Get Started with

ESPRIT

Get Started with ESPRIT
Copyright © 2011 DP Technology Corp. All rights reserved.
Information is subject to change without notice.
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means, graphic, electronic, or mechanical, including photocopying, recording, taping, or by any
information storage or retrieval system, without written permission from DP Technology Corp.
The software described in this document may only be used or copied in accordance with the
terms of the furnished license agreement and/or non-disclosure agreement. It is illegal to copy the
software onto any medium except as specified in the license or non-disclosure agreement.
All DP Technology Corporation software products contain integrated security programs and/or
plug-in modules that are required for the software license to properly operate. It is a violation of
the DP Technology Corporation copyrights and U.S. Copyright law to disable or attempt to disable
or remove or otherwise operate the software without the security programs and/or modules
installed. Any software not supplied by DP Technology Corporation which is intended to allow the
operation of the software without the required plug-in security module and/or integrated security
programs is a copyright violation.
ESPRIT is a registered trademark of DP Technology Corp.
All brand or product names or proprietary file types mentioned in this document are trademarks
or registered trademarks of their respective holders. Contact the appropriate companies for more
information regarding trademarks and registration.
DP Technology Corp.
1150 Avenida Acaso
Camarillo, California 93012
USA
Tel: +1 805 388 6000
Fax: +1 805 388 3085
www.dptechnology.com
Printed in the United States of America

Contents
Welcome to ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installing ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ESPRIT Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ESPRIT Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
The ESPRIT Graphical User Interface (GUI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Opening and Storing Files in ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Selecting Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Controlling the Display of Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Working with Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Geometry commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Work Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Draw 2D Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Working with Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Types of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Creating and editing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Feature Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Work Planes assigned to features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Import a CAD drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Position the part for machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Draw dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Create 3D features from a 2D drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Milling on a Standard Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SolidMill Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SolidMill Traditional Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Create a milling tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Create milling features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Simulate milling operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Perform the cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Contour the die openings . . . . . . . . . . . . . . . . 141 Groove the ID . . . . . . . . . . . 150 SolidWire Gold Machining Cycles . 137 Rough and finish the groove on the OD . . . . . . . . . . . . . . . . . . . . . . . . . 103 Turning on a Standard Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Burning on a 2-axis Wire EDM . . . . . . 171 Sort EDM operations . . . . . . . . . . . . . . . . . . 85 Cut the pockets and slot . . . . . . . . . . . . . . . . . . . . . .Create a stock model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Create lathe stock . . . . . . . . . . . . . . . . . 176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Mill and drill the holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Simulate turning operations . . . . 108 SolidTurn Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Create a stock model . 161 Create EDM features . . . . . . . . . . . . . . . . . . . . . . . . 140 Rough and finish the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Contour the group of holes . . . . . . . . . . . . . 107 SolidTurn Machining Technology . . . . . . . . . . . . . . . . . . 160 Set the EDM Machine Type . . . . . . . . . . . . 142 Thread the ID . . . . . . . . . . . . . . . . . . 118 Create turning features . . . . . . . . . . . . . . . . . . . . . 117 Create a turning tool . . . . . . . . . . . . . . 138 Contour the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Simulate wire EDM operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . 83 Remove excess material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 SolidWire Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Drill on the center line . . . 131 Rough the face and the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. and solid simulation and verification with dry runs rendered in dynamic solids for optimal part quality and consistency. and Swiss-style machine tools. multitasking mill-turn machining.Welcome to ESPRIT ESPRIT has all the power you need to machine any part. Welcome to ESPRIT   |  1 . ESPRIT’s multitasking component provides powerful capabilities for driving mill-turn machines. factory-certified post processors for all the leading multitasking machine tools. ESPRIT is a high-performance computer-aided manufacturing (CAM) system for a full range of machine tool applications.. surface. or wireframe). universal post processing to format G-code for virtually any machine tool. and dynamic solid simulations for dry run verification of the machining processes. ESPRIT’s high-performance capabilities include machining any part geometry (solid. ESPRIT provides synchronization of simultaneous cutting cycles using any combination of turrets and spindles for milling or turning. Get Started with ESPRIT teaches you the basics of how to machine your parts with ESPRIT. 2-22 axis turning. ESPRIT delivers powerful full-spectrum programming for 2-5 axis milling. multi-axis lathes. 2-5 axis wire EDM. and B-axis machine tools.

Installing ESPRIT
Please set your computer’s date correctly before installing ESPRIT and do not change the date
thereafter.
Important: An incorrect date can damage the security module and render ESPRIT inoperative. Your
ESPRIT software will not work again until a replacement security module and new password can be
shipped to you.
1. Download and install the latest Windows® service packs.
2. Disable any anti-virus software.
3. Plug your ESPRIT locking device, normally a hardware key (security dongle) provided by DP
Technology, into the appropriate USB or parallel port on your computer. If you have a parallel
port security dongle, plug it into the primary parallel port (LPT1) at the back of your computer.
Do not plug it into a serial port.

Hardware Key
Take special care to protect your security dongle from loss or damage. It is an integral component
of the software and your license.
The only device you may attach to the back of a parallel security dongle is a parallel printer.
Important: If you have a parallel security dongle, do not plug any tape backup systems, portable
CD-ROMs, DVD players or recorders, multi-function office systems (all-in-one printer/fax/scanner/
copier devices) into it. These will damage your hardware key.
If your security dongle becomes damaged, your ESPRIT software will not work until a replacement
security dongle and new password can be shipped to you at your expense. Security dongle
replacement is not covered by Software Maintenance Contracts.
Lost or stolen security dongles are your responsibility. Please check with your insurance carrier to
be sure your business insurance has them covered for the full value of your ESPRIT software.

Install ESPRIT from the DVD
1. Open the file "ESPRIT_ReadThisFirst.pdf" on the DVD.
2. Follow the instructions to perform a new installation of ESPRIT or to upgrade from a previous
version of ESPRIT.

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

2  |  Get Started with ESPRIT

ESPRIT Support
The DP Technology web site provides a wide variety of information about the company and its
products.
You can access the web site at: http://www.dptechnology.com
For support issues, please send an e-mail to: support@dptechnology.com

Phone Suppor t
Contact your reseller first. Resellers of ESPRIT give specialized information related to the custom
solution they provided to you. This is the best place to start.
If you do not have a reseller, contact the nearest DP Technology office.
Cor porat e O f f ic es

1150 Avenida Acaso
Camarillo, CA 93012
USA
Tel: +1 805 388 6000
Fax: +1 805 388 3085
dptechnology.com
Midwest USA

10275 West Higgins Road
Suite 420
Rosemont, IL 60018
USA
Tel: +1 847 297 8100
Fax: +1 847 297 8107
dptechnology.com
Ea st er n USA

3005 Senna Drive
Matthews, NC 28105
USA
Tel: +1 704 814 0445
Fax: +1 704 814 0446
dptechnology.com
DP Japan

Yokohama Sky Building 20F
2-19-12 Takashima, Nishi-ku
Yokohama 220-0011
Japan
Tel: +81 45 440 6670
Fax: +81 45 440 6001
dptechnology.jp

DP China

Sun Building
3553 North Zhong Shan Road, #1714-1715
Putuo District
Shanghai 200062
China PRC
Tel: +86 21 3133 5575
Fax: +86 21 5868 2803
dptechnology.cn
DP Europ e

"Le Thèbes"
68 Allée de Mycénes
34000 Montpellier
France
Tel: +33 4 67 64 99 40
Fax: +33 4 67 64 99 41
dptechnology.fr
DP G er many

Kirschäckerstr. 23
D-96052 Bamberg
Germany
Tel: +49 (951) 299 526-0
Fax: +49 (951) 299 526-29
dptechnology.de
DP I t aly

Via Iacopo Nardi 2
50132 Florence
Italy
Tel: +39 055 2342286
Fax: +39 055 2347858
dptechnology.it
Welcome to ESPRIT   |  3

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

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

4  |  Get Started with ESPRIT

.... you should familiarize yourself with how to work with part files in ESPRIT..ESPRIT Fundamentals Before you begin the lessons in this guide...... Deselecting Elements......1 9 Masks............... ................. the ESPRIT interface and its menus and toolbars should look familiar to you............... 13 The Group Command......... 7 Default Toolbars............................ and Rotate the View. elements using various selection modes such as HI......................... 17 Controlling the Display of Elements................... 9 Opening and Storing Files in ESPRIT......................... .. 21 ESPRIT Fundamentals   |  5 .................. and layers XX Before beginning to use ESPRIT... 12 Selecting Elements............... you should have a working knowledge of your computer............. Zoom.............................. ..... ............................................................. . and SUB-ELEMENTS • How to control the display of elements with views.... To review these techniques............................................................. SNAP.... 17 Selecting Items in the Project Manager...... 12 Saving a File.......................................................... As a native Windows-based application........................................ 9 Displaying the XYZ Axis and the UVW Axis.... .... refer to the documentation for Microsoft® Windows®............ This chapter introduces the ESPRIT work environment and explains how to work with ESPRIT part files.................................. 13 Selection Modes............ .. 14 You will learn: • How to use ESPRIT menus and toolbars • How to open and store ESPRIT files • How to select.................... the Microsoft® Windows® operating system and its conventions.......... 8 Other Toolbars...... .... ............... 8 The Smart Toolbar...... ..................... You should know how to use a mouse and standard menus and commands........................................................ 13 Selecting Elements in the Work Area........1 8 Views..................... 11 Creating a New File... ........18 Pan..................... ..... 6 Menus.. 21 Layers..............................18 Shaded and Wireframe Displays................ 11 Opening an Existing File.. masks................... or group.................... The ESPRIT Graphical User Interface (GUI)....... ......................

The Prompt area. Always pay attention to what the prompt is telling you. the information is constantly updated. This is the largest area of the screen. To view the Project Manager. at the bottom of the ESPRIT screen. 2. and every operation in the current session. every cutting tool. displays prompts that tell you what to do next. press the F2 key or click Project Manager on the View menu.The ESPRIT Graphical User Interface (GUI) Let’s start by taking a look at the ESPRIT screen. 1 2 3 4 ESPRIT also provides two specialized windows that provide additional information about the parts you are working on and provide an excellent way to manage your work. Menus and default toolbars along the top of the screen. The ESPRIT window contains: 1. 3. The Status area. You can select commands from the menus or from toolbars. 4. 5. A graphic work area where you can view your work. The Project Manager consists of a tabbed set of windows that list every feature. sort. at the bottom left of the screen. As you select commands or move the cursor. The Project Manager lets you manage. provides dynamic information about the current work environment. This window is displayed when you create a new file or open an existing one. and reorder these items. 6  |  Get Started with ESPRIT .

create and simulate machining operations. move the origin point or change the orientation of an imported model. and personalize ESPRIT. To view the Property Browser.6. • Machining: Set up the machine definition. surfaces. ESPRIT Fundamentals   |  7 . 5 6 Menus Commands are located on eight menus. • Tools: Set the system unit. • Window: Create new windows and arrange the display of multiple windows. • View: Set the display of the work environment. create cutting tools. • Edit: Copy or delete items. You can view and change individual properties for the selected item. Save files that have changed. load add-in programs. • File: Open an existing file or create a new one. surfaces. click Properties on the View menu or hold down the Alt key as you press Enter. or solids. create features. • Help: Access the online help files or learn about your current version of ESPRIT. Most of the menu commands are also available on the toolbars. • Create: Draw new geometry and dimensions. The Property Browser displays the specific properties of any item selected in the graphic work area or the Project Manager. • Analysis: Analyze solid models. create macros. The types of properties displayed depend on the type of item selected. and tool path.

layers.Default Toolbars The default toolbars are located near the top of the ESPRIT screen. and print files. If you click “Switch to SolidMill”. the milling commands are hidden and new commands display that let you create turning and mill/turn operations and tools. The Layers and Planes toolbar has commands for creating and selecting work planes. save. the geometry toolbars are hidden and milling tool commands are displayed. 1. just click the Geometry icon to activate the Geometry group of toolbars. 1 2 3 4 The Smar t Toolbar Use the Smart toolbar to quickly display and hide ESPRIT toolbars based on the type of work you want to do. 8  |  Get Started with ESPRIT . 2. 4. If you click “Switch to SolidTurn”. The Standard toolbar has file management commands that let you create. If you want to create geometry. If you click Milling Tools. and view planes. the toolbar is updated to display commands that let you create milling tools and operations. open. The first three icons on the toolbar relate to the machining modes in ESPRIT: milling. 3. This is also where you can find the Copy command when you want to copy elements in the work area. such as zooming and rotating the view plus commands that let you choose whether to display parts in shaded or wire frame modes. and wire EDM. turning. All visible toolbars activated from the Smart toolbar will always be shown in the same position so you never have to hunt for a command. The View toolbar has several commands that let you control the display in the work area. The Edit toolbar gives you selection tools that let you filter the types of elements that can be selected or automatically select (group) multiple elements from the selection of a single element.

Displaying the X Y Z A xis and the UV W A xis You can display two types of axes in the work area: XYZ Axis: The global axis positioned at the global origin point UVW Axis: The local axis of the current work plane The display of the two axes is controlled on the View menu. ESPRIT Fundamentals   |  9 . select the machining type on the Machining menu. • Right-click on any visible toolbar and select the toolbar you want to display • To show toolbars for machining operations. To display other toolbars: • On the View menu. click “Smart Toolbar Add-In” in the index. you can display other toolbars. and then select the machining type again on the secondary menu. and then select a toolbar from the list. click Toolbars. Any toolbar that has a check mark next to the name is already displayed on the screen. right-click on the toolbar and select Hide To move a toolbar. place the cursor on the double line at the top or to the right of the toolbar and drag it to a new location. If you would like to customize the Smart toolbar.. it will automatically snap to the edge..Other Toolbars In addition to the Smart toolbar.. click Toolbars. Press F1 to display the help and then click “Customize” in the index. such as SolidMill Traditional.. Instructions that describe how to create your own toolbars or customize existing toolbars are available in ESPRIT Help. When you drag a toolbar near the edge of the screen. and select a toolbar that has a check mark next to the name • Right-click on a toolbar and select the toolbar you want to hide • To hide a machining toolbar. To hide a toolbar: • On the View menu.

The UVW axis shows the origin and orientation of the current work plane. You will learn more about work planes in the lesson “Working with Geometry”.The XYZ axis shows the position of the part model in relation to the global axis. 10  |  Get Started with ESPRIT .

you can create templates that make it easier and faster to work on similar types of jobs. select <Blank Document> and click OK. As you become more familiar with ESPRIT. The display of the template dialog is controlled by the “Display Template Dialog” option on the Input page of the Options dialog. Creating a New File Clicking the New command closes the current file so that you can begin work on a new file. repeated geometry. By default. The commands on the File menu or the icons on the Standard toolbar (located near the upper left of the ESPRIT screen) are used to manage part files.Opening and Storing Files in ESPRIT When you start a new session in ESPRIT or create a new file. machine setup configurations. The <Blank Document> option opens a new file that uses the ESPRIT defaults. ESPRIT will prompt you to save those changes before the file is closed. For more information about how to create and use template files. You can create templates that include regularly used tools. If changes have been made to the current file. As a new user. and KnowledgeBase settings. you are given the choice of starting with a blank file or basing your new work session on a predefined template. the template dialog displays. available on the Tools menu. A template file contains user-defined elements and settings for the way you machine parts at your company. please refer to the ESPRIT help. simulation settings. ESPRIT Fundamentals   |  11 .

stereolithography (STL) files. Saving a File After working in ESPRIT. select the “Save as type” pulldown and then select a file extension. The Save command stores the current file as a native ESPRIT file or as another type of CAD format. If you want to convert the file to a different file format.esp extension).Opening an Existing File Clicking the Open command lets you open native ESPRIT files (.esp” file extension. 12  |  Get Started with ESPRIT . Since ESPRIT is based on the Parasolids kernel. This makes it easier to browse for the file you want. you can use the “Files of type” pulldown to list only files with a specific extension. After you click Open. XX The list of available file formats is based on the licensed options. you’ll want to save your work so you can retrieve it later. if your license does not allow you to open CATIA files. If the file you’re looking for has an unlisted extension. it is adept at opening a variety of solid model files. ESPRIT files are saved with a “. For example. and translated files such as IGES and STEP. native 2D and 3D files from other CAD systems such as SolidWorks or Pro/E. select “All Files”. this option will not display in the “Files of Type” pulldown.

Selecting Elements One of the most important tasks in any CAD/CAM system is the ability to select a variety of elements in the part file. you must have the ability to select individual components of an element. and toolpath. • Use your mouse to select an individual element in the work area • To select more than one element. remember to set the Selection type back to All. In addition. you will only be able to select geometry elements in the work area. If Geometry is chosen. hold down the Ctrl key as you select elements or drag a selection box over a group of elements • To select a group of connected elements. Selecting Elements in the Work Area Elements in the work area can be selected individually. When you are finished. wireframe geometry. The Group command lets you select all elements using the following criteria: • Element type • Color • Layer • Work Plane ESPRIT Fundamentals   |  13 . such as edges on a solid model or the endpoint of a line. surfaces. hold down the Shift key as you select an element Use the Selection Filter to select elements by type. as a group or by type of element. The Group Command If you want to select all elements that fit specific selection criteria. you can use the Group command on the Edit menu. A single part file may include one or more solid models.

click OK to automatically select all elements that meet those criteria. Selection Modes Five selection modes are provided in the status area at the lower right of the screen: • HI (highlight) mode • SNAP mode • SUB-ELEMENTS mode • INT (intersection) mode • GRID mode When a mode is grayed out. or even on top of.After you identify the selection criteria. an edge on that model. that means the mode is disabled. you can use HI mode to select a solid model. or feature created from a solid model. ESPRIT always asks you to confirm element selections. This allows you to select from elements that are close to. HI Mod e When HI mode is enabled. each other. Click on a mode to enable or disable it. For example. 14  |  Get Started with ESPRIT .

you want to select the feature but a segment is highlighted instead. ESPRIT will highlight the next closest element. ESPRIT Fundamentals   |  15 . answer No by pressing the right mouse button. You would click the right mouse button until the feature highlights. If this is not the correct element. When the correct element is highlighted. ESPRIT will prompt “Is this the correct choice” and highlights an element near the selection point.When HI mode is enabled. In this example. answer Yes by pressing the left mouse button.

faces loops. you can select the faces. For example.SNA P Mod e When SNAP mode is enabled. the cursor recognizes the intersections of segments. and FreeForm features. or edges of a solid model. With INT set on.ELEM ENTS mod e When SUB-ELEMENTS mode is enabled. With SNAP enabled. Pockets. and circles as valid point selections. arcs. the cursor changes to: when you hover over the end of a segment or arc when you hover near the midpoint of a segment or arc when you hover over the center point of a circle or arc SUB . You can also select the sub-elements of features. the cursor changes immediately to and remains as the INT cursor until an intersection is chosen. 16  |  Get Started with ESPRIT . The cursor exits INT mode immediately after an intersection is chosen. The Grouping Properties command relies on the selection of sub-elements to automatically group faces for several types of features: Holes. Draft Feature Recognition. Turning Profiles. The selection of sub-elements is extremely useful for selecting the individual faces on a solid model that you want to machine. you can select the individual sub-elements of solid models or features in the work area. lines. the cursor recognizes the midpoints and endpoints of lines and segments and the center points of circles and arcs as valid point selections. I NT Mod e When INT mode is enabled.

Most of the time. ESPRIT Fundamentals   |  17 . angles. You may want to set the grid spacing to match your part drawing values. distances.GR I D Mod e ESPRIT uses the grid configuration settings from the Options dialog box (from the Tools menu. This lets you select from a defined invisible array of screen locations in response to prompts for points. When a feature or operation is selected within the Project Manager. the same item highlights in the work area. and so on. Selecting Items in the Project Manager Features and machining operations can be selected directly in the Project Manager. select Options and then the Input tab). Deselecting Elements To deselect all items simply click anywhere in a blank area of the work area. this is much easier than selecting these items in the work area.

Shaded and Wireframe Displays For solids and surfaces. Silhouettes are not supported. Hidden Wireframe: Displays visible solids. surfaces. the display in the work area rotates to the new view orientation and the display automatically zooms to fit all elements within the screen. The display of the wireframe is light source dependent. Shaded Wire: Creates a shaded image with wireframe. Has no effect on geometry elements. you can set the display to shaded or wireframe mode. 18  |  Get Started with ESPRIT . and geometry as wireframe depending on the orientation of the part. Views ESPRIT provides several standard view orientations. Shaded: Creates a shaded image. You can also shade the simulation of cutting operations. Elements that would normally be hidden by a shaded view are not displayed. When you change from one view plane to another. and geometry as wireframe. Wireframes will appear in different colors and/or disappear depending on the part orientation with respect to the light. You can control the rotation animation speed on the Workspace tab of the Options dialog (available on the Tools menu). Wireframe: Displays all solids. surfaces.Controlling the Display of Elements ESPRIT provides a variety of methods that let you control how your parts are displayed. only true edges.

zoom. and move the mouse to quickly rotate the view. Pan. However. Zoom. pan and rotate the display of your part in the work area.You can also store your own view orientations. A l t e r nat i ve s • Click the Rotate command on the View toolbar • Hold down the Ctrl key and press the up or down keys to rotate 15° around the horizontal axis • Hold down the Ctrl key and press the right or left arrow keys to rotate 15° around the vertical axis • Hold down the Alt key and press the right or left arrow keys to rotate 15° around the normal axis • Hold down Shift+Ctrl and press the up or down arrow keys to rotate 90° around the horizontal axis • Hold down Shift+Ctrl and press the right or left arrow keys to rotate 90° around the vertical axis Zoom Spin the scroll wheel forward to zoom in. A l t e r nat i ve s • Use the zoom commands on the View toolbar: Zoom. Fast Rot at e Hold down the Ctrl key and the middle mouse button. If you hold the mouse button down over an axis or geometry element. Spin the scroll wheel backwards to zoom out. Zoom Dynamic • Hold down the Shift key and press the up or down arrow keys to zoom in or zoom out ESPRIT Fundamentals   |  19 . Pan. and Rotate the View Commands on the View toolbar let you fit. the view will rotate about that element. The zoom takes place from the location of the cursor on the screen. Zoom Previous. or scroll wheel. it is faster to use the mouse and keyboard to modify the view. rotate or zoom the view to the orientation you prefer and then create a new view to store the view for later use.

left. or scroll wheel. and move the mouse right. With Smart Zoom. 20  |  Get Started with ESPRIT . Press F8 to switch to an isometric view. up. Pan Hold down the middle mouse button. That way. or backward to pan the view. or scroll wheel. or down keys Keyboard Shor tcut s Press F5 to redraw the screen. left. A l t e r na t i ve s • Click the Pan command on the View toolbar • Press the right. Press F7 to switch to a top view. the zoom takes place from the center of the model regardless of the position of the mouse. Press F6 to fit all visible graphic elements on the screen. the model is always visible when you zoom. forward. and move the mouse forward to zoom in or move backwards to zoom out.Smar t Zoom Hold down the Shift key and the middle mouse button.

select the item in the dialog. For example. you can set up different layers for machine components.Masks The Masks command on the View menu lets you hide the display of specific types of elements. Items with a check mark are displayed. they are placed on the active layer. the initial part stock or casting. Layers can be turned on or off to hide or show the different aspects of your part. To display the elements again. When new elements are created. Elements can be placed on a different layer by first selecting one or more elements and then changing the “Layer” property in the Property Browser. Select any items you want to hide to remove the check mark. just temporarily hidden. All elements of that type will be hidden in the work area. Press Ctrl+M to display the dialog. roughing tool paths and finishing tool paths. You can turn a layer back on at any time. Layers Layers are very useful for controlling the display of different types of elements in a complex part file. The elements are not deleted. the finished part. or any other type of geometry. ESPRIT Fundamentals   |  21 .

22  |  Get Started with ESPRIT .

.... rectangles....... such as a line segment or arc.................... such as a circle or ellipse..27 Draw 2D Geometry............ ..... such as points.. For machinists. or add fillets and chamfers to corners............. Geometry commands...... points....... rectangles. the ability to create geometry to aid in the creation of proper tool path is critical...... ... Unbounded geometry has no end point or start point.......24 Unbounded Geometry.....25 Geometry creation modes...................... 26 Work Planes.................. In addition.. and polygons.....25 Entering Values. .... or the start point and end point are the same.............. Bounded geometry is limited to a start point and end point.Working with Geometry A basic requirement of any CAD/CAM system is to provide functions that allow the creation of 2-dimensional and 3-dimensional geometry.................... and circles • How to trim geometry and fillet corners • How to draw a hole pattern from an array of points Working with Geometry   |  23 ....... 26 Saving a work plane... 28 Some geometric elements are neither bounded or unbounded............... ESPRIT provides functions to create two types of geometry: unbounded and bounded.. You will learn: • About the commands for creating geometry • About work planes and how to modify their location and orientation • How to draw lines.... such as an infinite line........ The intent of this lesson is to teach you the basics of creating 2-dimensional geometry in ESPRIT..24 Bounded Geometry. ESPRIT lets you trim or extend geometry...

Trim: Trims the portion of an element between two reference elements. a segment to a line. or center point). or perpendicular to another line through a specified location. at the intersection of two elements. Point: Creates a point using a reference element or entered values. or a bounded ellipse to an unbounded ellipse. Circle 1: Creates a circle from one reference element. tangent to a circle or arc. Ellipse 3: Creates an ellipse from three points or Snap locations. the elements are either trimmed or extended to the end points of the fillet or chamfer. Ellipse 1: Creates an ellipse centered about a point or Snap location. midpoint. circular array. Line 2: Creates a line from two reference elements. 24  |  Get Started with ESPRIT . The line can be created through a point. Keep: Keeps the portion of an element between two reference elements and trims the rest. a point that defines the angle of the major axis and the major radius. This command can also be used to convert an arc to a circle.Geometry commands Geometry commands are available on two toolbars: Unbounded Geometry and Bounded Geometry. The user is prompted for the center point. at a specified distance along an element. The radius is calculated from the three locations. The circle is centered at a specified location or created concentric to another circle. segment. and a point anywhere on the ellipse. or choose a reference element to create a point: on a Snap location (end point. select grid points. The user can specify the number of points to create in a linear array. and minor radius. Horizontal/Vertical Line: Creates a line parallel to the X-axis (horizontal) or the Y-axis (vertical) at a specified distance. The circle is created through or tangent to three elements or Snap locations. or axis. The line can be created between two points. The user is prompted for the center point. The user can enter XYZ coordinate values. Unbounded Geometr y The Unbounded Geometry toolbar displays automatically when you click Geometry on the Smart toolbar. Point Array: Creates multiple points at evenly spaced intervals. or grid array. Depending on the selected geometry. or at a specified distance and angle from a reference location. tangent to circles or arcs. Fillet/Chamfer: Creates an arc (fillet) or segment (chamfer) between two reference elements. or parallel to another line. the user can choose to automatically create a PTOP feature from those points at the same time. The circle is created through or tangent to two elements or Snap locations. Line 1: Creates a line from one reference element. angle of major axis. major radius. In addition. Circle 2: Creates a circle from two reference elements. Circle 3: Creates a circle from three reference elements.

start angle. Entering Values Each geometry command displays a series of messages in the prompt area (located at the lower left corner of the screen). tangent to a circle or arc. or parallel to another line. Arc 1: Creates an arc from a center point. such as a center point for a circle or an end point for a line. an input box displays. You can accept the displayed value by pressing the Enter key or you can type a new value. such as a radius or distance. Working with Geometry   |  25 . When the reference points lie on the same plane. The user is prompted for the center point.Rectangle: Creates a rectangle or cube from two points or Snap locations. Ellipse 1: Creates an open ellipse centered about a point or Snap location. and end angle. The second point selected also defines the start point of the ellipse. or perpendicular to another line. When the reference points lie on different planes. Bounded Geometr y To display the Bounded Geometry tool bar. Segment 1: Creates a segment from one reference element. angle of major axis. The user specifies the length and angle. The messages typically prompt you to select a reference element in the work area. a point that defines the angle of the major axis and the major radius. or axis. or axis. a cube is created from twelve separate segments. and start and end angles. a rectangle is created from four separate segments. Segment 2: Creates a segment from two reference elements that define the start and end points. As soon as you begin typing on the keyboard. tangent to circles or arcs. Most of the commands are the same except that you can create segments instead of lines and arcs instead of circles. The segment can be created through a point. a radius value. Arc 2: Creates an arc with a specified radius through or tangent to two reference elements. segment. and an end point. Arc 3: Creates an arc from three reference elements that define the start point. Ellipse 3: Creates an ellipse from three points or Snap locations. minor radius. a point on the arc. The segment can be created between two points. major radius. and then prompt you to input a value. and the end point. The user is prompted for the center point. click 'Bounded Geometry' on the Create tool bar. Polygon: Creates a closed shape with any number of sides centered about a point or Snap location. segment.

Geometry is drawn on the ZX plane. all starting at the system origin point: • XYZ: U. and X respectively. and Z. and W share the same orientation as X. Z. Work Planes When geometry is created. you can create one circle after another. This tool bar displays automatically when 'Geometry' is clicked on the Smart tool bar. ESPRIT provides three work plane orientations. Geometry is drawn on the XY plane. Geometr y creation modes When a geometry command is clicked on the toolbar. and Y respectively. The location and orientation of the current work plane is shown by the UVW axis. V. 26  |  Get Started with ESPRIT . The mode stays active until you press the Escape key or click another command. and W are aligned along Y. such as SQR(PI*3) or 10/3. click 'UVW Axis' on the View menu. or Z. To display the UVW axis. Y. the tool axis is always aligned along the W. if you click the Circle 1 command. V. Work planes let you draw geometry on a plane other than the default XYZ plane. V. its mode of geometry creation is activated. In ESPRIT.You can type the value or you can enter a mathematical expression to calculate the value. • ZXY: U. axis. Geometry is drawn on the YZ plane. it is drawn on the current work plane. Users have the ability to create their own work planes in any orientation and location using the commands on the 'Modify Work Plane' tool bar. X. and W are aligned along Z. For example. • YZX: U.

The view is created with the 'W' of the UVW axis pointing out towards you so that you can create elements on the UV (or XY) plane. Follow the prompts at the lower left of the screen. you can use it immediately. Translate Work Plane: Moves the UVW axis incrementally according to the X. V. You can select elements to define the mirror plane (see Work Plane from Geometry) or use an existing plane as the mirror plane. Parallel Work Plane works the same as Translate Work Plane. Working with Geometry   |  27 . The first element selected defines the U axis. XX After a work plane is repositioned. An asterisk (*) displays after the new plane name in list for both Work Planes and View Planes to indicate that the work plane includes a view. Saving a work plane To save the current position of the UVW. Parallel Work Plane: Moves the UVW axis incrementally according to the U. and W axis.Work Plane from Geometry: Creates a work plane from selected elements that define a plane. The origin of the work plane will be set to (0. open the Work Planes dialog (press F10) and click New. V. Y. type the word "name" and then enter the name of the plane you want to use. If the UVW has the same orientation as the XYZ axis. The position of the elements you create will be based on the new location and orientation of the UVW axis. a circle. Any of the following can be selected: two intersecting lines or edges of a surface or solid. When "Include View" is checked. Rotate UVW: Rotates the UVW axis any angle about the U. three points not on the same line. a line and a point not on that line. Symmetry Work Plane: Moves the UVW axis symmetrically with respect to a selected plane. and W values you enter. 0. the same name and orientation is added to the list of View Planes so you can change to that view at any time. Work Plane from Active View: Creates a work plane from the current view. Follow the prompts at the lower left of the screen. the second element defines the V. 0). and Z values you enter and according to the orientation of the XYZ axis. To do so. Rotate Work Plane: Rotates the UVW axis any angle about a selected line or segment. Enter a name for the new plane and click OK.

You will draw the geometry using the dimensions in this drawing.Draw 2D Geometry In this lesson you will learn to draw points. lines. on the Tools menu. All dimensions are in millimeters. Create a new ESPRIT document You will start with a new document that does not have any geometry at all. Open ESPRIT or. is set to Metric. if ESPRIT is already running. Set the view to 'Top'. Make sure SNAP mode and HI mode are active. and circles and become familiar with how to trim elements. Make sure System Unit. 28  |  Get Started with ESPRIT . click New.

Select the origin point at the lower left of the screen. • You are prompted to "Select First Reference Point". The Rectangle command requires the entry of two point locations that define the opposite corners of the shape. • Click Rectangle . The first point is located at the origin. On the Smart tool bar. Select the point you created. so you only need to create a point for the upper right corner of the rectangle. • You are prompted to "Select Second Reference Point". Working with Geometry   |  29 . click Geometry. • Select 'Cartesian/Center'. click 'Zoom to Fit All' to see the point. • Enter the following values for the point: • X = 120 • Y = 90 • Z = 0 • Click Apply to add the point and then close the dialog. • On the View toolbar.Draw t he par t boundar y as a rect angle The outer boundary of the part is the perfect shape for using the Rectangle command. • Click Point .

• You are prompted to select an offset direction of "Up. • Click Line 1 .Draw t he boundar y lines for t he pocket The edges of the pocket are offset from the part boundary by 5 mm. • You are prompted to "Enter Distance". Down. Select one of the segments. You will use the segments in the boundary to create parallel lines. Left. 30  |  Get Started with ESPRIT . or Right". Digitize inside the boundary. you can use it as a reference for additional geometry. Type 5 and press Enter. Now that you have the boundary geometry. • You are prompted to "Select Reference Element".

• You are again prompted to select a reference element. so just press Enter. • Select a line by digitizing it inside the pocket boundary since this is the portion of the line you want to keep. Select another segment in the boundary. Working with Geometry   |  31 . • Again digitize inside the boundary. • Follow the prompts to create the next two lines for the pocket. • Digitize the other three lines in the same way so that all the lines are trimmed. Trim t he pocket boundar y • Click Keep . • This time the distance defaults to 5.

• Select the bottom segment of the part boundary and enter a distance of 45.Add more det ail to t he pocket The upper portion of the pocket is 35 mm across. • Digitize to the right of the selected segment. • Digitize above the selected segment. 32  |  Get Started with ESPRIT . There is also an angled line that starts 45 mm above the bottom of the part boundary. • Select the left pocket segment and enter a distance of 35. • Click Line 1 .

• Move the cursor over the intersection of the two lines you just created and click to select the intersection.Draw t he angled line With Line 1 still active. • You are prompted to "Enter Angle". Working with Geometry   |  33 . click INT mode to activate it. • Click 'Select' and then select the horizontal line. Press the Delete key since you do not need this line anymore. Type -10 and press Enter.

which is sharp. • Select the vertical segment above the intersection. • At each outer corner of the pocket. A fillet is created and the segments are automatically trimmed.Fillet t he pocket corner s All the corners of the pocket have a 6 mm fillet except for the intersection of the angled line. select each segment on the side that is inside the pocket boundary. • Select the angled segment to the right of the intersection. • Change the Radius to 0. • Click Fillet/Chamfer . • In the dialog. 34  |  Get Started with ESPRIT . set the Radius to 6.

enter 120-8 (width minus the offset). you know that one circle is positioned 8 mm away from the top right corner of the part boundary. • For the Y value. You also know the width and height of the part. • Click Point . enter 90-8 (height minus the offset). • Set Z to 0 and click Apply to create the first point. Working with Geometry   |  35 .Draw t he fir st point for t he hole pat tern From the drawing. • For the X value. so you can calculate the location for the first circle. • In the dialog. select 'Cartesian/Center'.

• Set 'Number' to 2 in the left column (number of points horizontally) and 2 in the right column (number of points vertically).Draw an array of point s The holes in the hole pattern are evenly spaced 64 mm horizontally and 30 mm vertically. 36  |  Get Started with ESPRIT . select 'Grid'. • Click Point Array . The easiest way to create a hole pattern is to use the Point Array command to create the center points. • Set 'Angle' to 0 horizontally and 90 vertically. Negative values are used because you want to create the array below and to the left of the point you just created. • Set 'Distance' to -64 (horizontal distance) and -30 (vertical distance). • Select the first point of the hole pattern. • In the dialog.

Create the other two circles in the same way. • Select a point. • You are prompted to "Enter Radius". • Press the Escape key to exit the Circle 1 command. Type 7/2 and press Enter. Working with Geometry   |  37 . • Select another point and press Enter to accept the default radius. • Click Circle 1 .Draw t he hole pat tern The last step is to draw the 7 mm diameter holes using the points you created.

38  |  Get Started with ESPRIT .

........................ • Features contain machining properties that control where material removal should occur.. face.................... 40 PTOP Feature.... In this way...... 40 Creating and editing features.41 Editing features........43 Work Planes assigned to features 44 Prerequisites...... Types of Features....41 Creating features...... ESPRIT uses standard manufacturing terms for features such as pocket...................... ESPRIT will automatically load the machining properties from the selected feature onto the operation technology page.......... . Associated tool paths are easily updated whenever a feature is modified............. ................................................. profile................ ............... ...... draft angles........ ......... ..........42 Feature Properties... and lead-in/lead-out points to name a few.......... 40 Chain Feature.... • When a feature (or features) is selected before a machining command is clicked..... 40 Custom Object......... ..................... 49 Create 3D features from a 2D drawing............... hole... 40 Feature Set.................... and so on........ • Features help automate machining processes because they provide a single source of information about how to cut a part................ cut direction.... These properties include cutting depths........ Any number of machining operations can be associated with a single feature. This saves time and prevents the errors caused by entering values manually. a set of features can describe the shape of an entire part.......... entry and exit points..............Working with Features Features are an integral component to the machining functions in ESPRIT and serve several purposes: • They describe the shape of the parts you want to machine...45 Position the part for machining 48 Draw dimensions... 51 You will learn: • About the different types of features • Commands for creating and editing features • Properties assigned to features • Work planes assigned to features • How to create 3-dimensional features from a 2D drawing Working with Features   |  39 ................ .....45 Import a CAD drawing..... The intent of this lesson is to introduce the user to the importance of features in machining operations and to provide an introductory lesson on how to create 2-dimensional features from the geometry in a drawing and modify those features to add 3-dimensional properties for machining.......... .. ........

A chain feature defines the start location. Chain features are quite simple and are used when you want the cutter to follow a defined path. Typically. Custom Object All EDM features created with the Draft Feature Recognition command are custom objects. direction. a simple pocket. A feature set is typically a Pocket feature that has sub-pockets or islands or it can be a Part feature containing all features found within a part boundary. these are contouring or profiling operations. PTOP features are typically used for drilling operations and can also be used for manual milling. and end location for a cutting path. Feature sets are represented by a folder in the Feature Manager.Types of Features When a feature is created. 40  |  Get Started with ESPRIT . PTOP features contain information about the depth and diameter of holes along the path as well as information about chamfers and counter bores. Custom Objects also have an associated Feature Type that designates the feature as a Draft Conic Feature (2axis) or Ruled Feature (4-axis). A chain feature could be the boundary around a part. it is classified as one of the following: Chain Feature An individual feature is considered to be a chain feature. PTOP Feature A PTOP (point-to-point) feature defines a path connecting a series of holes or points. Feature Set A collection of individual features that comprise an area to be machined is considered a feature set. In most cases. The tool will follow this path to drill each hole. or a path constructed of wire frame geometry. the tool can be centered on the chain feature or offset to the right or left.

Turning Profiles: Analyzes a part to find OD. A turning profile can be created from a solid model. surface composite. Holes: Automatically recognizes holes on a solid model using criteria that defines the allowable range of diameter values. Cam: Creates a chain feature of a cam profile based on values provided by the user. Face Profiles: Creates a profile feature from any combination of solid faces. For solid models. Manual Chain: Creates a chain feature from manually selected elements or point locations. solid faces. or composite. or face projection profiles and generates a profile for use in turning operations. The feature can be created from grouped elements or a manually selected start point. NURB surface. A Pocket feature can be created from a solid model. Feature Parameters: Defines the parameters used for automatic hole recognition in the Holes and Face Profiles commands and the recognition of milled holes in the Pocket command. optionally. Pocket: Recognizes pockets. or a chain feature. Gear: Creates a chain feature of an inner or outer involute gear from specified gear data. found within a closed boundary and creates features on them. grouped wire frame geometry. This command can also be used to re-open a chain for editing. This command is only available when the machining mode is set to SolidWire. For NURB surfaces and composites. solid edges. and an end point. Part Profile: Creates geometry or. the geometry marks the silhouette of the part projected along the W axis onto the UV plane. The calculated profile can be created as a chain feature or as individual geometric elements. Two toolbars display: Create Features and Edit Features. Face Profiles also processes any holes within the selected face like the Holes command. a face or face loop on a solid model. ID. Draft Feature Recognition: Creates a 2-axis or 4-axis EDM feature automatically from a solid model. a cross-section is created at the UV plane. click Features on the Smart tool bar. using the allowable range of hole diameters defined in Feature Parameters. face loops. surfaces. Auto Chain: Creates a chain feature automatically from elements that form a closed or open shape. Creating features Features are created from commands on the Create Features toolbar. or solid faces. the next element in the chain. a chain feature at the intersection of the UV plane of the UVW axis and a selected solid. To display the toolbar. Manual PTOP: Creates a PTOP feature from grouped or manually selected circles or point locations. and any internal islands.Creating and editing features Features are created using the commands on the Features toolbar. or STL model. or wire frame geometry. An additional setting controls the creation of multiple pockets when the Pocket function is used. Working with Features   |  41 .

internal corners only. clockwise corners. Find Shortest Path: Optimizes the travel distance between points in a PTOP or Hole feature. Remove Thread at Angle . Remove Slug Retention Profile . then automatically applies a user-defined corner style to those corners.Adds a new synchronization line to a 4-axis ruled feature. Arcs can be applied to the entire chain or any portion of a chain. Move Back: Removes any number of elements.Adds an extra break point to an existing EDM feature at a user-defined location and distance. Insert Point: Inserts a point in an existing PTOP feature.Removes slug retention profiles from EDM die features.Adds small slots or grooves to an EDM die feature to prevent a slug from staying in the die during a punching operation. Add Match Line . chain feature. A corner style can be applied to all corners. Reverse: Reverses the direction of a curve. Modify Internal/External Corners: Analyzes a chain or EDM feature to find and identify all corners. This command is available only when the Manual Chain function is active. Remove Extra Cut-off . Remove from PTOP Feature: Removes a point from a PTOP feature.Adds a tilted thread line to a 4-axis ruled feature.Removes a tilted thread line from a 4-axis ruled feature. or PTOP feature. 42  |  Get Started with ESPRIT . Modify Sharp Corner: Places arcs on corners (non-tangent junctions) of a chain feature. Taper Change . Add Slug Retention Profile . from last to first. or counter clockwise corners.Inserts a pivot or gradual taper change into a draft conic feature.Removes an extra break point that was previously added to an EDM feature. Remove Match Line .Deletes a synchronization line from a 4-axis ruled feature.Editing features The Features tool bar also displays commands you can use to edit features. New Start: Changes the start location on a chain feature to any element defined in the original chain. external corners only. on an existing chain or PTOP feature. Add Extra Cut-off . Command s to edi t EDM f eatures Several commands on the Edit Features toolbar are designed specifically for EDM features. Add Thread at Angle .

Features always have machining properties.Feature Properties The Property Browser displays all the properties of a selected item. To edit a feature property. To display the Property Browser. the length of segments in a chain feature. each feature also has properties for each subelement such as the position of each point in a PTOP feature. hold down the Alt key as you press the Enter key (Alt+Enter) or select Properties on the View menu. plus attributes that show whether an edge is open or closed. layer. and element type plus any machining properties. you can create a feature from 2D geometry and quickly give it 3D properties by adding depth and draft angles. These include general properties such as color. In addition to properties for the entire feature. In this way. You can highlight subelements in a selected feature using HI mode. Working with Features   |  43 . click on the value to the right of the property and make your change.

a work plane is assigned to it automatically. ESPRIT protects you from accidentally deleting the work plane by displaying a warning that your action is not allowed. ESPRIT assigns only one work plane to each feature. If you try to delete a work plane associated with an existing feature. regardless of the complexity of the feature. You can view the work plane property in the Property Browser. It has no effect on the orientation of the wire in EDM operations.Work Planes assigned to features Each time a new feature is created. The assigned work plane property affects the orientation of the tool for milling and turning operations placed on that feature. 44  |  Get Started with ESPRIT .

You will control the display of the geometry with layers. Import a CAD drawing You will start by opening an AutoCAD file in ESPRIT. If you would like to review and simulate the machining operations from this lesson. All dimensions in this lesson are in millimeters. Click Open. On the Standard toolbar. click Open. Click OK to close the Options dialog. the completed ESPRIT file is available in the folder “completed_parts”. Make sure “System Unit” on the Tools menu is set to “Metric”. such as the drawing border and title section. There is other geometry that you do not need. The files are also available for download from ESPRITWeb » File Library » ESPRIT 20XX. This drawing has part geometry that you will use to create features. Working with Features   |  45 .Prerequisites The files for this lesson are available on the ESPRIT DVD in the ‘Get Started’ folder. Browse and select the following file: drawing.dxf In the dialog. click Options and make sure ‘File Unit’ is Metric.

You can hide these elements so you only see the geometry for the part. When you imported the drawing.If the Feature Manager is not displayed. you can turn off that layer to hide all elements on that layer. You can turn the layer back on at any time to show the elements. Turn of f layer s to hide element s This drawing already has layers that were created in AutoCAD. When elements of any type are placed on a layer. press Alt+Enter (if necessary. not deleted. Layers let you hide and show different aspects of your drawing. you imported the layers as well. The CAD drawing has elements that you do not need for machining operations. drag the Property Browser below the Feature Manager). 46  |  Get Started with ESPRIT . such as the drawing border and title box. click the Layers icon. press F2. If the Property Browser is not displayed. The elements are temporarily hidden. On the ‘Layers and Planes’ toolbar.

type ‘Features’ and click OK • Close the dialog Working with Features   |  47 . it is automatically set as the active layer. and ‘Hidden (ISO)’. All new elements are created on the active layer. ‘Visible (ISO)’. • In the Layers dialog. click New • For the layer name.Uncheck all layers except ‘Default’. Create and act ivate a new layer You need to create a new layer for the features you will create. The active layer is displayed with a red box around it. When a new layer is created.

• On the Edit menu. To make this part easier to machine. you will move the origin point to the lower left corner of the part boundary since this is a good touch-off location for the machinist. ESPRIT makes it easy to change the origin point without moving the part itself.Position the part for machining The origin point in the AutoCAD drawing is not located on the part geometry. click ‘Move Origin Point’ • You are prompted to “Select New Origin Point” • Select the snap location at the lower left corner of the part boundary 48  |  Get Started with ESPRIT .

click Dimensioning.Draw dimensions This drawing does not have any dimensions. You can then use those values to add depth to the features you create. You will draw some dimensions on the top view of the part to see the depths of the pockets and the holes. • Click the Text tab • Make sure ‘Length Unit’ is set to ‘Metric’ • Click the Font button and set the font size to 12 • Click OK to close the Font dialog • Click OK to close the Parameters dialog Working with Features   |  49 . On the Tools menu.

add dimensions for the depths of the pockets • Press the ESC key to exit Dimension mode • In the Status area. • Click Dimension • In the Status area.On the Smart toolbar. click Dimensioning. enable SNAP mode 50  |  Get Started with ESPRIT . select SNAP mode to turn it off • Select a segment on the top and the bottom of the top view • The system displays a preview of the dimension that moves with your cursor • Move the cursor to the left of the geometry and click to place the dimension • Select a segment on the top and a segment at the bottom of a drilled hole • Place the dimension to the right of the geometry • In the same way.

Create a hole feature On the Smart toolbar. • Click the arrow button next to ‘Max Diameter’ and select an inner circle from one of the drilled holes • Click OK to create a hole feature that connects all the drilled holes Working with Features   |  51 . it is useful to be able to use the geometry in the drawing to create 3-dimensional features that can be machined. click Features.Create 3D features from a 2D drawing When a machine shop receives a drawing from a customer. ESPRIT lets you create features on 2-dimensional geometry and add 3-dimensional properties to them. Click Holes.

select the value for the ‘Depth’ property • Enter a value of 15 and press Enter • Select the value for ‘Chamfer Diameter’ • Click the arrow button next to the value and then select an outer circle from one of the drilled holes • Change the value for ‘Chamfer Angle’ to 90 52  |  Get Started with ESPRIT . • In the Project Manager. select the Hole feature • In the Property Browser.Edit t he hole feature These holes have a depth of 15 mm and a countersink with a total angle of 90 degrees. Change the view to ‘Isometric’ so you can see the updates to the feature as you add machining properties.

and one for the circular island.Create chain features for t he pocket You will create three features for the pocket: one for the closed boundary of the pocket. Right. or Center. Cutting side is based on the direction of the feature and can be set to Left. one for the rectangular island. the cutting side is important because it controls where material is removed (on the inside or outside of the chain). For features that define a pocket. • Change the view back to ‘Top’ • Hold down the Shift key and select a single element in the pocket profile • All connected elements are grouped automatically • Click Auto Chain • The start point for the chain is created in the middle of the longest segment and has a counterclockwise direction Working with Features   |  53 .

change ‘Cutting Side’ to ‘Left’ and press Enter • Notice that ‘Material Removal’ changes to ‘Inside’ • Select the feature ‘2 Chain’ and change the property for ‘Cutting Side’ to ‘Right’ and press Enter • ‘Material Removal’ for the island feature is ‘Outside’ • Select the feature ‘3 Chain’ and change ‘Cutting Side’ to ‘Right’ 54  |  Get Started with ESPRIT .• Hold down the Shift key and select a single segment of the rectangular island • Click Auto Chain • Select the circle inside the pocket and click Auto Chain • Select the feature ‘1 Chain’ in the Feature Manager • In the Property Browser.

Since the features for the pocket all share the same depth. only the properties that are common to all the elements can be edited in the Property Browser. You can edit the sub-elements of a feature to define edges as open or closed. • In the Feature Manager. you can update the depth for all three features at one time.Add dept h to t he chain features When several elements are selected. select the three chain features • Change the property for ‘Depth’ to 18 and press Enter Create a chain feature for t he open pocket The area located at the upper right of the part is defined as an ‘open’ pocket because it defines a closed boundary that has some edges along a wall and other edges that are open. • Hold down the Ctrl key and select the segments and arcs that define the boundary of the open pocket (the CTRL key lets you continue adding elements to a group) • Click Auto Chain • Change the cutting side of the feature to Left • Change the depth of the feature to 24 Working with Features   |  55 .

make sure SUB-ELEMENTS mode is enabled • In the work area. change the attribute for ‘Open Edge’ to ‘True’ • In the same way. select an outer edge of the feature • When the entire chain highlights. press the right mouse button to highlight only the edge of the chain • Press the left mouse button to accept this choice • In the Property Browser. select the other sub-elements on the outer edge and change the ‘Open Edge’ attribute to ‘True’ 56  |  Get Started with ESPRIT . click Masks • Select ‘Geometry’ to hide the display of the geometric elements (do not close the dialog yet) • In the status area.• On the View menu.

After you select the end point of the profile. you need to click the Cycle Stop command to let ESPRIT know that you are finished selecting elements for the chain.• Change the view to ‘Isometric’ • You can see that the open edges are displayed as dashed lines • In the Masks dialog. click Cycle Stop to create the feature • Change the cutting side to Right • Change the depth to 24 Working with Features   |  57 . select ‘Geometry’ to show the geometric elements and close the dialog Create a chain feature on t he inside edge Features along the edges of a part are useful for contouring operations. • Click Auto Chain • Select the start point shown • Select the angled segment to the left of the start point • Select the end point shown • On the Edit toolbar. This chain defines an open profile with the start point and the end point in different locations.

58  |  Get Started with ESPRIT . • Click Manual Chain • Use SNAP mode to select the four corners of the part boundary (be sure to select the corners in order) • Change the cutting side so that material removal is on the outside of the boundary • Change the depth of the feature to 30 XX To see the features more clearly you can mask the geometry.Create a manual chain on t he outer boundar y A chain around the boundary of the part can be used for facing and contouring operations.

....... 68 SolidMill Traditional Machining Cycles. ........................ ............................. 64 Milling Clearances.................. .. you will learn how to use the commands on the SolidMill Traditional toolbar to mill a part on a 2-1/2 axis mill... . 92 Mill and drill the holes. ........................... providing both ease-of-use and a high level of control over every aspect of a milling operation... 76 Create a stock model...................................... 64 Feeds and Speeds.......... ..Milling on a Standard Mill ESPRIT has very strong capabilities in 2.... 66 Depths of Cut.................. 70 Prerequisites..71 Open the part file................. .......... 85 Cut the pockets and slot.............72 The Tool Manager............... 99 You will learn: • About SolidMill Traditional machining technology and machining cycles • How to create a milling tool • How to create features for milling operations • How to create a stock model • Techniques to quickly remove stock material • Two pocketing techniques: high-speed and standard • Drilling techniques for hole patterns and a milled hole • Simulation with Stock Automation Simulate milling operations...5D milling...71 Create a milling tool..........72 Create milling features...... SolidMill Machining Technology 60 Saving Machining Technology..... ..............83 Remove excess material..... .............. The intent of this project is to teach you the process for creating standard milling operations using the standard milling technology in ESPRIT................ For this project........... 103 Milling on a Standard Mill   |  59 ........... ..............

The interface is organized in three main areas: • Toolbar area • Vertical tabs • Parameters area 60  |  Get Started with ESPRIT . This technology is called SolidMill. SolidMill technology lets you define the physical properties of your milling machine.SolidMill Machining Technology ESPRIT has machining technology that is designed specifically for 2-axis through 5-axis mills. create milling tools and stock models. create specialized milling features with automatic feature recognition. create milling operations and simulate them. The technology for SolidMill machining cycles is displayed on a tab in the Project Manager. The technology for a machining cycle will not open unless a valid feature is selected first. The user can also click on any of the other tabs in the Project Manager to make it easier to select features or create new cutting tools. This makes it easy to enter machining parameters and view the part model at the same time. The way that machining parameters are organized for all SolidMill machining cycles is consistent to make it easy to learn and use the technology.

The Toolbar area contains commands to validate (OK) and close (Cancel) the current technology
as well as a Help button to open the help file for the current technology. The drop-down button
displays the context menu for the technology. The icon reflects the last command used by the user.

The vertical tabs are arranged to save space. Parameters are grouped on the tabs in a “top down”
approach, where you define the most general information about the cutting cycle on the General
tab, then move to the Strategy tab to define a bit more detail such as the cutting strategy or
depths, moving down each tab to add more detail about your machining operation.

The display of some tabs is controlled by a parameter setting. For example, if the parameter ‘Finish
Pass’ on the Strategy tab is set to ‘Yes’, the Finish tab will display to let you define parameters for a
final finishing pass. If ‘Finish Pass’ is set to ‘No’, the tab is hidden.

Milling on a Standard Mill   |  61

The Parameters area displays the machining parameters for the current technology. Parameters
are grouped by category and each group control can be collapsed or expanded for visualization
purposes.

As parameters are selected, the interface updates to show only the parameters you need. Options
that are not used are hidden. If the user changes a parameter, the interface updates to show or
hide a different set of parameters.
62  |  Get Started with ESPRIT

For example, if the user sets ‘Trochoidal Move’ to ‘Yes’ for high-speed tool path, all the parameters
to define the trochoidal movement are displayed.

Otherwise, they are hidden.

When an arrow button displays next to a parameter, you can click the arrow and select an element
in the work area to load a value.

Features can also be loaded from the Features tab. Click inside the parameter field, click the
Features tab, select a feature from the list, and then click the technology tab.
If the value for a parameter is invalid or missing, an error displays next to the parameter. If
you hover your mouse over the error icon, a description of the error displays so that it can be
corrected.

Milling on a Standard Mill   |  63

it can be loaded in a technology page. browse to the file. you can only load Pocketing technology into a Pocketing cycle. To save the technology for a machining cycle. browse to the location where you want to save the file. The column on the left is for actual feed and speed values. click Save on the drop-down menu. XX The type of technology in the file must match the machining cycle. and click Save. Click ‘Open’ on the drop-down menu. If you enter a value in one column.prc (process) file and used over and over for the machining of similar parts. Cut speed is affected by the tool diameter. it is important to name the saved technology file with the type of technology in the file. while the column on the right is used for chip load programming.Saving Machining Technology Machining technology settings can be easily saved as a separate *. For example. This allows you to “fine tune” your feed and speed values. the value in the next column is automatically calculated. Enter a name for the file. After a technology file has been saved. Cut speed is defined as the distance in feet or meters that the edge of the rotating tool travels per minute. a larger tool diameter results in a greater cutting speed. 64  |  Get Started with ESPRIT . and click Open. Feeds and Speeds The settings for feed rates and spindle speed are set on the General tab and displayed in two columns that are interactive. Cut Sp e ed You can use ‘Cut Speed RPM’ (Revolutions Per Minute) or ‘Cut Speed SPM’ (Surface feet/meters Per Minute). At a fixed number of RPMs. For this reason.

There are three types of moves possible in the XY plane. These moves are represented by the following examples of NC code. The feed rate increases around exterior arcs and decreases around interior arcs in the NC code output.When a value is entered in ‘Cut Speed RPM’. To calculate the feed rate PT (per tooth) from the feed rate PM (per minute). Milling on a Standard Mill   |  65 . Feed rate is defined as units (inch/millimeter) per minute (PM) or per tooth (PT). The value you enter for Z Feedrate determines the feed rate for these four types of moves. When set to Yes. The system uses the following formula: RPM in Inch = (12 * SPM) / (PI * Tool Diameter) RPM in Metric = (1000 * SPM) / (PI * Tool Diameter) X Y Fe edrat e PM . the feed rate is the speed at which the cutter moves with respect to the work material. In general terms. the feed rate is adjusted on arcs to maintain the feed rate at the edge of the tool where it contacts the material. the system takes that value and the tool diameter and calculates the Cut Speed RPM. The relationship of RPM to SPM is based on the following formula: SPM in Inch = RPM * PI * Tool Diameter / 12 SPM in Metric = RPM * PI * Tool Diameter / 1000 You can also go in the opposite direction. Type 1: N15 G01 X_ Y_ Type 2: N15 G01 X_ Type 3: N15 G01 Y_ Z Fe edrat e PM . the system uses the following formula: PT = PM / (Number of Flutes * RPM) Going the other way. The value you enter for XY Feedrate determines the feed rate for these three types of moves. If you set Cut Speed SPM. the system uses the following formula: PM = PT * Number of Flutes * RPM XX The Tool Diameter and Number of Flutes are set on the tool page. XY Feedrate allows you to specify the feed rate for movement in the XY plane. Type 1: N15 G01 X_ Y_ Z_ Type 2: N15 G01 X_ Z_ Type 3: N15 G01 Y_ Z_ Type 4: N15 G01 Z_ Const ant Removal Rat e This option can be set to Yes or No. PT Z Feedrate allows you to specify the feed rate for moves along the tool axis. the system takes that value and the tool diameter and calculates and displays the value for ‘Cut Speed SPM’. PT These values are also interactive. These moves are represented by the following examples of NC code. The Max Feedrate setting is used to limit the increase in feed rate.

Once you define the two distances. The inserted speeds and feeds are affected by the “Tool Material” and “Number of Flutes” specified on the tool page of the same Tool ID. measured from the origin of the coordinate system. The only time that clearance is not measured from the top of the feature is if the starting depth is a 66  |  Get Started with ESPRIT . ESPRIT lets you define two separate distances for retract moves: Clearance and Full Clearance. • Full Clearance: This is an absolute value. ESPRIT supports two types of coordinate systems: global (system default) and local (user defined). Sometimes the top of the feature is below the top of the work piece (for example. measured from the top of the feature or the starting depth. Clearances define how you want to position the tool when it makes a rapid move from one location to another. When set to Yes. you can use them to control the heights of retract moves. feed and speed values from the KnowledgeBase will be inserted automatically. holes in the floor of a pocket). Before setting this option to Yes. P T Max Feedrate is used to place a limit on the feed rate increase around exterior arcs when Constant Removal Rate is set to Yes. Milling Clearances Parameters that control tool clearances during milling are located on the Links tab.M a x Fe e d r at e PM . you must: • Have speed and feed data set up in the Speed Feeds Manager in the KnowledgeBase • Select a Speeds Feeds Standard and Material Class in KnowledgeBase Document Setup (on the Common Machining tool bar) • Select a tool in Tool ID • Select a Type of Cut (the Type of Cut option displays only when Use Feed and Speed KB is set to Yes) ESPRIT will combine the Speeds Feeds standard and material selected in KnowledgeBase Document Setup with the tool and technology settings on the operation page to provide acceptable cutting speeds and feed rates. Use Fe ed and Sp e ed K B This option can be set to Yes or No. but other situations may apply. • Clearance: This is a relative value. The Type of Cut selected on the operation page also affects the inserted speed and feed values. This is usually the top of the workpiece.

To save time. In that case. The distance is an absolute value. such as clamps and fixtures. always measured from ESPRIT origin P0. If you are not sure about when the retract plane is used. When you know the heights of specific obstacles on the work table. When the tool must avoid all obstacles (such as fixtures and clamps) while moving to the next position. Return Plane and Retract Plane share the same four options. this is a good choice. • Return Plane: This setting establishes the plane position of the tool as it rapids to the beginning of an operation and rapids away at the end of an operation. Milling on a Standard Mill   |  67 . you can use a different option for each. Whether the Retract Plane is used depends on the areas that are being machined.negative (-) value. When the tool will encounter no obstacles during repositioning. Initial Clearance: The value for Initial Clearance is specified on the tool page for the selected tool. you can set a minimum retract height in Clearance that keeps the tool as close to the work piece as possible. XX The Return Plane is always used. See “Depths of Cut”. you can use Full Clearance to make the tool retract to a safe height that will always avoid those obstacles. In addition to the retract distances. this is a good choice. measured from the Starting Depth. However. ESPRIT lets you control the behavior of the tool between separate machining operations and between sections of a single operation. it is a good idea to set the retract plane and return plane to the same option. Both methods of measurement have advantages. • Retract Plane: This setting establishes the plane position of the tool as it rapids between two sections of a cutting operation (for example. clearance is measured from the starting depth since it is above the feature. O pt ions for Retur n Plane and Ret rac t Plane Clearance: The tool retracts to the Clearance distance. when the tool needs to move between two pocket areas in a Pocketing operation).

this value is measured from the origin of the Work Coordinate used. this is a good choice.Full Clearance: The tool retracts to the distance entered in Full Clearance. When you know the tool will be repositioning to a lower plane. The depth settings let you control the z-level where the tool will start cutting. and the depth of the final cutting pass. 68  |  Get Started with ESPRIT . If you are outputting from World coordinates. this is a good choice. the depth of each incremental pass. Depths of Cut The depths of cutting passes are controlled by the Depth settings on the Strategy tab. Partial Depth: The tool retracts to the Clearance distance measured from the tool location at the time of the retract. When the tool must avoid vertical obstacles on the work piece between operations. this value is measured from P0. If you are outputting from a local coordinate system.

measured from the selected feature. Since this setting controls a tool retract distance. and Partial Depth options that are used for clearances. the operation cuts to the total depth plus the distance for the through depth. • Starting Depth: This value establishes the top Z level for cutting passes.• Total Depth: This value establishes the bottom Z level for cutting passes. this setting does not apply. Initial Clearance. When a value is entered. Milling on a Standard Mill   |  69 . • Retract for IDepth: This value controls the retract position of the tool before and after each incremental pass. a negative value cuts above. The values for Total Depth and Incremental Depth are used to determine the number of depth passes. This value is measured from the selected feature. You can also use the None option to have the tool feed between incremental passes without retracting. • Through Depth (Pocketing only): This value is used only when a pocket has no floor. it shares the Full Clearance. A positive value cuts below the selected feature. The first incremental depth pass is measured from this top Z level. The Surface Clearance option is similar to the Clearance option except that the retract is either the clearance distance above the feature or the clearance distance above the starting depth. A positive value cuts below the selected feature. a negative value cuts above. Enter a value beyond the depth of the pocket so the tool can cut completely through. • Retract Between Cuts (Contouring only): This value controls the retract position before and after each lateral contouring pass. If the contour does not have lateral steps. The depth of the last incremental pass may be adjusted depending on the value for Total Depth and any stock allowance applied to the floors. whichever is higher. • Incremental Depth: This value controls the distance between each Z-level cutting pass.

Creates a milling operation based on wire frame geometry. Wire Frame Milling .Removes material inside a closed boundary using the fastest possible feed rates. The linear and contouring passes are combined into a single operation to save you time and to guarantee a consistent amount of stock on floors and walls. Manual Milling creates a tool path on the centerline of the tool without compensation.Creates vertical or tapered cuts along the contour of a selected profile. Manual Milling . The previous operation becomes the “parent” operation and the rest machining operation applied to it becomes the “child” operation. Spiraling . Within a single pocketing operation. Trochoidal Pocketing brings benefits to any type of machine by providing a more constant tool load and a better surface finish. This command lets you create a simple freeform milling operation from planar geometry. including canned cycles. Rest Machining . you have the option to create separately definable phases for roughing. When a pocket or face profile feature is chosen. SolidMill Facing quickly removes material at the depth (or depths) you specify with simple linear passes followed by a final contouring pass around any islands to provide a uniform amount of stock on wall areas.Creates a drilling operation. Although developed for high-speed machining. Drilling . although you can define different incremental depths for finishing passes as well as different speeds and feeds. Pocketing . To display the SolidMill Traditional toolbar. Contouring . and cutter load. The child operation inherits many of the settings from the parent operation. The parent operation is used as the basis for calculating the areas to machine.Creates rapid or feed moves based on manually selected elements or coordinate locations. Within a single contouring operation.Creates either spiral or helical cutting passes based on the selection of a feature with a circular shape or a PTOP feature. you have the option to create separately definable phases for roughing and finishing. The same tool is used for both roughing and finishing.SolidMill Traditional Machining Cycles All SolidMill Traditional machining cycles are displayed on the SolidMill Traditional toolbar and on the Machining menu under SolidMill Traditional. Trochoidal Pocketing quickly roughs parts at a constant material removal rate and provides multiple levels of control over tool motion pattern.Removes a flat portion of stock material based on a feature that matches the stock perimeter. Several types of drilling cycles are supported. wall finishing. A rest machining operation can be applied to any existing SolidMill Traditional operation. Facing .Removes material inside a closed boundary. click ‘Switch to SolidMill’ on the Smart toolbar and then click SolidMill Traditional.Creates an operation to remove material remaining from previous operations. One profile is swept along the other to create a 3-dimensional shape for the toolpath. 70  |  Get Started with ESPRIT . Threading . Trochoidal Pocketing . feed rates. Two separate profiles are used. the operation automatically finds any subordinate islands within the feature boundary. and floor finishing passes that each let you use a different tool.Creates a standard threading or single-point threading operation using basic milling technology.

If you would like to review and simulate the machining operations from this lesson. click Open. Set the view to ‘Isometric’.esp. Open the part file On the Standard toolbar. Milling on a Standard Mill   |  71 . Make sure “System Unit” on the Tools menu is set to “Metric”. All dimensions in this lesson are in millimeters. Browse and select the following file: milled_part. the completed ESPRIT file is available in the folder “completed_parts”. If the Project Manager is not displayed. press F2.Prerequisites The files for this lesson are available on the ESPRIT DVD in the ‘Get Started’ folder. The files are also available for download from ESPRITWeb » File Library » ESPRIT 20XX.

The Tool Manager lets you create. and even a custom mill for cutting the milled hole. If you use a very specific type of tool that is not on the list. Milling tools can be created from the Tool Manager or from commands on the Milling Tools toolbar.Create a milling tool This file already contains several types of tools. drills. Tools in the list can be sorted on any column and the user can choose which columns to display using the Field Chooser. You can also transfer tools between the Tool Manager and the KnowledgeBase. copy. The Tool Manager All cutting tools are managed on the Tools tab of the Project Manager. ESPRIT provides an extensive list of pre-defined milling tools. you can create a Custom Mill from geometry you define. edit. Instructions on how to create a custom mill are provided in ESPRIT Help. Tools are grouped by where they are mounted on the machine: on a milling head or a lathe turret (for a mill-turn machine). The Tool Manager displays all the available tools in the current document. and delete tools. These options are available by right-clicking on any column heading. rename. 72  |  Get Started with ESPRIT . You will learn how to create a face mill that will be used to remove the stock at the top of the part. such as end mills.

click Milling Tools. On the General tab: • Set ‘Tool ID’ to ‘FM 60’ • Set ‘Tool Number’ to 1 Milling on a Standard Mill   |  73 . Click Face Mill.Create a face mill tool You will create a new face mill tool with a diameter of 60 mm. This face mill has 6 cutting inserts that have a rectangular shape. On the Smart toolbar.

Y. Z’ to ‘Home’ for all three positions • Set ‘Turret Name’ to ‘Head’ On the Holder tab: • Set ‘Holder Diameter’ to 60 • Set ‘Overall Length’ to 100 • Set ‘Tool Length’ to 80 On the Shank tab: • Set ‘Type’ to ‘Cylindrical’ • Set ‘Shank Diameter’ to 30 • Set ‘Cutting Length’ to 1.5 74  |  Get Started with ESPRIT .On the Machine tab: • Set ‘Movement X.

On the Cutter tab: • Set ‘Tool Diameter’ to 60 • Set ‘Bottom Clearance’ to 10 • Set ‘Number of Inserts’ to 6 • Set ‘Insert Type’ to ‘Rectangular’ • Set ‘Corner Radius’ to 1 • Set ‘Insert Width’ to 30 • Set ‘Insert Height’ to 10. Click OK to add the new tool to the Tool Manager. Milling on a Standard Mill   |  75 .

76  |  Get Started with ESPRIT .Create milling features Milling features have machining properties that help to automate milling operations. ESPRIT uses automatic feature recognition to analyze the part geometry and automatically create the appropriate features for milling operations. click Create Features. make sure HI mode and SUB-ELEMENTS mode are active. Make sure the work plane is set to ‘XYZ’. Set t he work plane When automatic feature recognition is used. When features are created on a solid model. This allows you to create features automatically on different sides of a part. If the feature is modified to change any of the machining properties. These properties assist the user because SolidMill technology is designed to use these properties each time a milling operation is created. draft. such as faces and face loops. cutting side. Any cylinder with a diameter greater than the ‘Maximum Diameter’ will be recognized as a pocket. Recognize t he pocket s In the status area. the direction of the W axis of the active work plane controls the direction of feature recognition. The user is not limited to selecting only the solid model. to create features on a specific portion of the solid model. any milling technology that is applied to that feature can be updated quickly by simply rebuilding the operation. On the Smart toolbar. These properties include depth. such as a change in the depth property. and whether material is removed on the inside or outside of the feature. The user can also select sub-elements of a solid model. Pocket Feature Recognition uses the ‘Maximum Diameter’ parameter located in the Feature Parameters dialog to recognize cylindrical pockets.

Click Feature Parameters. • Click the arrow button next to ‘Max Diameter’ and use HI mode to select the edge of a hole on the corner of the part • Click OK • Select the solid model • Click Pocket Milling on a Standard Mill   |  77 .

This makes it easier to select the correct feature when you want to apply a machining operation and it is extremely helpful to other users if they need to modify operations at a later time. • Click the Features tab in the Project Manager • Expand the folder for the pocket • Right-click on the feature for the pocket in the middle of the part • Select ‘Rename’ • Rename the feature to ‘Medium Pocket’ and press Enter 78  |  Get Started with ESPRIT . It is helpful to give descriptive names to features.Rename t he pocket features Features for the pockets and island were created automatically and placed in a folder in the Feature Manager.

• In the same way. select the feature for the slot and rename it ‘Slot’ • Rename the small pocket ‘Small Pocket’ • Rename the cylindrical pocket ‘Milled Hole .Upper’ Milling on a Standard Mill   |  79 .

Recognize t he boundar y • Click Face Profiles • Use HI mode to select the face loop around the top of the part • Click OK 80  |  Get Started with ESPRIT .

Recognize t he drilled holes • Click Holes • The value for ‘Max Diameter’ is already set to the diameter of the hole you selected for the pocket features • Click OK • Rename the group of large holes ‘Counterbore’ • Rename the group of small holes ‘Countersink’ Milling on a Standard Mill   |  81 .

change the value for the Depth property to 38. you can create a simple Hole feature that matches the size of your largest drill. To do this. select the new hole feature • In the Property Browser. • Click Holes • Set ‘Max Diameter’ and ‘Min Diameter’ to 42 • Click OK • Press Alt+Enter to display the Property Browser • In the Feature Manager.Create a hole feature for t he milled hole It is more efficient to pre-drill the milled hole before applying a milling operation.1 • Change the value for the Diameter property to 30 and press Enter • Close the Property Browser 82  |  Get Started with ESPRIT .

and from points that define a block. In this lesson. Stock models can be defined in a variety of ways: from an existing solid model. you will create the stock model from a chain feature that defines the shape of the boundary.Create a stock model Stock models for milling operations are created in Simulation Parameters on the Simulation toolbar. click Simulation. from a feature. Stock models are created as solid models that aid in the visualization of material removal during the simulation process. On the Smart toolbar. • Click the Solids tab • Set ‘Type’ to ‘Stock’ and set ‘Create From’ to ‘Extrusion’ • Click the arrow button and select the feature ‘Stock Profile’ in the work area • Set ‘Z+’ to 1 • Set ‘Z-’ to 53.1 Milling on a Standard Mill   |  83 . Click Simulation Parameters. from an external file.

click Single Step • Click Stop to exit simulation mode 84  |  Get Started with ESPRIT .• Set ‘Indexing’ to ‘None’ • Click Add • Click OK • To view the new stock model.

Then you will create a 3D contour around the island on the top face. You will finish by roughing and finishing the outer profile of the part. In the Feature Manager. the part is cut from standard rectangular stock. click SolidMill Traditional. click ‘System Default All’ to reset all the technology parameters to the system default settings Milling on a Standard Mill   |  85 . To do this.5 mm will remain on the walls of the island after the operation is complete. there is an island on the face that must be avoided. The first thing you need to do is remove the excess material from the top and around the sides of the part. The Facing command lets you select and avoid islands and pocketed areas. XX As you enter values on the technology page you can use the Tab key to move from one parameter to the next. • On the dropdown menu. On the Smart toolbar. This operation will start slightly below the selected feature and cut at incremental depths of 8mm in a simple back and forth tool motion.Remove excess material In this project. Click Facing. Pressing the Enter key will apply the current settings to the selected feature. select the feature ‘Stock Profile’. Face t he top of t he par t For this facing operation. A stock allowance of 0. Be careful not to press the Enter key. you will first create a facing operation to quickly remove as much stock as possible from the top of the part. No stock allowance will remain on the floors.

click Help.• Under ‘Operation Name’. type Facing • Select the tool ‘FM 60’ for ‘Tool ID’ • Click the Strategy tab • Set ‘Overhang Direction’ to ‘One Way’ • For detailed information about this setting.5 • Set ‘Total Depth’ to 15 • Set ‘Incremental Depth’ to 8 • Set ‘Starting Depth’ to -1 86  |  Get Started with ESPRIT . • Set ‘Include Islands’ to ‘Yes’ • Set ‘Stock Allowance Walls’ to 0.

• Click the Islands tab • Click inside ‘Island Features’ and then select the island feature in the work area • Click the Links tab • Set ‘Entry Mode’ to ‘Rapid Down. Feed Over’ • Set ‘Exit Mode’ to ‘Feed Over. Rapid Up’ • Click OK Milling on a Standard Mill   |  87 .

prc • Click the Wire Frame tab • Click the arrow button next to ‘Drive Curve’ and select the drive curve feature in the work area 88  |  Get Started with ESPRIT . • Select the feature ‘Wireframe Basic Curve’ • Click Wire Frame Milling • On the drop-down menu. you will use two existing features.Create a simple 3 D milling operat ion For this operation. The ‘Wireframe Drive Curve’ defines the curved profile for the walls around the island on the face. click Open • Open the following technology file: Processes\M1-Wire_Frame_Milling. The ‘Wireframe Basic Curve’ feature is located on the top face of the island and defines the path the profile will follow.

• Notice that ‘Machine Along’ is set to ‘Basic’ so that the flow lines of the tool path will follow the shape of the basic curve • Click OK Milling on a Standard Mill   |  89 .

Rough and finish t he outer profile To cut the external profile of the part. ‘Stock Allowance Walls’ is set to 0.5 and ‘Incremental Depth’ is set the same as the diameter of the tool.5 mm stock on the walls and then finish with a 20mm end mill. Because the roughing and finishing operations use very different settings. • Click OK 90  |  Get Started with ESPRIT . you will create two separate Contouring operations.prc • Click the Strategy tab • Notice that there will be 1 rough pass and no finish pass. • Select the profile feature on the boundary of the part • Click Contouring • Open the file: M2-Contour_Rough. you will first rough the profile with a 30mm end mill that will leave 0.

1 rough pass is generated with no stock allowance • Click OK Milling on a Standard Mill   |  91 .prc • On the Strategy tab. click Contouring • Open the file: M3-Contour_Finish.• With the same feature selected.

you will first remove as much material as possible as quickly as possible with a Trochoidal Pocketing operation. A stock allowance of 0.5mm will remain on the walls and floors of the pocket. • Inside the ‘Pocket’ feature group. • For details on trochoidal tool motion. Rough t he medium pocket To mill the medium pocket. select the feature ‘Medium Pocket’ • Click Trochoidal Pocketing • Open the file: M4-Rough_Pocket.Cut the pockets and slot The part in this project contains two pockets and a slot. notice that ‘Trochoid’ tool motion is used and that the trochoid step over is set to 25% of the tool diameter when ESPRIT detects that the tool is fully engaged in the material.prc • On the Strategy tab. ESPRIT offers two types of pocketing operations that you will use to cut each pocket: Trochoidal and Traditional. click the Help button • Click OK 92  |  Get Started with ESPRIT .

Finish t he medium pocket You will use a traditional Pocketing operation to first finish the walls and then the floors of the pocket. Then the tool path changes to adjustable curves that adapt to the shape of the pocket.prc • On the Strategy tab. • Select the feature ‘Medium Pocket’ • Click Pocketing • Open the file: M5-Finish_Pocket.Notice that the tool path starts in the largest area of the pocket and spirals outward until it reaches an obstacle. notice that ‘Rough Pass’ is set to ‘No’ and both ‘Wall Finish Pass’ and ‘Floor Finish Pass’ are set to ‘Yes’ Milling on a Standard Mill   |  93 .

• Click the Wall Finish tab • A single contouring pass will be applied to the walls with a stock allowance of 0.2 mm • Click the Floor Finish tab • The floor of the pocket will be finished with a constant step over of 2.5 mm and no stock allowance 94  |  Get Started with ESPRIT .

• Click OK Milling on a Standard Mill   |  95 .• Click the Links tab • ‘Passes Order’ is set to ‘R | AW | AF’. ‘AF’ means that All Floors will be cut last. ‘AW’ means that All Walls will be cut next. This means that any roughing passes will be applied first.

Corner clearing is applied when there is only one exposed edge (corners). between a wall and an island).Remove material in t he corner s To remove any material remaining in the corners. • Click OK 96  |  Get Started with ESPRIT . • Select the feature ‘Medium Pocket’ • Click Rest Machining • Open the file: M6-Corner_Finish. notice that the tool motion for area clearing is set to ‘Concentric In’. Area clearing is applied when an area has more than one exposed edge of material (for example.prc • On the Strategy tab. you will apply a Rest Machining operation.

prc • Click OK Milling on a Standard Mill   |  97 .Rough and finish t he small pocket You will use a single pocketing operation to rough the pocket and then finish the walls using a different tool. • Select the feature ‘Small Pocket’ • Click Pocketing • Open the file: M7-Small_Pocket.

Cut t he slot To cut the slot. The tool will enter the material using a ramping move and then cut the slot with a single pass. you will use a traditional Pocketing operation using a tool with a diameter the same width as the slot. The tool will enter the slot with a long ramping pass at a 10 degree angle.prc • Click the Rough tab and notice that ‘Entry Mode’ is set to ‘Ramp Along Pass’. • Select the feature ‘Slot’ • Click Pocketing • Open the file: M8-Slot. • Click OK 98  |  Get Started with ESPRIT .

First. Then. you will drill the hole with a 30mm drill. you will create a Spiraling operation to mill the upper diameter to a depth of 30mm. For this project. You will cut this hole in two steps.prc • Click OK Milling on a Standard Mill   |  99 . including a milled hole.drill and mill t he large hole The milled hole has a diameter of 42 mm. you will create drilling and spiraling operations depending on the type and size of the hole. • Select the Hole feature for the milled hole • Click Drilling • Open the file: M9-Drill_Milled_Hole.Mill and drill the holes This part has different types of holes. Pre.

• In the ‘Pocket’ feature group.Upper’ • Click Spiraling • Open the file: M10-Spiral.prc • On the Strategy tab. • Click OK 100  |  Get Started with ESPRIT . select the feature ‘Milled Hole . The tool path will be created as arcs that are tangent to one another. notice that ‘Strategy’ is set to ‘Tangent Arcs’.

right-click on the feature ‘Counterbore’ and select File > Open Process • Open the file: M11-Counterbore.prc • Again. right-click on the feature ‘Counterbore’ and open the file: M12-Drill_Counterbore.prc Milling on a Standard Mill   |  101 .Drill t he holes • In the Feature Manager.

right-click on the feature ‘Countersink’ and open the file: M14-Drill_Countersink.• Right-click on the feature ‘Countersink’ • Open the file: M13-Countersink.prc • Again.prc • To view the settings for any of these operations. double-click on an operation to open the technology page 102  |  Get Started with ESPRIT .

click ‘Stop’ . On the Smart toolbar. click Simulation.Simulate milling operations Operations are simulated in the same order as they are listed in the Operation Manager. • Click ‘Pause’ to temporarily stop the simulation • Click ‘Run’ again to restart the simulation . • Click ‘Run’ to start the simulation . Milling on a Standard Mill   |  103 . . • When the simulation is finished.

you simulated all of them from the beginning and the simulation started with the initial stock defined in Simulation Parameters. open ESPRIT Help (press F1) and look for ‘Stock Automation’ in the index. • Click the Operations tab in the Project Manager to display the Operation Manager. • Right-click on a heading and select Advanced > Field Chooser from the menu. you can use Stock Automation. For details on what each icon means. Stock Automation also displays icons next to each operation in the Operation Manager to let you know whether the stock has been calculated. • Notice that the display in the Operation Manager changes to show the status of the stock for each milling operation. click Options.S imulate wit h Stock Automat ion When you simulated the operations. Stock Automation will start the simulation of one or more operations with the previous stock already removed. select ‘Enable Stock Automation’ and click OK. • Select ‘Stock’ and click OK. • On the Machining tab. • On the Tools menu. 104  |  Get Started with ESPRIT . But what if you want to simulate only one operation without simulating all the operations before them? In that case.

• Click Stop to exit the simulation. Milling on a Standard Mill   |  105 . • The simulation starts with the calculated stock from all previous operations.• Select any operation in the Operation Manager and click Run.

106  |  Get Started with ESPRIT .

.......... and ID of the part • Center drilling • Grooving on the OD and the ID • Finish contouring • Threading on the ID • Simulation with Stock Automation Rough and finish the groove on the OD... . ...... ......... ................... .... Saving Machining Technology. the global axis labeled “X” is the spindle axis (the Z axis).... SolidTurn Machining Technology 108 The intent of this project is to teach you the process for creating basic lathe operations using the lathe machining technology in ESPRIT....... 118 Create turning features..... ..................... 142 Thread the ID............................ .. .......131 Rough the face and the OD......................141 Groove the ID.......... .. OD.......117 Open the part file.... ....................... 116 Commands for machine-specific functions. In order for ESPRIT to accommodate both standard milling and standard turning operations...............................Turning on a Standard Lathe A standard lathe permits movement within a single plane defined by the Z and X axes—the Z axis being parallel to the stock and the X axis perpendicular..........111 Feature Extensions..... .114 Commands for part transfers....... ...... .. 144 Simulate turning operations... 140 Rough and finish the ID...................... 138 Contour the OD...137 You will learn: • About SolidTurn machining technology and machining cycles • How to create a turning tool • How to create features for turning operations • How to create lathe stock • Roughing techniques on the face...... SolidTurn Machining Cycles.............................. 118 The Tool Manager.............................. 115 In this lesson you will create machining operations to cut a part on a standard 2-axis lathe................. ......................133 Drill on the center line.... ....... ............ ... 116 Prerequisites..143 Perform the cutoff...............................121 Create lathe stock............ The global axis labeled “Y” is the lathe X axis..117 Create a turning tool................111 Feeds and Speeds......... 146 Turning on a Standard Lathe   |  107 . ........... .

This technology is called SolidTurn. The user can also click on any of the other tabs in the Project Manager to make it easier to select features or create new cutting tools.SolidTurn Machining Technology ESPRIT has machining technology that is designed specifically for lathes. The technology for SolidTurn machining cycles is displayed on a tab in the Project Manager. XX The technology for a machining cycle will not open unless a valid feature is selected first. This makes it easy to enter machining parameters and view the part model at the same time. create turning tools and lathe stock. create specialized turning features and turning operations. SolidTurn technology lets you define the physical properties of your lathe machine. and simulate turning operations with section views that let you see the simulation on the inside as well as the outside of the turning stock. The way that machining parameters are organized for all SolidTurn machining cycles is consistent to make it easy to learn and use the technology. The interface is organized in three main areas: • Toolbar area • Vertical tabs • Parameters area 108  |  Get Started with ESPRIT .

For example. The display of some tabs is controlled by a parameter setting.The Toolbar area contains commands to validate (OK) and close (Cancel) the current technology as well as a Help button to open the help file for the current technology. where you define the most general information about the cutting cycle on the General tab. if the parameter ‘Finish Passes’ on the Strategy tab is set to ‘No’. Parameters are grouped on the tabs in a “top down” approach. The icon reflects the last command used by the user. moving down each tab to add more detail about your machining operation. The drop-down button displays the context menu for the technology. the Finish tab will not display because those parameters are unnecessary for the operation. Turning on a Standard Lathe   |  109 . then move to the Strategy tab to define a bit more detail such as the cutting strategy or entry and exit moves. The vertical tabs are arranged to save space.

XX When an arrow button displays next to a parameter. a description of the error displays so that it can be corrected. If the value for a parameter is invalid or missing. you can click the arrow and select an element in the work area to load a value. the interface updates to show or hide a different set of parameters. Options that are not used are hidden. Parameters are grouped by category and each group control can be collapsed or expanded for visualization purposes. the interface updates to show only the parameters you need.The Parameters area displays the machining parameters for the current technology. As parameters are selected. an error displays next to the parameter. If the user changes a parameter. For example. 110  |  Get Started with ESPRIT . if the stock type for a roughing operation is changed from ‘Automation’ to ‘Diameter’. If you hover your mouse over the error icon. the parameter ‘Stock Diameter’ displays to let the user define the diameter.

and click Open. browse to the location where you want to save the file. Feeds and Speeds The settings for feed rates and spindle speed are set on the General tab and displayed in two columns that are interactive. For this reason.prc (process) file and used over and over for the machining of similar parts. browse to the file. Enter a name for the file. Turning on a Standard Lathe   |  111 . XX The type of technology in the file must match the machining cycle. and click Save.Saving Machining Technology Machining technology settings can be easily saved as a separate *. it is important to name the saved technology file with the type of technology in the file. it can be loaded in a technology page. To save the technology for a machining cycle. This allows you to “fine tune” your feed and speed values. click Save on the drop-down menu. the value in the next column is automatically calculated. you can only load Roughing technology into a Roughing cycle. After a technology file has been saved. For example. Click Open on the drop-down menu. If you enter a value in one column. Sp e ed You can use Speed RPM (Revolutions Per Minute) or Speed CSS (constant surface speed) to control the speed of the spindle.

and Contouring operations. The percentage value is used to reduce or increase the feed rate for any tool movement that is not parallel to the main cut direction. If you are machining a constant diameter. the system uses the following formula: PM = PR * RPM Ref erenc e Diamet er This value is used by ESPRIT to automatically calculate the spindle speed. By default. Feed rate is defined as units (inch/millimeter) per minute (PM) or per revolution (PR).When a value is entered in ‘Speed RPM’. Sp e ed Uni t Speed Unit controls whether the value for Speed RPM or Speed CSS is used. If you set Speed CSS. 112  |  Get Started with ESPRIT . PR These values are also interactive. the system takes that value and the reference diameter and calculates and displays the value for ‘Speed CSS’ (in surface feet/meters per minute). this value is set to the value of ‘Bar Diameter’ in Machine Setup. the system takes that value and the reference diameter and calculates the Speed RPM (in revolutions per minute). enter the approximate diameter at the machining location. For diameters that are not constant. Fe ed Uni t Feed Unit controls whether the value for Feedrate PM or Feedrate PR is used. To calculate the feed rate PR (per revolution) from the feed rate PM (per minute). In general terms. the system uses the following formula: PR = PM / RPM Going the other way. Transver se Fe edrat e % This setting is available only for Roughing. ‘Per Minute’ uses the value for Feedrate PM. Balanced Roughing. The system uses the following formula: RPM in Inch = (12 * CSS) / (PI * Reference Diameter) RPM in Metric = (1000 * CSS) / (PI * Reference Diameter) Fe edrat e PM . ‘Per Revolution’ uses the value for Feedrate PR. the feed rate is the speed at which the cutter moves with respect to the work material. The relationship of RPM to CSS is based on the following formula: CSS in Inch = RPM * Reference Diameter * PI / 12 CSS in Metric = RPM * Reference Diameter * PI / 1000 You can also go in the opposite direction. enter an average diameter. Tool movement in the main cut direction uses the programmed feed rate.

Before setting this option to Yes. The transverse feed rate is always calculated using the initial feed rate. This value controls the maximum revolutions per minute allowed for the spindle. For synced operations. By default. Use Fe ed and Sp e ed K B This option can be set to Yes or No. A machining operation will not be allowed to exceed this limit. The options represent different levels of spindle ranges and vary depending on your machine. Spindl e Pr ior i t y This setting is used only for multi-turret applications where two or more turning operations are synchronized. this value is the same as the ‘Max RPM’ that is defined for the spindle in Machine Setup. you must: • Have speed and feed data set up in the Speed Feeds Manager in the KnowledgeBase • Select a Speeds Feeds Standard and Material Class in KnowledgeBase Document Setup (on the Common Machining tool bar) • Select a tool in Tool Selection • Select a Type of Cut (the Type of Cut option displays only when Use Feed and Speed KB is set to Yes) Turning on a Standard Lathe   |  113 . Spindle priority can also be set on the operation page. M a ximum RPM This value is applied only when Speed Unit is set to CSS. it will be overwritten at the next slope angle change if the transverse feed rate is not 100%. When set to Yes. In general. you can specify which operation controls the spindle speed.When ‘Type of Work’ on the Strategy tab is set to ‘ID’ or ‘OD’: • Vx = F * Transverse Feedrate % • Vz = F When ‘Type of Work’ is set to ‘Face’: • Vx = F • Vz = F * Transverse Feedrate % XX If a feed rate change is inserted into the tool path manually. Spindl e Rang e This setting is used for RPM cutting. feed and speed values from the KnowledgeBase will be inserted automatically. It does not use the feed rate the user has inserted. set Spindle Range to ‘Off’ for CSS cutting. You can set spindle priority for more than one operation.

lead-in and lead-out moves are disabled.ESPRIT will combine the Speeds Feeds standard and material selected in KnowledgeBase Document Setup with the tool and technology settings on the operation page to provide acceptable cutting speeds and feed rates. The Type of Cut selected on the operation page also affects the inserted speed and feed values. In this case. However. The feature itself is not modified. A positive or negative value can be entered. There are also times when the user wants the tool to continue cutting past the end point of a feature. Options are available that let the user automatically extend the start point or end point of the selected profile feature so that machining can begin or end outside the feature. Feature Ex tensions When features are created for turning operations. you can use the Feature Extension settings to extend the profile for the canned cycle for a safe start. XX When a canned cycle is used. Entering a negative value has the same effect as making the feature shorter. The inserted speeds and feeds are affected by the “Tool Material” specified on the tool page of the same Tool ID. only the reference path for the tool path. 114  |  Get Started with ESPRIT . In ESPRIT. they are created on the profile of the finished part. A distance can be entered to extend the starting element or ending element of the feature. there is no need to modify the features to obtain the correct tool path. there are many times when the tool needs to be positioned outside the feature to avoid stock material that has not been removed yet. The start or end point is extended tangent to the feature.

Balanced Roughing performs a roughing operation about twice as fast as a normal roughing operation by using two tools mounted on separate turrets. To display the SolidTurn toolbar. or face of a part with or without a stock allowance. and part profiles with ease. SolidTurn Threading includes a thread database that allows the selection of industry-standard threads (UN. UNF.Creates a single contouring pass along a profile.Creates a threading operation.SolidTurn Machining Cycles All SolidTurn machining cycles are displayed on the SolidTurn toolbar and on the Machining menu under SolidTurn. you can create separate roughing and finishing passes. B-Axis Contouring .Creates a drilling operation aligned with the spindle axis. the part is spinning and the tool is fixed. external threads on the OD of a part. ESPRIT lets you define exactly when and where the finishing passes will be created in relation to the roughing passes. M Profile..Creates two separate roughing operations using two tools.Creates a single contouring pass that continuously rotates the tool about the B-axis while cutting. In SolidTurn Drilling.Creates a roughing operation containing roughing passes and.Creates a manual turning operation from selected points. UNC. or to cut a spiral on the face of a part. optionally. When the two tools cut simultaneously. arcs. lines. Within a single operation. the feed rate can be doubled while maintaining the same tool load. Independent rough and finish passes use separate feeds and speeds and lead-in/lead-out moves. SolidTurn Contouring creates a single pass along a selected feature in either a forward or reverse direction. a finish pass. resulting in a smoother surface. roughing patterns. Drilling . The two tools can cut simultaneously or one tool can lead and the other trail behind by a specified distance.Creates a grooving operation. Threading . the Roughing cycle supports a variety of stock shapes. Profiles that normally require a series of turning tools can be cut with just one operation. Depth of cut calculations optimize material removal during roughing and automatic safe transition movements between rough and finish cuts guard against collisions.) or user-defined threads. click ‘Switch to SolidTurn’ on the Smart toolbar and then click SolidTurn. Grooving . Within a single operation. ID. Balanced Roughing . Contouring .. The B-axis can be mounted on the turret or on the spindle. Manual Turning . A threading operation is used to create internal threads on the ID of a part. Turning on a Standard Lathe   |  115 .. Several types of drilling cycles are supported. each on a different turret. UNR. or features. Roughing . Contouring passes can be created on the OD. When roughing and finishing passes are combined. including canned cycles.

Bar Feed .Creates a steady rest operation from manually selected points to support long or heavy stock. A bar feed can be performed using another spindle or a stock stop tool. Tailstock can be mounted independently on the machine or mounted on a turret. Commands for machine .Creates a tailstock operation to support long stock. Tailstock . Steady Rest .Creates a bar feed or stock repositioning operation. Tailstock properties are defined in SolidTurn Machine Setup.Creates a cutoff operation to separate a machined part from the stock so that it can be removed from the machine or transferred to a sub-spindle for additional processing.Commands for par t transfers Four commands are available that let you remove the finished part from the machine or transfer the part to another spindle for additional machining.specif ic functions Two commands let you control components added to your machine. the same spindle and reference location must be used. When a Release operation is performed after a Pickup. The Steady Rest operation controls the movement of the steady rest as well as the opening and closing of the clamps. A steady rest can be mounted independently on the machine or mounted on a turret. 116  |  Get Started with ESPRIT . Pickup . A bar feed can be performed at the beginning or end of operations. Release . and stops.Creates an operation to pick up a part using either the turret spindle or a sub-spindle. Cutoff . Steady rest properties are defined in SolidTurn Machine Setup.Creates an operation to release a part. dwells. A Pickup operation is typically performed before a Cutoff operation to prevent the part from dropping after it is separated from the stock.

All dimensions in this lesson are in millimeters. If you would like to review and simulate the machining operations from this lesson.Prerequisites The files for this lesson are available on the ESPRIT DVD in the ‘Get Started’ folder. Click Open. the completed ESPRIT file is available in the folder “completed_parts”. The files are also available for download from ESPRITWeb » File Library » ESPRIT 20XX. press F2. If the Project Manager is not displayed.esp. Turning on a Standard Lathe   |  117 . click Open. Open the part file On the Standard toolbar. Browse and select the following file: turned_part. Make sure “System Unit” on the Tools menu is set to “Metric”.

The user can choose which columns to display using the Field Chooser. You will learn how to create a grooving insert that will be used to cut the groove on the OD of the part. the tool is unmounted from its current location. Turning tools can be created from the Tool Manager or from commands on the Turning Tools toolbar. When a tool is created in the Tool Manager.Create a turning tool This file already contains several tools for turning and drilling. The Tool Manager displays all the available tools in the current document. edit. Tools are grouped by turret. The Tool Manager lets you create. 118  |  Get Started with ESPRIT . rightclick on the tool and select Copy To or Move To. SolidTurn users can create both milling tools (for drilling and mill-turn work) and turning tools. and delete tools. rename. you can select the tool station where you want to mount the tool before the tool is created. The Tool Manager All cutting tools are managed on the Tools tab of the Project Manager. Tools can also be unmounted or moved from one turret to another. To move or copy a tool. If you choose Unassigned. You can also transfer tools between the Tool Manager and the KnowledgeBase. Right-click on any column heading and then select Field Chooser to view a list of options. copy.

click the Tools tab.Create a groove tool In the Project Manager. Right-click on Station 6 and click New > Turning Tools > Grooving Insert. Use the Tab key to move to the following settings and set the values: • Shape = Groove • Nose Angle (NA) = 90 • Nose Radius (NR) = 1 • Thickness = 4 • Width (W) = 4 • Size (S) = 4 • E = 40 • Hand = Right Turning on a Standard Lathe   |  119 .

Y. 120  |  Get Started with ESPRIT . 0. Z. • Holder Type = Grooving • Style = AS Side Mount • Shank AxB = 20 . Z’ is set to ‘Home’. 10. Y’ to -30. Set ‘Tool Shift X.Click the Holder tab.20.00 • Clamp Style = S Screw • Hand of Tool = Right Enter the following dimensions for the holder: • A = 20 • B = 20 • C = 90 • D = 40 • E = 50 • F = 20 Click the General tab. • Tool ID = Groove W4 • Tool Number = 1 • Orientation = 3V Make sure each setting for ‘Movement X. Click OK to create the new tool in Station 6.00 x 20.

the entire solid model highlights. Turning on a Standard Lathe   |  121 . or STL model to find internal and external profiles. The Turning Profiles command analyzes the shape of a selected solid model. Create turning profiles on t he front face and back face You will start by creating turned profiles from selected faces on the solid model. For simple 2-axis work. When the face highlights. make sure HI mode and SUB-ELEMENTS mode are active. you only need to create chain features on the inner and outer part profiles. In this project. The calculated profile can be created as a chain feature or as individual geometric elements. Use HI mode to select the front face of the part (when you first click on the part. ESPRIT rotates the part around the x-axis to find the OD profile. The Turning Profiles command lets you select solid models or solid faces. Set the view to ‘Front Isometric’.Create turning features Standard turning operations use chain features and PTOPs to define the cutter path. For multiple-axis work. Right-click to select the next available element. On the Smart toolbar. ID profile or projections of the front face or back face. Click Turning Profiles. surface. click the left mouse button to confirm the selection). click Create Features. you will use the Turning Profiles command to create features for turning operations. you must create chain features on the upper and lower sides of the part profile because they correspond to upper and lower turrets. In the status area.

Set ‘Profile Type’ to ‘Front Face’.
Set ‘Create’ to ‘Feature’.
Set ‘Profile Location’ to ‘Top’.
Click OK.

Set the view to ‘Back Isometric’.
Again, click Turning Profiles.
Use HI mode to select the back face.
Set ‘Profile Type’ to ‘Back Face’ and click OK.

122  |  Get Started with ESPRIT

Rename t he features
It is helpful to give descriptive names to features. This makes it easier to select the correct
feature when you want to apply a machining operation and it is extremely helpful to other users
if they need to modify operations at a later time.
• Click the Features tab in the Project Manager
• Right-click on ‘1 Chain’ and select Rename
• Rename the feature ‘Front Face’ and press Enter
• In the same way, rename ‘2 Chain’ to ‘Back Face’

Turning on a Standard Lathe   |  123

Create a profile on t he OD groove
This time you will create a profile of geometry so that you can create several chain features from
the same geometry.
• Click Turning Profiles
• Select the solid model
• Set ‘Profile Type’ to ‘Full (solids only)’
• Set ‘Create’ to ‘Geometry’
• Click OK

On the View menu, click Masks to display the Masks dialog.
Select ‘Solid’ to remove the check mark and close the dialog.

124  |  Get Started with ESPRIT

Cycle Stop must be used to end the selection process). 1 2 3 Turning on a Standard Lathe   |  125 . Click Cycle Stop (when a chain is created with an open shape. Select end point (1) as the starting element. not the midpoint). Rename ‘3 Chain’ to ‘OD Groove’.Change the view to ‘Top’ and zoom the view so that you can select the elements that form the groove on the OD. Select end point (3) as the ending element. Select segment (2) as the next element in the chain (be careful to select the segment. Click Auto Chain.

Select midpoint (3) to end the chain in the middle of the segment. Click Cycle Stop . 1 2 3 126  |  Get Started with ESPRIT . Select end point (1). Rename ‘4 Chain’ to ‘OD Undercut’. Select segment (2) to the left of the end point.Create a profile on t he undercut area Click Auto Chain .

• Click Manual Chain • Select end point (1) • Select the end point on the other side of the groove (2) • Click Auto Chain • Select the segment shown (3) • Select the end point on the front face (4) Feature selection reverts back to Manual Chain because the start point. direction. and end point for Auto Chain have been defined.Create a contouring profile You will create this chain feature using a combination of the Manual Chain and Auto Chain commands. • Click Cycle Stop • Rename ‘5 Chain’ to ‘OD Finish’ 1 2 3 4 Turning on a Standard Lathe   |  127 . This profile will go over the groove on the OD. since the groove and the OD will be cut with different machining operations.

128  |  Get Started with ESPRIT . Click Turning Profiles . Set ‘Profile Type’ to ‘OD’. Set ‘Create’ to ‘Feature’ and click OK. Rename ‘6 Chain’ to ‘OD Rough’.Create a roughing profile on t he OD Press Ctrl+M and select ‘Solid’ to show the solid model again. Select the solid model.

• Mask the display of the solid. You do not need the solid model for the rest of the lesson • Click Manual PTOP • Select the point at the origin • Click Cycle Stop Turning on a Standard Lathe   |  129 .Create a drilling feature You will create a PTOP feature for the drilled hole on the front face of the part.

When the geometry is selected first. you do not need to click Cycle Stop. the geometry that defines the chain can be selected before or after the command is run.Create profiles on t he ID When the Auto Chain command is used. • Select all the geometry of the ID groove and click Auto Chain • Rename the chain ‘ID Groove’ • Select all the geometry at the front of the ID and click Auto Chain • Rename the chain ‘ID Rough and Finish’ • Use HI mode to select the line segment beneath the ID chain and click Auto Chain • Rename the chain ‘ID Thread’ 130  |  Get Started with ESPRIT . The chain is created automatically.

or as a casting. The current operation calculates the stock material based on any previous turning operations or the initial stock defined in Machine Setup or Simulation. That knowledge can then be used to calculate the stock for any subsequent turning operations. a tube. • Press Ctrl+M to display the Masks dialog • Click the Details tab • Select ‘Lathe Stock’ and close the dialog Turning on a Standard Lathe   |  131 . The stock model in SolidTurn Machine Setup can be defined as a solid bar.Create lathe stock A solid stock model can be created for automatic calculation of the stock as turning operations are created and for simulation purposes. Display t he lat he stock Lathe Stock Automation maintains awareness of the state of lathe stock at any moment during the machining process. After any turning operation is created. The visibility of the lathe stock on the screen is controlled through the Masks dialog. ESPRIT updates the knowledge of the stock. Stock models for turning operations can be created in Simulation Parameters or defined in Machine Setup.

Click Machine Setup.Define t he bar stock in Machine Setup You can see that the diameter of the default stock is too small. On the Smart toolbar. The length of the bar stock and the part stock are the same. You will define the stock in Machine Setup as a solid bar with a diameter of 60 mm. • Set ‘Stock Type’ to ‘Bar’ • Set ‘Bar Diameter’ to 60 • Set ‘Total Bar Length’ to 81 • Set ‘Part Stock Length’ to 81 • Click OK 132  |  Get Started with ESPRIT . click Common Machining.

click SolidTurn. click Open • Open the following technology file: Processes\T1-Face_Rough.prc Turning on a Standard Lathe   |  133 . You will use two roughing operations on the OD: the first to rough the profile and the second to remove material in the undercut area. select ‘Front Face’. On the Smart toolbar. Click Roughing. Rough t he face In the Feature Manager. • On the drop-down menu.Rough the face and the OD You will start by removing the excess material on the front face and the OD of the part.

For detailed information on all the settings for Roughing. Notice that ‘Type of Work’ is set to ‘Face’ and that ‘Finish Pass’ is set to ‘No’.Click the Strategy tab. Also notice that feature extensions are added to the feature so that the tool starts outside the bar stock and ends at the center line. click Help. Click the Rough tab. Notice that Stock Type is set to Automation to allow the system to automatically calculate the stock for you. Only rough passes will be generated. Under ‘Passes’ you can see that this operation uses a constant depth of cut of 2 mm. 134  |  Get Started with ESPRIT .

prc. On the Rough tab. The OD Rough operation uses the same roughing tool as the Face Rough operation. Notice that the lathe stock is automatically updated. the stock is updated so that the next operation will not create cutting passes in areas where material has already been removed.Click OK. ‘Type of Work’ is now set to OD. open the file: T2-OD_Rough. click Open. On the drop-down menu. Each time an operation is applied. Turning on a Standard Lathe   |  135 . Click OK. Rough t he OD Select the feature ‘OD Rough’ and click Roughing . Depth Variation is now set to ‘Even Steps’ instead of a constant depth of cut. In the same Processes folder.

136  |  Get Started with ESPRIT .Rough t he undercut area on t he OD Select the feature ‘OD Undercut’ and click Roughing . notice that ‘Undercutting Mode’ is set to ‘Below’.5 mm is used for this operation. a constant depth of cut of 0. On the Rough tab. On the Strategy tab. Open the file: T3-OD_Rough_Undercut. Any undercut areas in front of the tool will be ignored. ESPRIT will recognize and cut any undercut areas located below the tool.prc. Click OK.

Click OK.prc. Turning on a Standard Lathe   |  137 . Open the file: T4-Center_Drill.Drill on the center line Select the PTOP feature and click Drilling. This is a standard drilling cycle that uses a 21 mm drill to a depth of 52 mm.

prc. click Help. For more information on these settings.Rough and finish the groove on the OD Select the feature ‘OD Groove’ and click Grooving. On the Strategy tab. the groove will be cut with multiple plunge moves using the ‘Smart’ step over mode. notice that a rough pass and a finish pass will be created in the same operation. 138  |  Get Started with ESPRIT . On the Rough tab. Open the file: T5-OD_Groove.

the ‘Finish Mode’ will create 2 finish passes.On the Finish tab. Click OK. starting at each side of the groove and retracting at the middle. Turning on a Standard Lathe   |  139 .

140  |  Get Started with ESPRIT . Open the file: T6-OD_Finish.Contour the OD Select the feature ‘OD Finish’ and click Contouring. The OD of the part is now complete and you are ready to start working on the ID. Click OK.prc.

On the Strategy tab. you created only roughing passes. the rough passes are created as even steps with a maximum depth of 2 mm. On the Rough tab. On the Finish tab. Click OK.prc. Now you will create a single roughing operation that includes roughing passes followed by a single finishing pass.Rough and finish the ID When you roughed the OD of the part. Select the feature ‘ID Rough and Finish’ and click Roughing . Turning on a Standard Lathe   |  141 . The same tool is used for all cutting passes. the feeds and speeds and the lead-in/lead-out are different for the finish pass. ‘Type of Work’ is now set to ‘ID’ and the Finish tab displays because ‘Finish Pass’ is set to ‘Yes’. Open the file: T7-ID_RoughFinish.

142  |  Get Started with ESPRIT .prc’ and click Open. Select the file ‘T8-ID_Groove.Groove the ID This operation is almost the same as the OD grooving operation except that the grooving tool for the ID uses a round insert and the approach/exit moves have been changed to cut on the ID. Right-click on the feature ‘ID Groove’ and click File > Open Process.

‘Thread Definition’ is set to ‘From Profile’ so that the threads will follow the selected chain feature. The system automatically gets the ‘Major Diameter’ of the ID thread from the location of the feature. Turning on a Standard Lathe   |  143 . Click OK. the thread parameters are imported from a database. When ‘Thread Definition’ is set to ‘From Database’.Thread the ID Select the feature ‘ID Thread’ and click Threading. On the Thread tab. Open the file: T9-ID_Thread.

On the drop-down menu. click ‘System Default All’ to set all the parameters to the system defaults.Perform the cutoff Select the feature ‘Back Face’ and click Cutoff. • Type Cutoff in ‘Operation Name’ • Set ‘Tool’ to ‘Cutoff Tool’ • Set ‘Speed RPM’ to 1910 and press the Tab key to update the CSS speed • Set ‘Feedrate PM’ to 191 and press the Tab key to update the PR feed rate 144  |  Get Started with ESPRIT .

Click the Strategy tab. • Set ‘Entry Mode’ to ‘X Only’ and then enter a value of 30 for the X movement (you are not allowed to enter a value for Z) • Set ‘Exit Mode’ to ‘X Only’ and also set the X value to 30 Click the Rough tab. Turning on a Standard Lathe   |  145 . • Set Stock ‘Type’ to ‘Automation’ • Set ‘Rough to Diameter’ to -1 so that the tool will cut slightly below the center line Click OK.

• Click ‘Run’ to start the simulation . Operations are simulated in the same order as they are listed in the Operation Manager. On the Smart toolbar. You can now simulate the complete movement of the operations. 146  |  Get Started with ESPRIT . including spindles and turrets. • Click ‘Pause’ to temporarily stop the simulation . . click ‘Stop’ . • Click ‘3/4 Section’ so that you can see the simulation on the inside of the stock • Click ‘Run’ again to restart the simulation . the part and the machine to see how the operations you just created work together. are already defined in Machine Setup. • When the simulation is finished. click Simulation.Simulate turning operations The details of the machine.

S imulate wit h Stock Automat ion When you simulated the operations. • Select ‘Stock’ and click OK. Turning on a Standard Lathe   |  147 . But what if you want to simulate only one operation without simulating all the operations before them? In that case. • Click the Operations tab in the Project Manager to display the Operation Manager. XX Stock Automation is different than Lathe Stock Automation because it only affects the display of the stock when turning operations are simulated. Stock Automation will start the simulation of one or more operations with the previous stock already removed. you can use Stock Automation. you simulated all of them from the beginning and the simulation started with the initial bar stock defined in Machine Setup. Stock Automation also displays icons next to each operation in the Operation Manager to let you know whether the stock has been calculated. • Right-click on a heading and select Advanced > Field Chooser from the menu.

• On the Tools menu. • Select any operation in the Operation Manager and click Run. click Options. For details on what each icon means. select ‘Enable Stock Automation’ and click OK. • Click Stop to exit the simulation. open ESPRIT Help (press F1) and look for ‘Stock Automation’ in the index. • On the Machining tab. 148  |  Get Started with ESPRIT . • The simulation starts with the calculated stock from all previous operations. • Notice that the display in the Operation Manager changes to show the status of the stock for each turning operation.

.. . ..... ....... ...... .. ................. ............ ....... Machining strategies for dies and punches..... ...................... ....166 Contour the group of holes. ..................................154 EDM Machine Types............. 161 Create a stock model....174 You will learn: • About SolidWire Gold machining technology and machining cycles • How to create features for wire EDM operations • How to create a stock model • Techniques to quickly contour a group of features • Advanced sorting of EDM operations • Simulation with slug removal Simulate wire EDM operations ... ........ .160 Set the EDM Machine Type............ . 156 Cut strategies for lands and tapers 157 SolidWire Gold Machining Cycles 159 Prerequisites......176 Burning on a 2-axis Wire EDM   |  149 ...169 Contour the die openings.......Burning on a 2-axis Wire EDM ESPRIT offers a complete tool set for a range of wire EDM machines.. This gives you full control over the advanced features and unique functionality of the leading machines on the market.......... 161 Create EDM features.160 Open the part file......171 Sort EDM operations............ The unique cutting technology and methodologies for each manufacturer are integrated into specialized technology pages. 155 Cutting planes....................... 155 The intent of this project is to teach you the process for creating 2-axis wire EDM (Electrical Discharge Machine) operations using the standard wire EDM technology in ESPRIT........ SolidWire Machining Technology 150 Saving Machining Technology...............

XX The technology for a machining cycle will not open unless a valid feature is selected first. The interface is organized in three main areas: • Toolbar area • Vertical tabs • Parameters area 150  |  Get Started with ESPRIT . The way that machining parameters are organized for all SolidWire machining cycles is consistent to make it easy to learn and use the technology. SolidWire technology lets you define the physical properties of your wire EDM. create specialized EDM features with automatic feature recognition. create stock models. This technology is called SolidWire.SolidWire Machining Technology ESPRIT has machining technology that is designed specifically for 2-axis through 5-axis wire EDM. The user can also click on any of the other tabs in the Project Manager to make it easier to select features. This makes it easy to enter machining parameters and view the part model at the same time. create wire EDM operations. including machines equipped with a rotary axis. and perform simulations with either automatic or manual slug removal. The technology for SolidWire machining cycles is displayed on a tab in the Project Manager.

The Toolbar area contains commands to validate (OK) and close (Cancel) the current technology as well as a Help button to open the help file for the current technology. taper information. • The Cut Data tab contains the machining parameters for the primary and land cuts • The Approaches tab contains the parameters that affect the way the wire moves in and out of the part and between skim cuts • The Advanced tab contains the parameters that give the user more control over the wire path. All EDM machine types use the same interface to group machining parameters in a consistent way. information about the workpiece. such as optimized wire path. The vertical tabs are arranged to save space. The drop-down button displays the context menu for the technology. the machining strategy. and control over machine functions Burning on a 2-axis Wire EDM   |  151 . and a comment area. The icon reflects the last command used by the user. • The General tab contains all the general information about the operation such as the operation name. cut-off moves.

Parameters are grouped by category and each group control can be collapsed or expanded for visualization purposes. To make the selection of parameters easier. 152  |  Get Started with ESPRIT .The Parameters area displays the machining parameters for the current technology. if the selected feature has a land depth. the interface shows the user only what is needed based on the current input. the ‘Land Cut’ parameters display on the Cut Data tab. For example.

you can click the arrow and select an element in the work area to load a value. When an arrow button displays next to a parameter. Burning on a 2-axis Wire EDM   |  153 .If the feature has taper only. the ‘Land Cut’ settings are hidden.

Enter a name for the file. If you hover your mouse over the error icon. an error displays next to the parameter. browse to the file. it is important to name the saved technology file with the type of technology in the file. To save the technology for a machining cycle. click Save on the drop-down menu. you can only load Pocketing technology into a Pocketing cycle. browse to the location where you want to save the file.prc (process) file and used over and over for the machining of similar parts. XX The type of technology in the file must match the machining cycle.If the value for a parameter is invalid or missing. After a technology file has been saved. 154  |  Get Started with ESPRIT . and click Open. For example. Saving Machining Technology Machining technology settings can be easily saved as a separate *. a description of the error displays so that it can be corrected. Click ‘Open’ on the drop-down menu. it can be loaded in a technology page. and click Save. For this reason.

especially important when you are cutting multiple work pieces or work pieces that require multiple cuts. Burning on a 2-axis Wire EDM   |  155 . The machine type you choose determines the options that are available on the operation technology pages. select ‘Generic’. and possibly a skim cut for each cut-off. ESPRIT offers a collection of machining strategies that provide a quick and easy mechanism to generate highly efficient machining.EDM Machine Types Before you create SolidWire operations. All existing operations must be deleted before the user is allowed to change the machine type. A dialog displays all the machine types available in ESPRIT. you must first select the type of EDM you are using. the machine type cannot be changed. XX After machining operations are created. each cutoff. Machining strategies for dies and punches A single EDM operation generates a separate operation for the rough cut. each skim cut. If your machine type is not shown on the list. The EDM machine type is selected from the Tools menu.

then all skim cuts for each feature. These plane heights are automatically loaded from the feature properties. then all cut-offs. • [Rough][Cut-off][Skim]: This strategy is generally used when the thread point and retract are inside the feature (a die). If a chain feature is selected as input. For this reason. 156  |  Get Started with ESPRIT . The following strategies are available: • [Rough][Skim]: The rough cut for each selected feature is performed first. the cut-off distance is applied to the rough cut and no retract takes place. then all skim cuts. these properties are contained in the feature and are loaded automatically in the technology page. it is recommended to use EDM features. the Z-axis position of the feature is used for the location of the work piece bottom and the user must enter the other values. The rough cut for each feature is performed first. then all skim cuts for each feature. Cut ting planes Parameters that control the heights of cutting planes are shown on the General tab. then the cut-off.The ‘Strategy’ parameter lets you choose the order in which these cutting passes are created. If an EDM feature is selected as input.The rough cut for each selected feature is performed first. The cut-off strategy can insert a stop or optional stop code before the cut-off move for parts that are run unattended. If a cut-off strategy is selected. • [Rough][Skim][Cut-off]: This strategy is generally used when the thread point and retract are outside the feature (a punch).

Burning on a 2-axis Wire EDM   |  157 . XX Although a rough cut is included in each strategy. When a feature contains both a taper and a land.• Workpiece Thickness is the total thickness of the workpiece • Reference Plane is the distance from the work table to where you are holding size for a taper cut. you can use the ‘Suppress Rough’ parameter to output only skim cuts. The Expert System is a database that lets you view and choose cutting data before it is inserted on a SolidWire technology page. a rough pass and skim cuts. or skim cuts only. The taper is taken from this position. The Expert System is launched from a button located on the contouring and pocketing technology pages. ESPRIT also provides the SolidWire Expert System for several types of machines. Up to 9 skim cuts can be created after the rough cut. Land cuts cannot be created when this value is equal to the work piece bottom or the calculated top of the work piece (work piece bottom + work piece thickness). separate strategies can be defined for each type of cut. • Workpiece Bottom is the Z location at the bottom of the workpiece Cut strategies for lands and tapers The user can choose to create a rough pass only.

The Expert System has two sets of data: a default (Master) database and a User Custom Database. 158  |  Get Started with ESPRIT . XX Charmilles machines use their own CT-Expert System provided by AgieCharmilles. The User Custom Database contains data that is set up by the user. You can select data from either database. The Default Database contains manufacturerrecommended data that cannot be changed. Press F1 to display the Help window and look for ‘Expert System’ in the index. Details about how to set up and use data in the Expert System are provided in ESPRIT Help.

EDM Drilling is a simple routine that allows the input of a PTOP feature or a single point to define the locations where holes will be drilled.This versatile machining cycle supports any number of straight or tapered rough and skim cuts. Part Setup also defines the initial position of the wire. Part Setup .Creates a 2-axis wire EDM contouring operation using any combination of rapid or feed moves along manually selected geometric elements. Part Setup controls which codes are output when SolidWire operations are converted to NC code. if the group of sub-elements includes isometric corners. you must use the Taper Change command to insert the taper.Creates a 2-axis wire EDM pocketing operation that uses concentric cutting passes to gradually remove all the material inside a cavity from the inside out.This machining cycle follows a series of points to drill holes in forward or reverse order at the depth and number of repetitions you specify. However. and unattended machining are included.Sorts a group of SolidWire operations according to user-defined criteria. Manual EDMing .Part setup is the first step for every machining process.SolidWire Gold Machining Cycles All SolidWire Gold machining cycles are displayed on the SolidWire Gold toolbar and on the Machining menu under SolidWire Gold. Advanced Operation Sorting . EDM Drilling . Taper Change . die. When the size of the work piece makes it difficult to handle slugs efficiently. It is easier to apply a constant taper using the Property Browser. Contouring . Burning on a 2-axis Wire EDM   |  159 . This command offers a range of automatic sorting options to help optimize machining time. click ‘Switch to SolidWire’ on the Smart toolbar and then click SolidWire.This command simplifies the process of inserting a gradual taper between selected sub-elements in a draft conic feature. Between cuts ESPRIT automatically handles all the necessary wire-cut and wire-thread instructions. Strategies for all styles of EDM machining such as punch. Pocketing . Simply select one or more sub-elements in a draft conic feature and change the Draft property. multi-cavity parts. To display the toolbar. this no-core pocket machining cycle erodes away all the material inside a cavity without creating a slug.

click Open. the completed ESPRIT file is available in the folder “completed_parts”. All dimensions in this lesson are in millimeters. press F2. Browse and select the following file: wire_part. 160  |  Get Started with ESPRIT .Prerequisites The files for this lesson are available on the ESPRIT DVD in the ‘Get Started’ folder.esp. Open the part file On the Standard toolbar. Make sure “System Unit” on the Tools menu is set to “Metric”. If the Project Manager is not displayed. If you would like to review and simulate the machining operations from this lesson. The files are also available for download from ESPRITWeb » File Library » ESPRIT 20XX. Set the view to ‘Isometric’.

Set the EDM Machine Type For this lesson. • Make sure Generic is selected and click OK. Create EDM features When you have a large number of shapes to cut. You will also automatically place the new features into a feature group. Create a group of hole features You will use Draft Feature Recognition to create the hole features. The current work plane serves two purposes: • The W-axis of the current work plane defines what is vertical • The origin of the current work plane defines Z=0 for the feature. the orientation of the feature is based on the current work plane.. Set t he work plane When an EDM feature is created. click EDM Machine Types.. The height of the UV and XY planes are measured from the origin of the plane. you can save time by creating features as a group and then applying a machining cycle to all of them at once. you can create all the features at once using the face propagation capabilities in ESPRIT. Instead of creating features one at a time. • On the Tools menu. you will use the technology for a generic machine. For this lesson. Draft Feature Recognition will automatically recognize any holes in a solid model and create specialized features with the thread point automatically placed at the center of each hole. make sure the current work plane is set to XYZ. click Features. Click Draft Features. You will create draft conic features for the die openings and the holes. On the Smart toolbar. Select the solid model. Burning on a 2-axis Wire EDM   |  161 .

• Set ‘Part Type’ to ‘Hole’
• Click the selection arrow next to Maximum Diameter
• Select an edge of one of the holes to automatically load the value on the technology page

162  |  Get Started with ESPRIT

• Click the Rules tab
• Set ‘Group to Folder’ to ‘Yes’
• Click OK
XX Full descriptions of the draft feature dialog settings are available in ESPRIT Help.

The Feature Recognition Report dialog displays a message that the positions of the thread points
was calculated by ESPRIT. The display of this dialog is controlled on the Rules page with the
‘Display Error Messages’ setting.

Burning on a 2-axis Wire EDM   |  163

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

Create a group of die features
Next you will create a group of die features.
For these features, you will select the thread points instead of letting Draft Feature Recognition
calculate them for you.
• Set the Selection Filter to ‘Point’
• Change the view to ‘Top’
• Draw a selection box around all the points
• Set the Selection Filter back to ‘All’

164  |  Get Started with ESPRIT

• Hold down the Ctrl key and select the solid model. • Click Draft Features • Click the ‘Draft Feature Properties’ tab • Set ‘Part Type’ to ‘Die’ • Set ‘Approach Type’ to ‘Normal’ • Click the Rules tab • Set ‘Group to Folder’ to ‘Yes’ • Click OK • Set the view back to ‘Isometric’ Burning on a 2-axis Wire EDM   |  165 .

and from points that define a block. you will hold down the Shift key during the selection process. from a feature. Stock models can be defined in a variety of ways: from an existing solid model.Create a stock model Stock models for wire EDM operations are created in Simulation Parameters on the Simulation toolbar. from an external file. Stock models are created as solid models that aid in the visualization of material removal during the simulation process. You will create the stock model by creating a chain feature on the outer profile of the part and then use the Simulation Parameter command to extrude that profile. • Hold down the Shift key and select a segment in the outer profile • Click Auto Chain 166  |  Get Started with ESPRIT . To automatically select all the connected segments that form the profile of the part.

On the Smart toolbar. • Click the Solids tab • Set ‘Type’ to ‘Stock’ and set ‘Create From’ to ‘Extrusion’ • Click the arrow button and select the chain feature in the work area • Set ‘Z+’ to 0 • Set ‘Z-’ to 20 Burning on a 2-axis Wire EDM   |  167 . click Simulation. Click Simulation Parameters.

• Click Add • Click OK • To view the new stock model. click Single Step • Click Stop to exit simulation mode 168  |  Get Started with ESPRIT .

select the ‘Hole Group’ folder. you only need to define a few machining parameters. On the Smart toolbar. In the Feature Manager.Contour the group of holes First you will create a single contouring operation and apply that operation to all the holes. Since most of the machining information is extracted directly from the selected features. click SolidWire. Click Contouring. • Make sure ‘Strategy’ is set to [Rough][Skim] • Click the Cut Data tab • set ‘Strategy’ to ‘Rough and 1 Skim’ • Click OK Burning on a 2-axis Wire EDM   |  169 .

if any of those settings are updated later in the parent operation. You can also treat the child operations as independent operations by changing some of the technology settings. However. If you change the parent operation. the parent will override the children.Notice that a Contour operation is created for the entire group (the ‘parent’ operation) and an individual Contour operation is created for each feature in the group (the ‘child’ operations). Each child operation has the exact same technology settings as the parent operation. the child operations will be updated automatically. 170  |  Get Started with ESPRIT .

Then you will create a Contouring operation for the triangular opening.Contour the die openings You will again create a Contouring operation to cut all the rectangular openings. To make it easier to apply a single operation to all the rectangular die openings. • Open the folder for the ‘Die Group’ • Click on each feature until the feature for the triangular opening is highlighted in the work area • Drag the feature to the ‘XYZ’ coordinate to move it outside the group Burning on a 2-axis Wire EDM   |  171 . you can move the feature for the triangular die opening out of the feature group.

• Select the ‘Die Group’ folder • Click Contouring • Make sure ‘Strategy’ is set to [Rough][Skim] • Click the Cut Data tab • Set ‘Strategy’ for the primary cut to ‘Rough’ • Set ‘Strategy’ for the land cut to ‘Rough and 2 Skims’ • Click OK 172  |  Get Started with ESPRIT .

• Select the ‘Die’ feature for the triangular opening • Click Contouring • Click the Cut Data tab • Set ‘Strategy’ to ‘Rough and 1 Skim’ • Click OK Burning on a 2-axis Wire EDM   |  173 .

The Advanced Operation Sorting command gives you plenty of options for sorting operations to optimize cutting time. You will use Advanced Operation Sorting to sort the operations by type of cut so that all the roughs are performed first. This is typically not the optimum order in which you will want to cut the final part. ESPRIT offers several methods for sorting SolidWire operations in the Operation Manager. • Click the Operations tab in the Project Manager. Then you will practice optimizing the cutting path using different optimization methods. You can sort operations by type of cut or by cavity and then optimize the cutting path between operations. • Right-click in the heading area and select Field Chooser • Select ‘Cutting Cycle’ to display the type of cycle in the Operation Manager • Close the dialog 174  |  Get Started with ESPRIT . The operations you created in this project are currently sorted by feature.Sort EDM operations SolidWire operations are added to the Operation Manager in the same order as they are created. • Manually sort operations by dragging them to a new location in the operations list • Automatically sort operations based on the available fields in the Operation Manager (right-click in the Operation Manager and click Advanced > Sorting) • Automatically sort operations based on user-defined criteria in Advanced Operation Sorting. Advanced Operation Sorting offers the advantage of optimizing the wire path in addition to sorting operations by type.

• Click Advanced Operation Sorting • Set ‘Sort By’ to [Rough][Cut-Off][Skim] • Set ‘Routine’ to ‘Shortest Path’ • Click the selection arrow and select the lower left feature • Click Apply to see the results • Set ‘Routine’ to ‘Zigzag’ • Set ‘Zigzag Type’ to ‘Horizontal’ • Set ‘Band Width’ to 10 • Click Apply to see the results • Click OK Burning on a 2-axis Wire EDM   |  175 .

• Click Simulation Parameters • Uncheck ‘Automatic Slug Removal’ and click OK 176  |  Get Started with ESPRIT . For this project. On the Smart toolbar. you will manually remove the slugs. click Simulation. you have the option to display the removal of the slugs automatically while the operations simulate or you can wait until the simulation is complete and then simulate the removal of the slugs manually.Simulate wire EDM operations When SolidWire operations are simulated.

• Click ‘Slug Removal’ • Select different stock items in the list and click ‘Move Down’ or ‘Move Up’ (ESPRIT will prevent you from moving the tapered stock above the block because this is not possible) • Click ‘Stop’ to exit simulation mode Burning on a 2-axis Wire EDM   |  177 .• Click ‘Run’ to simulate all the operations .

178  |  Get Started with ESPRIT .