents of the part at the set Lower Z
value.
Cutting Order –
These options allow you to specify how the cutting order will be created.
The By Zone option will force the cycle to machine the profiles in regions. All levels, within a region,
will be machined before the cycle moves to the next region.
The By Level option will force the cycle to machine profile based on the height. All areas that exist
on the same level will be machined before the cycle moves to the next level.
Advanced Dialogue Descriptions

Contact Angle Limits –
This is the angle between the normal to the surface (at the point of contact) and the tool axis. You
can specify angles between 0 and 90, except for Minimum Contact Angle which can only be up to
85. The defaults are 0 (min) and 90 (max).
Only the regions where the contact angle is within the Minimum and Maximum values are machined
and these values cannot be the same.
If these settings break the tool path into separate regions, the normal rules for leads, links and
ordering are applied to each region and the move between the regions.
To avoid the tool path fragmenting into small sections, additional Z level passes may be included
outside the contact angle range. (see parallel cuts)
Finish Shallow Areas –
This option allows extra passes to be inserted to correct for the Z level passes being too far apart to
give a uniform finish (due to the surface being near-horizontal).
None –
Take no special measures to finish shallow areas.
Constant Cusp –
The extra passes are created by projecting the Z level passes, with an offset calculated to give a
constant cusp height. The extra passes are stopped if and when they meet a Z level pass.
Projected –
The extra passes are created by projecting the Z level passes across the surface with a constant XY
offset (as you’d see looking from the top), which is defined by the XY Step-over value. The extra
passes are stopped if and when they meet a Z level pass.
Note that for the extra passes, the 3D tool path spacing (as you’d see looking at right angles onto
the surface) gets smaller as the surface gets flatter. This is the opposite of the Z-level areas, where
the 3D spacing gets larger as the surface gets flatter.
Lace –
This will insert extra passes using a Parallel Lace strategy. This is generally used on flat faces of
prismatic type parts.
XY Step-over –
This value is used for each of the strategies above, specifying the distance between each tool pass
as a percentage of the tool diameter.
Clip to Depth –
If checked, the tool path in the shallow regions will be clipped at the Depth value. If unchecked, the
cycle behaves as if the shallow region surface extended into a flat region at the Depth height.
Mill Type –
See Mill Type options in the General tab settings.
Corners –
This option controls how external corners are handled. External sharp corners can be controlled by
replacing them with loops or arcs to improve part quality, beneficial in the area of high speed
machining.
Parallel
The Parallel 3D machining strategy is an excellent general purpose method for semi roughing or
finishing. This option is the finish machining option available in Standard.
The tool paths are be generated in straight lines in any direction over any amount of surfaces/faces.
Any amount of boundaries can be used to limit the machined areas. These will be treated as Hard or
Soft Boundaries and the tool will be kept inside or outside or allowed to move until the tool centre
line is on the boundary.
You can allow stock in X & Y or just in Z when semi finishing.
The step over between cuts is controlled either by Width of Cut or Cusp Height.
The cuts can be climb, conventional or optimised (Bi-Directional).
The upper and lower Z Levels can be configured to contain the machining within the reach of the
tool. When the lower level is specified the tool path will runoff at this level. If the clip to depth option
is activated no runoff is generated and the tool path is clipped to this Z level.
The cutting type can be specified
The cutting direction is specified where 0 or 180 cut in the X axis and 90 or 270 cut in the Y axis
though any angle can be specified.
Advanced Tab
The Advanced tab is only available in Advanced and Ultimate module levels.
Exclude Flat Areas when checked will NOT machine the flat areas with the parallel strategy.
Ignore External edges with clip the tool path to the edges of the surface/faces.
Any additional tool paths that are generated because of the controlling criteria that are not required
can be deleted.
Perpendicular Lace
The perpendicular lace will add additional tool paths that are perpendicular to the main tool path to
ensure an even surface finish on the different surfaces/faces.
There are two options for perpendicular lace, bounded and unbounded. If the bounded option is
selected the original tool paths are removed where the perpendicular paths are created (each area
is only machined once). If the unbounded option is used where perpendicular tool paths are created
these areas are cut in both directions.
Bounded Unbounded
The contact angle restricts the perpendicular cuts.
Up Down Mill
This restricts how the surface/faces are cut. The Down Mill options causes the tool to always cut in
a downward direction and the Up Mill option cause the tool to always cut in and upward direction.
Down Mill Up Mill
Projected Contours
This method requires one or more boundaries to control how the tool paths are calculated. The
ghost tool sets whether it is to be used as Hard or Soft Boundary.
The method constantly offsets the closed boundaries to create projected paths onto any amount of
surfaces. The step over is controlled by Width of Cut or Cusp Height.
Cut in a clockwise or anti-clockwise direction. Cut from inside to outside, or outside to inside. Two
variations of path can be achieved. One method offsets the outer boundary inwards and trim it to
the inner boundary. The other offsets the inner boundary outwards and trim it to the outer boundary.
As this style of 3D machining uses boundaries to contain the toolpaths, it can also be used for
engraving parts should a suitable text font be selected, i.e. not a single line font.
Radial
This method requires one single closed boundary. The ghost tool sets whether it is used as a Hard
or Soft Boundary. The user selects the centre of the radius from which all the radial cuts
theoretically pass as the centre points does not have to lie inside the boundary. The width of cut is
controlled by degree of angle between radial lines. The start and end angles are configurable to
further control the area to be cut. Cut from the inside out or outside to inside. Remember that the
cut width gets wider as the tool gets further from the centre of the radius thus limiting the areas for
which this strategy might be suitable.
A more practical use for the Radial strategy is when clearing areas within pockets that have blend
radii between the walls and the floor, commonly found in aerospace parts where the radii blend
adds strength to the transition between the vertical and horizontal faces.
Spiral
You can machine several faces of a 3D model.
You do not use a boundary but are asked to specify an inner radius and an outer radius for the
spiral, whether the machining is to be from the inside to the outside or vice versa, and whether the
spiral is to be clockwise or counter-clockwise. The spiral tool paths are projected onto the surfaces
and ‘trimmed’ to keep the tool contact point to be at the edge of the outer surfaces. Note that this
means that a ball end or bull nose tool will drop off the edge of a surface if the outer radius is
outside the surface edge.
Rest Machining
Pencil trace runs the cutter along corner radius’s that are that same or smaller than the tool.
Rest machining creates multiple cuts along corner radius’s that are that same or larger than the tool
where the previous tool has left material on.
The previous tool can be automatically selected or any other tool can be selected as the previous
tool to force the rest machining tool paths to be created.
Drive Curves
This method is a superior version of 3D Project. Drive curves can be either Geometry or Tool paths
the type of drive curve is set in the surface/solid machining Dialogue box. The geometry/polyline or
tool path can be in any work plane and any orientation to generate a drive curve over any number of
surfaces/faces. The tool will track along the drive curve being projected onto the surfaces.
Using Geometries
The drive curves have been created using the Waves add-in macro.
Waves add-in used to create the initial

geometries for use as the Drive Curves
Geometries selected and toolpaths projected to

the actual model.
Resulting final part.
Using Toolpaths
In certain manufacturing circumstances it may prove more effective to generate the desired tool
path using conventional 2D cycles and the projecting those to the solid model.
In this example a conventional 2D pocket cycle is used as the Drive Curve, created on the Flat Land
and selected for projection.
Using this type of Drive Curve, there is no requirement to add any Z depths to the cycle as they will
be wrapped to the model for completion.
Flat Area
This method is ideal for the machining of flat surfaces with flat or bull nose tools. Alphacam will
automatically identify the flat areas and their boundaries are automatically created and the area
pocketed by the tool.
You can set the cutting parameters in the third Dialogue as shown below.
When the distance between isolated areas at the same Z level, are less than the value set in
Connect Aircut Length, the tool path will be kept at the cutting height and feed rate across the gap,
thus reducing short rapid motions.
The Rest Finish option allows residual machining of flat areas multiple tools reducing in size
Helical Z
Helical Z tool paths are always closed tool paths and cannot be created as open tool paths. The
tool paths are produced either going all the way around the inside or the outside of the shape. It
cannot be used to cut along a shape.
Helical tool paths can either cut from top to bottom or bottom to top. The width of cut will equal the
helical pitch which can be limited between an upper Z level and lower Z levels.
It can also be to set either Climb or conventional cutting and undercut if the tool will allow.
It is critically important to set the option Cut Inner Surfaces when an internal detail is required.
Cylindrically Parallel
This allows cylindrical parts to be cut with a ball ended tool using a 4 axis cutting method. The
amount of the cylinder to be cut is controlled by the starting and finishing angles.
The max and min values refer to the X axis limits.
The Tool Offset from Centre Line option

This option helps prevent the tool from always cutting on its centre.
Example with this value set to 0 Example with this value set to 2…
Cylindrical Profiling
The same style of machining as described in the Parallel option but the tool path is created around
the part in a similar method to a turned part.
Constant Cusp
This cycle produces a toolpath that can be defined from a drive curve, boundary or both.
When using boundaries, this cycle will collapse from the selected boundary or outer edge of the
selected solids. This generates an even surface finish over the entire model.
When using drive curves, the toolpath offsets on both sides. The toolpath will expand in/out from
the curve for the specified number of passes or until it comes into contact with the boundary or the
edge of the selected solids.
This machining strategy has two tabs, General and Advanced
General
Cusp Height – The height of the uncut material between each pass
Mill Type – The Optimized option results in an optimized, bidirectional tool path. The Conventional
and Climb options can be used if consistent (single) direction cuts are desired.
Number of Offset Passes – When using drive curves, this specifies the maximum number of
offsets to expand out on either side of the drive curve. If 0 is specified, offsets will be created until
they come into contact with the boundary or the edge of the selected surfaces/solids.
Connect Aircut Length – The maximum distance allowed for rapid moves between cuts within the
cycle. Rapids moves with lengths less than this distance will be converted to feed moves, keeping
the tool at the cut depth.
Start Cutting at Inside – If checked, the cycle will start with the innermost toolpath first.
Cut Between Z Levels – With the Auto option checked, the Upper Z and Lower Z values are
automatically populated from the extents as determined from within the active drawing. If Auto is
unchecked, the Upper Z and Lower Z values can be explicitly specified. If Clip to Depth is checked,
the tool path is clipped at the point at which the tool is in contact with the part. If Clip to Depth is
unchecked, the tool path continues to the extents of the part at the set Lower Z value.
Advanced
Contact Angle Limits – This is the angle between the normal to the surface (at the point of contact)
and the tool axis. You can specify angles between 0 and 90, except for Minimum Contact Angle
which can only be up to 85. The defaults are 0 (min) and 90 (max).
Only the regions where the contact angle is within the Minimum and Maximum values are machined
and these values cannot be the same.
If these settings break the tool path into separate regions, the normal rules for leads, links and
ordering are applied to each region and the move between the regions.
To avoid the tool path fragmenting into small sections, additional Z level passes may be included
outside the contact angle range.
Comparison of tool paths for the same cusp height.
Projected contours Constant cusp
This method creates paths that are at constant Z Levels. The distance between the levels is
controlled by either Width of Cut or Cusp Height. The Upper Z Level and Lower Z Level can also be
set to limit the machining to within the reach of the tool. You can machine any amount of surfaces.
There are options to machine all of the selected surfaces or contain the machining within
boundaries which can be any shape. These will be treated as Hard or Soft Boundaries and the tool
will be kept inside or outside or allowed to move until the tool centre line is on the boundary.
There is an option to allow the tool to undercut. Unlike the new Horizontal Z Contours this tool path
algorithm does not consider the shank or body of the tool but treats the tool as being a spherical
ball.
This then generates tool paths that are more easily converted using the tool Axis conversion
options.
Tool paths generated with Horizontal Z
Tool Paths Generated with Z (Enhanced Undercuts)
3D Finish Machining tutorial example.
4
5
7
3
6
7
7
2
2
Finish Machining Outline

1. Z Contour Rough
a. Create Material with 3mm XY Stock and 2 mm on top Z
b. Z Contour Rough to 20mm from bottom face.
2. Parallel
a. Draw rectangle boundaries snapping to model edges
b. Extract Surfaces from Faces 2
c. Un-trim the surfaces
d. Extend the Surfaces
e. Offset the geometries to be able to machine past the solid edges.
3. Constant Cusp, Projected Contours, Helical Z, Horizontal Z
a. Extract the geometry from the Top edge of the pocket to use as the boundary.
4. Projected Contours or Constant Cusp
a. Extract the edge around area 4.
b. Offset the curved section bigger, by 0.5 less than tool radius
to allow the tool to get down the side
5. Horizontal Z
a. Project Face outlines to Work plane and edit the geometry to give boundary for the
horizontal Z, Offset the curved section bigger, by 0.5 bigger than tool radius.
6. Flat Area
7. Pencil Trace
 Note that these are suggestions on the many differing methods that are
available in Solid Machining. Use the information you have gained to apply various
different tool paths to the sample part.
Model Examples
Bracket
Curved Block
Curved Recess
Helical Z
Male Form 1
Mould Insert
Mould 1
Mould 2
Mould 3
Mould 4
Panel + Shape
Part Machined with lollipop cutter
Pipe
Pocketed Plate
Tool Axis Conversion

Further control of 2D and 3D tool paths can be achieved with tool axis conversion.
Tool axis conversion works differently between the advanced and ultimate modules.
Tool axis conversion is only possible on tool paths using Ball cutters.
Tool Paths created by Alphacam are already either 2 or 3 Axis so you may wonder why we want 2
and 3 Axis Conversion. Sometimes it is easier to get the type of cutting strategy required by
creating the Paths in an angled work Plane.
Tool Axis conversion to 4 or 5 axis is only available in Alphacam ultimate
The actions available will depend upon the type to which you are converting.
 It is useful to mention at this point the checkbox “Tool can Under-cut” on the Dialogue in
the Z Level type strategies, if a lollipop tool is selected then this will be on by default,
however If the tool is normal it will be off by default, but the user can activate it, and this
will let the tool undercut in preparation for the conversion.
Tool Axis conversion is better applied to specific tool path operations via the
project manager local popup menu command.
Convert 3D work plane tool path to Vertical

In this example the Spiral Path in an Angled Plane is converted to 3axis vertical which would yield a
very good surface coverage.
When the 3 Axis Type is selected, all the Action Selections are greyed out. The selected tool path
should be converted into Flat Land or if a work plane is active, the user is prompted to confirm the
transformation to the current plane.
Convert 2 Axis tool path in work plane to Vertical

In this Example there are 2 operations each multi cut at a single depth, the depth being increased
for the second cut. The first two diagrams show the 2D tool paths in the work plane. The first solid
diagram shows the tool orientation as created. The second solid diagram shows the tool path after
conversion. The simulation shows the ball ended cutter however this could be changed to a flat
ended end cutting cutter on the machine.
4 Axis XZ or YZ Rotation
Through Axis
With this option the user will be asked to select a point on the Axis. The conversion will then make
the tool paths Rotate about the selected axis.
Parallel tool paths
Before Conversion
After Conversion through axis at centre of circle.
Helical Z tool paths in work plane

Used with Z (enhanced undercuts)
Before Conversion
After Conversion through axis at centre of circle on end.
5 Axis
XZ Rotation Confine with Boundary
This will work with the same principles as the 5 axis option with the limitation of the Axis control
dependent upon the Axis configuration selected. YZ or XZ
Before Conversion machining with lollipop tool Horizontal Z using lower boundary and selected
faces, setting the option for tool can undercut.
After Conversion tool confined to upper boundary, this will allow tool paths to be created with a
lollipop tool but a straight ball tool can be used on the machine.
Normal to Curve or Curves

Only one guide curve can be selected and this must be perpendicular to the XZ or YZ axis
dependent upon the selection.
Before Conversion machining tool paths created using projected contours.
After Conversion using guide curve on plane causes tool to cut on the side of the ball for better
machining.
XY Rotation Tool at Fixed Tilt Angle

Through Point
With this option the user will be asked to select an XY point in the flat Plane. The conversion will
then be made similar to the 5 Axis option, but the tool will stay at the fixed tilt angle and the XY
Vector around the Z axis will point towards the selected point
Before Conversion Projected Contours
After Conversion to a tilt angle of 45° and the point selected at centre or recess
Project through Point

The tool axis vector will be transformed so that the tool axis will always pass through or point
towards a user defined point. There is a prompt asking the user if the picked point is on the tool
side of the part. If the point is on the tool side of the part, then the tool axis will pass through that
point. If the point is not on the tool side of the part, then the tool will point towards the user defined
point, but not pass through it.
Before Conversion Projected contours as 4 Axis XY Rotation Tool at Fixed Tilt Angle previous
After Conversion with point at centre of dish and at Z 100 on tool side.
After Conversion with point at centre of dish and at Z -200 not on tool side.
Project through Axis

With this transformation the tool axis will always be normal to the selected Line Axis. The user will
be prompted to select Line of Axis of Revolution.
 Using the points that describe this axis and the point at the centre of the ball tool
we will calculate the vector perpendicular to the axis in the plane created by the
three points.
Before Conversion Parallel cuts
After Conversion tool adjusted to point at polyline axis.
Confine with Boundary

This method requires the user to select a boundary. The boundary must be a closed geometry and
the tool direction Inside\Outside will determine as to whether the tool axis remains inside or outside
the boundary. When the tool exceeds the boundary it can no longer remain vertical so the tool axis
needs to be tilted keeping the tool normal to the boundary.
Before Conversion tool path cut using horizontal Z contours allowing the tool to undercut and cut
from bottom to top.
After 5 axis conversion with boundary.
Project through Guide Curves

The tool axis control can be set with either one or two curves. If there is only one curve selected,
then the plane that the geometry is within controls the angle of the tool axis, which is then rotated
within that plane to be normal to the profile at the nearest point. If there are two guide curves, then
they must be in planes that are perpendicular to each other.
Before Conversion
After Conversion
Cut Spline or Polyline

This command will drive any tool along any spline or polyline. If a spline is being machined, the
chord Tolerance is asked for, which determines the accuracy with which the straight line XYZ tool
moves match curves in the spline. For a polyline, the tool is simply moved along the straight line
segments.
In Standard, and Advanced modules, the tool is assumed to be vertical, with the tool tip centrally on
the spline or polyline, and you are not given any options about tool angle.
If the module is Ultimate and you have selected a 4 or 5 axis post processor, you are able to set the
tool to be left, centre or right of the spline or polyline. The check box Show Ghost Tools will
immediately show the direction of the spline or polyline so that you can determine which side is left
and which is right.
You can set the Tool Angle to be Normal to nearest Surface/Solid, Parallel to nearest Surface/Solid
or at angles relative to the line or as absolute angles. For angles relative to the line, the angle is
measured from the vertical, and the sign is set by looking along the direction of the spline or
polyline. That is, looking at the ‘back of the tool as it moves away from you along the line. If the tool
is leaning to the left, the angle is counter-clockwise and is therefore positive. If the tool is leaning to
the right, the angle is clockwise and the sign is negative.
 If the selected post processor has been configured to take account of the ability of
the controller to apply Tool Radius Compensation (G41/42) (this is indicated in the
post by setting $148 to 1 and the tool has been set to be right or left of the spline
or polyline, then a check box – Machine Compensation – is enabled. Select this to
produce the necessary code Please note that the post has to have the correct
code in $40. Post variable TCF = 1 if G41/42 is selected when Alphacam is used,
TCX, TCY, TCZ gives the tool displacement unit vector, that is the direction from
the contact point to the tool tip. CPX, CPY, CPZ gives the contact point on the
polyline.
4 Axis Cut With side of tool
The angle can be cut using either:

“ cut spline/polyline” parallel to model faces
or
“Cut between 2 geometries”
Version amendments
Software Amended
V Amendment Description A Version Date
1 Update to new functions and new course delivery 1 2012R2 19/07/2012
1 Add additional notes relating to cusp height 2 2012R2 27/07/2012
1 Update to 2013 R1 addition more Z contour Rough example and use test part as tutorial 4 2013R1
example, addition of model pictures.
2 Update to add 3D Z contour roughing notes and new finish machining tutored example 0 2013 R2 11/03/13
3 Update to new format update 3D Z contour Roughing add new Drive Curves example 0 2013 R2 05/07/2013
4 Updated to 2014 R1. Reference to Background Processing added. 0 2014 R1 01/12/2013
5 Updated to 2014 R2. Added updated images and extra references to sections 0 2014R2 30/04/2014

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Chord Tolerance along Cut 24

Conventions used in this guide

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

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

 This is a highlighted note to emphasise information

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

 This is a tip. It is generally used in exercises and offers further advice.

1 This is the first line a number list item

• The order is not important.

Recommended Operating Systems and Hardware for Alphacam

• nVidia or ATI Open GL Graphics Card with 512Mb dedicated memory

Windows NT, 95,98,ME and XP are not supported operating systems

Front End Dialogue (Advanced)

Front End Dialogue (Ultimate)

Z Contour Roughing Dialogue 1

 The Waveform roughing strategy is a high speed machining technique that

Close Open Pockets (contour option)

Smoothing Radius (waveform option)

• Conventional Tool cuts on right of the profile

• Optimised Cycle is optimised to reduce link moves.

• Always Ramp There is a retract for the link (rapid) move.

• Optimised The faster of the two methods above is automatically selected

High Speed Cornering

Take Account Previous Machining

Use Geometry Boundaries Instead of Material

• Select Allows the use of materials from previous operations to be

• Use Allows for the addition of extra controlling 2D geometric

Z Contour Roughing Dialogue 2

Material Top and Bottom

• Automatic The cycle automatically applies an appropriate ramp method.

Z Contour Roughing Dialogue 3

Trochoidal for Full-Width Moves

Adaptive Feed Rates

 The adjustment is only made to XY feeds; it is not applied to any Z feeds.

Z contour Roughing Tutorial Example

3D Finish Machining Strategies

It is not uncommon to have to use several different machining strategies on one

Multi-Processing of 3D Machining Operations

Finish Machining Strategy Options

3D Solid Machining Accuracy

Tool Width Width Width Width Width

Tool Width Width Width Width Width

Chord Tolerance along Cut

Round Straight Loop High Speed

Parameter Line Machining (surfaces only)

The selection criteria are:

Advanced Dialogue Descriptions

The contact angle restricts the perpendicular cuts.

Down Mill Up Mill

Waves add-in used to create the initial

Geometries selected and toolpaths projected to

Resulting final part.

The Tool Offset from Centre Line option

Tool Paths Generated with Z (Enhanced Undercuts)

3D Finish Machining tutorial example.

Finish Machining Outline

Part Machined with lollipop cutter

Tool Axis Conversion

Convert 3D work plane tool path to Vertical

Convert 2 Axis tool path in work plane to Vertical