RhinoCAM GettingStartedGuide

RhinoCAM - Getting Started Guide
1997-2012, MecSoft Corporation 1

MecSoft Corporation
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 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 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 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 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 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 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 Rhinoceross 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 support@mecsoft.com
MecSoft offers Online training as well as personalized full day training sessions. Please look
up our website or email us at sales@mecsoft.com for further details
Please do continue to visit our home page to learn about the latest updates to RhinoCAM
and any other help material.


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.
Dont 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- axis machining operation called Profiling.
The part will be machined out of a 10 x 6 x inch poplar wood sheet using a 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 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 Axis Profiling operation.
2 Axis Profiling

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

This brings up the 2 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 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 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 2 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 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 Axis Profile for the Outer Region

1. Switch to Program tab
2. Select the 2 Axis Profiling operation under Setup 1,
3. Right mouse button click and left click on Copy.

4. Right mouse button click on 2 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 Profiling toolpath is now regenerated with the changes.


13. Switch to Simulate tab, select the 2
nd
2 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 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 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 inch poplar wood sheet.
The part will be machined using a single 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
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.

properties.
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 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 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 2 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 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 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 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 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 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 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 Axis Facing to machine around the boss and 2 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 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.
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
Create/Edit Tools.






parameters.

properties.


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

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

This brings up the 2 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 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. 2 Axis Facing toolpath is now generated, and the operation is


Simulate toolpath
17. Switch to Simulate tab, Select 2 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 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 2
nd
Facing operation under Setup.

4. Double click on the 2 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 Axis Facing operation under Setup
and click Play to run the simulation.




2 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 Rhinoceross 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. 2 Axis Pocketing toolpath is now
generated and is listed under the 2 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 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 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 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 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 2
nd
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 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- 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 axis machining operation.
The part itself will be machined out of a 10.75 inch x 4 inch x 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.



parameters.

properties.
In this process, we will create 2 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 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 1/8
th
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,



parameters.

properties.


In this process, we will create 2 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.
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 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 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,


parameters.

properties.

Create Machining Operation
In this process, we will create 2 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 Axis
Facing operation programmed.


Chamfering
1. Select 2 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 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 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 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- 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
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.

properties.
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 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 2 Axis Profile toolpath is now generated and the operation is listed under the
Simulate toolpath
13. Switch to Simulate tab, select the 2 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. Dont 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
parameters.
Created tools are now listed under Tools tab in Machining Objects browser.

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:


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.




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. Dont 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. 4
th
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



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, 4
th

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


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. 4
th
axis Parallel Finishing toolpath is now generated and listed under
Setup 3 in RhinoCAM MOps browser.


Simulate toolpath

7. Switch to Simulate tab, select 4
th
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.
7. 4
th







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.



parameters.

properties.
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 4
th
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 4
th
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.
7. 4
th







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.

properties.


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:


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
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!

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