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Get Started with

ESPRIT
Get Started with ESPRIT
Copyright © 2012 DP Technology Corp. All rights reserved.
Information is subject to change without notice.
No part of this manual may be reproduced, transmitted, translated in any form or by any
means, graphic, electronic, or mechanical, including photocopying, recording, taping, or by any
information storage or retrieval system, without written permission from DP Technology Corp.
The software described in this document may only be used or copied in accordance with the
terms of the furnished license agreement and/or non-disclosure agreement. It is illegal to copy the
software onto any medium except as specified in the license or non-disclosure agreement.
All DP Technology 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
Create a stock model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Remove excess material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Cut the pockets and slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Mill and drill the holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Simulate milling operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Turning on a Standard Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
SolidTurn Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
SolidTurn Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Create a turning tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Create turning features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Create lathe stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Rough the face and the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Drill on the center line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Rough and finish the groove on the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Contour the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Rough and finish the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Groove the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Thread the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Perform the cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Simulate turning operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Burning on a 2-axis Wire EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
SolidWire Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
SolidWire Gold Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Set the EDM Machine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Create EDM features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Create a stock model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Contour the group of holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Contour the die openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Sort EDM operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Simulate wire EDM operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Welcome to ESPRIT

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

Welcome to ESPRIT   |  1
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 DP China


1150 Avenida Acaso Sun Building
Camarillo, CA 93012 3553 North Zhong Shan Road, Room 1714-5
USA Putuo District
Tel: +1 805 388 6000 Shanghai 200062
Fax: +1 805 388 3085 China PRC
dptechnology.com Tel: +86 21 3133 5575
Fax: +86 21 5868 2803
Midwest USA
dptechnology.cn
10275 West Higgins Road
Suite 420 DP Europ e
Rosemont, IL 60018 MIBI, 672 rue du Mas de Verchant
USA 34000 Montpellier
Tel: +1 847 297 8100 France
Fax: +1 847 297 8107 Tel: +33 (0)4 67 64 99 40
dptechnology.com Fax: +33 (0)4 67 64 99 41
dptechnology.fr
Ea st er n USA
3005 Senna Drive DP G er many
Matthews, NC 28105 Kirschäckerstr. 23
USA D-96052 Bamberg
Tel: +1 704 814 0445 Germany
Fax: +1 704 814 0446 Tel: +49 (951) 299 526-0
dptechnology.com Fax: +49 (951) 299 526-29
dptechnology.de
DP Japan
L43, Yokohama Landmark Tower DP I t aly
2-2-1 Minato Mirai, Nishi-ku Via Iacopo Nardi 2
Yokohama 220-8143 50132 Florence
Japan Italy
Tel: +81 45 228 9020 Tel: +39 055 2342286
Fax: +81 45 228 9021 Fax: +39 055 2347858
dptechnology.com/co/jp 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


ESPRIT Fundamentals

Before you begin the lessons in this guide, you should The ESPRIT Graphical User
familiarize yourself with how to work with part files in ESPRIT. Interface (GUI)...................................... 6
As a native Windows-based application, the ESPRIT interface Menus............................................................ 7
and its menus and toolbars should look familiar to you.
Default Toolbars.................................... 8
This chapter introduces the ESPRIT work environment and
The Smart Toolbar............................... 8
explains how to work with ESPRIT part files.
Other Toolbars........................................ 9
Displaying the XYZ Axis and the
UVW Axis.. .................................................... 9

Opening and Storing Files in


ESPRIT. . ...................................................... 11
Creating a New File. . .......................... 11
Opening an Existing File. . .............. 12
Saving a File.. .......................................... 12

Selecting Elements.......................... 13
Selecting Elements in the Work
Area................................................................ 13
The Group Command......................... 13
Selection Modes................................... 14
You will learn: Deselecting Elements....................... 17
• How to use ESPRIT menus and toolbars Selecting Items in the Project
• How to open and store ESPRIT files Manager.. ..................................................... 17
• How to select, or group, elements using various selection Controlling the Display of
modes such as HI, SNAP, and SUB-ELEMENTS Elements. . ................................................18
• How to control the display of elements with views, masks, Shaded and Wireframe Displays.1 8
and layers
Views. . ...........................................................18
XX Before beginning to use ESPRIT, you should have a working Pan, Zoom, and Rotate the View.1 9
knowledge of your computer, the Microsoft® Windows®
Masks............................................................ 21
operating system and its conventions. You should know
how to use a mouse and standard menus and commands. Layers........................................................... 21
To review these techniques, refer to the documentation for
Microsoft® Windows®.

ESPRIT Fundamentals   |  5
The ESPRIT Graphical User Interface (GUI)
Let’s start by taking a look at the ESPRIT screen. This window is displayed when you create a new
file or open an existing one.
The ESPRIT window contains:
1. Menus and default toolbars along the top of the screen. You can select commands from the
menus or from toolbars.
2. A graphic work area where you can view your work. This is the largest area of the screen.
3. The Prompt area, at the bottom left of the screen, displays prompts that tell you what to do
next. Always pay attention to what the prompt is telling you.
4. The Status area, at the bottom of the ESPRIT screen, provides dynamic information about the
current work environment. As you select commands or move the cursor, the information is
constantly updated.

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.
5. The Project Manager consists of a tabbed set of windows that list every feature, every cutting
tool, and every operation in the current session. The Project Manager lets you manage,
sort, and reorder these items. To view the Project Manager, press the F2 key or click Project
Manager on the View menu.

6  |  Get Started with ESPRIT


6. The Property Browser displays the specific properties of any item selected in the graphic work
area or the Project Manager. The types of properties displayed depend on the type of item
selected. You can view and change individual properties for the selected item. To view the
Property Browser, click Properties on the View menu or hold down the Alt key as you press
Enter.

Menus
Commands are located on eight menus. Most of the menu commands are also available on the
toolbars.

• File: Open an existing file or create a new one. Save files that have changed.
• Edit: Copy or delete items, move the origin point or change the orientation of an imported
model.
• View: Set the display of the work environment.
• Create: Draw new geometry and dimensions, create features, surfaces, or solids.
• Machining: Set up the machine definition, create cutting tools, create and simulate machining
operations.
• Analysis: Analyze solid models, surfaces, and tool path.
• Tools: Set the system unit, create macros, load add-in programs, and personalize ESPRIT.
• Window: Create new windows and arrange the display of multiple windows.
• Help: Access the online help files or learn about your current version of ESPRIT.

ESPRIT Fundamentals   |  7
Default Toolbars
The default toolbars are located near the top of the ESPRIT screen.
1. The Standard toolbar has file management commands that let you create, open, save, and
print files. This is also where you can find the Copy command when you want to copy elements
in the work area.
2. The View toolbar has several commands that let you control the display 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.
3. 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.
4. The Layers and Planes toolbar has commands for creating and selecting work planes, layers,
and view planes.
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.
The first three icons on the toolbar relate to the machining modes in ESPRIT: milling, turning, and
wire EDM.

If you click “Switch to SolidMill”, the toolbar is updated to display commands that let you create
milling tools and operations. If you click “Switch to SolidTurn”, the milling commands are hidden
and new commands display that let you create turning and mill/turn operations and tools.

If you want to create geometry, just click the Geometry icon to activate the Geometry group of
toolbars.

If you click Milling Tools, the geometry toolbars are hidden and milling tool commands are
displayed. 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.

8  |  Get Started with ESPRIT


Other Toolbars
In addition to the Smart toolbar, you can display other toolbars.
To display other toolbars:
• On the View menu, click Toolbars... and then select a toolbar from the list. Any toolbar that has a
check mark next to the name is already displayed on the screen.
• Right-click on any visible toolbar and select the toolbar
you want to display
• To show toolbars for machining operations, select
the machining type on the Machining menu, such as
SolidMill Traditional, and then select the machining type
again on the secondary menu.
To hide a toolbar:
• On the View menu, click Toolbars... 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, 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. When you drag a toolbar near the edge of the
screen, it will automatically snap to the edge.
Instructions that describe how to create your own toolbars or customize existing toolbars are
available in ESPRIT Help. Press F1 to display the help and then click “Customize” in the index.
If you would like to customize the Smart toolbar, click “Smart Toolbar Add-In” in the index.
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
The XYZ axis shows the position of the part model in relation to the global axis.

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”.

10  |  Get Started with ESPRIT


Opening and Storing Files in ESPRIT
When you start a new session in ESPRIT or create a new file, you are given the choice of starting
with a blank file or basing your new work session on a predefined template.

The <Blank Document> option opens a new file that uses the ESPRIT defaults. A template file
contains user-defined elements and settings for the way you machine parts at your company.
You can create templates that include regularly used tools, machine setup configurations,
simulation settings, repeated geometry, and KnowledgeBase settings. As you become more
familiar with ESPRIT, you can create templates that make it easier and faster to work on similar
types of jobs.
As a new user, select <Blank Document> and click OK.
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.
The display of the template dialog is controlled by the “Display Template Dialog” option on the
Input page of the Options dialog, available on the Tools menu. By default, the template dialog
displays.
For more information about how to create and use template files, please refer to the ESPRIT help.
Creating a New File
Clicking the New command closes the current file so that you can begin work on a new file. If
changes have been made to the current file, ESPRIT will prompt you to save those changes before
the file is closed.

ESPRIT Fundamentals   |  11
Opening an Existing File
Clicking the Open command lets you open native ESPRIT files (.esp extension), native 2D and
3D files from other CAD systems such as SolidWorks or Pro/E, stereolithography (STL) files, and
translated files such as IGES and STEP.

Since ESPRIT is based on the Parasolids kernel, it is adept at opening a variety of solid model files.
After you click Open, you can use the “Files of type” pulldown to list only files with a specific
extension. This makes it easier to browse for the file you want. If the file you’re looking for has an
unlisted extension, select “All Files”.

XX The list of available file formats is based on the licensed options. For example, if your license
does not allow you to open CATIA files, this option will not display in the “Files of Type”
pulldown.
Saving a File
After working in ESPRIT, you’ll want to save your work so you can retrieve it later.
The Save command stores the current file as a native ESPRIT file or as another type of CAD format.
ESPRIT files are saved with a “.esp” file extension. If you want to convert the file to a different file
format, select the “Save as type” pulldown and then select a file extension.

12  |  Get Started with ESPRIT


Selecting Elements
One of the most important tasks in any CAD/CAM system is the ability to select a variety of
elements in the part file. A single part file may include one or more solid models, wireframe
geometry, surfaces, and toolpath.
In addition, you must have the ability to select individual components of an element, such as edges
on a solid model or the endpoint of a line.
Selecting Elements in the Work Area
Elements in the work area can be selected individually, as a group or by type of element.
• Use your mouse to select an individual element in the work area
• To select more than one element, hold down the Ctrl key as you select elements or drag a
selection box over a group of elements
• To select a group of connected elements, hold down the Shift key as you select an element
Use the Selection Filter to select elements by type. If Geometry is chosen, you will only be able to
select geometry elements in the work area. When you are finished, remember to set the Selection
type back to All.

The Group Command


If you want to select all elements that fit specific selection criteria, you can use the Group
command on the Edit menu.
The Group command lets you select all elements using the following criteria:
• Element type
• Color
• Layer
• Work Plane

ESPRIT Fundamentals   |  13
After you identify the selection criteria, 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, that means the mode is disabled. Click on a mode to enable or disable
it.
HI Mod e

When HI mode is enabled, ESPRIT always asks you to confirm element selections. This allows you
to select from elements that are close to, or even on top of, each other. For example, you can use
HI mode to select a solid model, an edge on that model, or feature created from a solid model.

14  |  Get Started with ESPRIT


When HI mode is enabled, ESPRIT will prompt “Is this the correct choice” and highlights an element
near the selection point.

If this is not the correct element, answer No by pressing the right mouse button.
ESPRIT will highlight the next closest element. In this example, you want to select the feature but a
segment is highlighted instead. You would click the right mouse button until the feature highlights.

When the correct element is highlighted, answer Yes by pressing the left mouse button.

ESPRIT Fundamentals   |  15
SNA P Mod e

When SNAP mode is enabled, the cursor recognizes the midpoints and endpoints of
lines and segments and the center points of circles and arcs as valid point selections.
With SNAP enabled, 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 - ELEM ENTS mod e

When SUB-ELEMENTS mode is enabled, you can select the individual sub-elements of
solid models or features in the work area. For example, you can select the faces, faces
loops, or edges of a solid model. You can also select the sub-elements of features.
The selection of sub-elements is extremely useful for selecting the individual faces
on a solid model that you want to machine. The Grouping Properties command relies
on the selection of sub-elements to automatically group faces for several types of
features: Holes, Pockets, Draft Feature Recognition, Turning Profiles, and FreeForm
features.

I NT Mod e

When INT mode is enabled, the cursor recognizes the intersections of segments, lines, arcs, and
circles as valid point selections.
With INT set on, the cursor changes immediately to and remains as the INT cursor until an
intersection is chosen. The cursor exits INT mode immediately after an intersection is chosen.

16  |  Get Started with ESPRIT


GR I D Mod e

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

ESPRIT Fundamentals   |  17
Controlling the Display of Elements
ESPRIT provides a variety of methods that let you control how your parts are displayed.
Shaded and Wireframe Displays
For solids and surfaces, you can set the display to shaded or wireframe mode.

Shaded Wire: Creates a shaded image with wireframe. The display of


the wireframe is light source dependent. Wireframes will appear in
different colors and/or disappear depending on the part orientation
with respect to the light. Silhouettes are not supported, only true
edges.

Shaded: Creates a shaded image. Has no effect on geometry elements.


You can also shade the simulation of cutting operations.

Hidden Wireframe: Displays visible solids, surfaces, and geometry as


wireframe depending on the orientation of the part. Elements that
would normally be hidden by a shaded view are not displayed.

Wireframe: Displays all solids, surfaces, and geometry as wireframe.

Views
ESPRIT provides several standard view orientations.

When you change from one view plane to another, the display in the work area rotates to the new
view orientation and the display automatically zooms to fit all elements within the screen. You can
control the rotation animation speed on the Workspace tab of the Options dialog (available on the
Tools menu).

18  |  Get Started with ESPRIT


You can also store your own view orientations. Pan, rotate or zoom the view to the orientation you
prefer and then create a new view to store the view for later use.

Pan, Zoom, and Rotate the View


Commands on the View toolbar let you fit, zoom, pan and rotate the display of your part in the
work area. However, it is faster to use the mouse and keyboard to modify the view.
Fast Rot at e

Hold down the Ctrl key and the middle mouse button, or scroll
wheel, and move the mouse to quickly rotate the view.
If you hold the mouse button down over an axis or geometry
element, the view will rotate about that element.
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. Spin the scroll wheel backwards to zoom out. The zoom
takes place from the location of the cursor on the screen.
A l t e r nat i ve s
• Use the zoom commands on the View toolbar: Zoom, Zoom Previous, Zoom Dynamic
• Hold down the Shift key and press the up or down arrow keys to zoom in or zoom out

ESPRIT Fundamentals   |  19
Smar t Zoom

Hold down the Shift key and the middle mouse button, or
scroll wheel, and move the mouse forward to zoom in or
move backwards to zoom out.
With Smart Zoom, the zoom takes place from the center
of the model regardless of the position of the mouse.
That way, the model is always visible when you zoom.

Pan

Hold down the middle mouse button, or scroll wheel, and


move the mouse right, left, forward, or backward to pan
the view.
A l t e r na t i ve s
• Click the Pan command on the View toolbar
• Press the right, left, up, or down keys
Keyboard Shor tcut s

Press F5 to redraw the screen.


Press F6 to fit all visible graphic elements on the screen.
Press F7 to switch to a top view.
Press F8 to switch to an isometric view.

20  |  Get Started with ESPRIT


Masks
The Masks command on the View menu lets you hide the display of specific types of elements.
Press Ctrl+M to display the dialog. Items with a check mark are displayed. Select any items you
want to hide to remove the check mark. All elements of that type will be hidden in the work area.
To display the elements again, select the item in the dialog.

Layers
Layers are very useful for controlling the display of different types of elements in a complex part
file. For example, you can set up different layers for machine components, the initial part stock
or casting, the finished part, roughing tool paths and finishing tool paths, or any other type of
geometry.

When new elements are created, they are placed on the active layer. Layers can be turned on or off
to hide or show the different aspects of your part. The elements are not deleted, just temporarily
hidden. You can turn a layer back on at any time.
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.

ESPRIT Fundamentals   |  21
22  |  Get Started with ESPRIT
Working with Geometry

A basic requirement of any CAD/CAM system is to provide Geometry commands.....................24


functions that allow the creation of 2-dimensional and Unbounded Geometry.. .....................24
3-dimensional geometry. For machinists, the ability to create
Bounded Geometry.. ...........................25
geometry to aid in the creation of proper tool path is critical.
Entering Values....................................25
ESPRIT provides functions to create two types of geometry:
Geometry creation modes.. .......... 26
unbounded and bounded. Unbounded geometry has no
end point or start point, such as an infinite line, or the start Work Planes........................................ 26
point and end point are the same, such as a circle or ellipse. Saving a work plane.........................27
Bounded geometry is limited to a start point and end point,
Draw 2D Geometry......................... 28
such as a line segment or arc.
Some geometric elements are neither bounded or
unbounded, such as points, rectangles, and polygons. In
addition, ESPRIT lets you trim or extend geometry, or add
fillets and chamfers to corners.
The intent of this lesson is to teach you the basics of creating
2-dimensional geometry in ESPRIT.

You will learn:


• About the commands for creating geometry
• About work planes and how to modify their location and
orientation
• How to draw lines, rectangles, points, and circles
• How to trim geometry and fillet corners
• How to draw a hole pattern from an array of points

Working with Geometry   |  23


Geometry commands
Geometry commands are available on two toolbars: Unbounded Geometry and Bounded
Geometry.
Unbounded Geometr y
The Unbounded Geometry toolbar displays automatically when you click Geometry on the Smart
toolbar.

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

24  |  Get Started with ESPRIT


Rectangle: Creates a rectangle or cube from two points or Snap locations. When the reference
points lie on the same plane, a rectangle is created from four separate segments. When the
reference points lie on different planes, a cube is created from twelve separate segments.
Polygon: Creates a closed shape with any number of sides centered about a point or Snap
location.
Bounded Geometr y
To display the Bounded Geometry tool bar, click 'Bounded Geometry' on the Create tool bar. Most
of the commands are the same except that you can create segments instead of lines and arcs
instead of circles.

Segment 1: Creates a segment from one reference element. The segment can be created
through a point, tangent to a circle or arc, or parallel to another line, segment, or axis. The user
specifies the length and angle.
Segment 2: Creates a segment from two reference elements that define the start and
end points. The segment can be created between two points, tangent to circles or arcs, or
perpendicular to another line, segment, or axis.
Arc 1: Creates an arc from a center point, a radius value, and start and end angles.
Arc 2: Creates an arc with a specified radius through or tangent to two reference elements.
Arc 3: Creates an arc from three reference elements that define the start point, a point on the
arc, and the end point.
Ellipse 1: Creates an open ellipse centered about a point or Snap location. The user is prompted
for the center point, angle of major axis, major radius, minor radius, start angle, and end angle.
Ellipse 3: Creates an ellipse from three points or Snap locations. The user is prompted for the
center point, a point that defines the angle of the major axis and the major radius, and an end
point. The second point selected also defines the start point of the ellipse.
Entering Values
Each geometry command displays a series of messages in the prompt area (located at the lower
left corner of the screen). The messages typically prompt you to select a reference element in the
work area, such as a center point for a circle or an end point for a line, and then prompt you to
input a value, such as a radius or distance.

You can accept the displayed value by pressing the Enter key or you can type a new value. As soon
as you begin typing on the keyboard, an input box displays.

Working with Geometry   |  25


You can type the value or you can enter a mathematical expression to calculate the value, such as
SQR(PI*3) or 10/3.

Geometr y creation modes


When a geometry command is clicked on the toolbar, its mode of geometry creation is activated.
The mode stays active until you press the Escape key or click another command. For example, if
you click the Circle 1 command, you can create one circle after another.

Work Planes
When geometry is created, it is drawn on the current work plane. Work planes let you draw
geometry on a plane other than the default XYZ plane. The location and orientation of the current
work plane is shown by the UVW axis. To display the UVW axis, click 'UVW Axis' on the View menu.

ESPRIT provides three work plane orientations, all starting at the system origin point:
• XYZ: U, V, and W share the same orientation as X, Y, and Z. Geometry is drawn
on the XY plane.
• ZXY: U, V, and W are aligned along Z, X, and Y respectively. Geometry is drawn
on the ZX plane.
• YZX: U, V, and W are aligned along Y, Z, and X respectively. Geometry is drawn
on the YZ plane.
In ESPRIT, the tool axis is always aligned along the W, or Z, axis.

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. This tool bar displays automatically when
'Geometry' is clicked on the Smart tool bar.

26  |  Get Started with ESPRIT


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

When "Include View" is checked, the same name and orientation is added to the list of View Planes
so you can change to that view at any time. 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. 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.

Working with Geometry   |  27


Draw 2D Geometry
In this lesson you will learn to draw points, lines, and circles and become familiar with how to trim
elements.
You will draw the geometry using the dimensions in this drawing. 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, if ESPRIT is already running, click New.

Make sure System Unit, on the Tools menu, is set to Metric.

Set the view to 'Top'.

Make sure SNAP mode and HI mode are active.

28  |  Get Started with ESPRIT


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. The
Rectangle command requires the entry of two point locations that define the opposite corners of
the shape. The first point is located at the origin, so you only need to create a point for the upper
right corner of the rectangle.
On the Smart tool bar, click Geometry.

• Click Point .
• Select 'Cartesian/Center'.
• 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, click 'Zoom to Fit All' to see the point.
• Click Rectangle .
• You are prompted to "Select First Reference Point". Select the origin point at the lower left of
the screen.
• You are prompted to "Select Second Reference Point". Select the point you created.

Working with Geometry   |  29


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

30  |  Get Started with ESPRIT


• You are again prompted to select a reference element. Select another segment in the
boundary.
• This time the distance defaults to 5, so just press Enter.
• Again digitize inside the boundary.
• Follow the prompts to create the next two lines for the pocket.

Trim t he pocket boundar y


• Click Keep .
• Select a line by digitizing it inside the pocket boundary since this is the portion of the line you
want to keep.
• Digitize the other three lines in the same way so that all the lines are trimmed.

Working with Geometry   |  31


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

32  |  Get Started with ESPRIT


Draw t he angled line
With Line 1 still active, click INT mode to activate it.

• Move the cursor over the intersection of the two lines you just created and click to select the
intersection.
• You are prompted to "Enter Angle". Type -10 and press Enter.
• Click 'Select' and then select the horizontal line. Press the Delete key since you do not need
this line anymore.

Working with Geometry   |  33


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,
which is sharp.
• Click Fillet/Chamfer .
• In the dialog, set the Radius to 6.
• At each outer corner of the pocket, select each segment on
the side that is inside the pocket boundary. A fillet is created
and the segments are automatically trimmed.

• Change the Radius to 0.


• Select the angled segment to the right of the intersection.
• Select the vertical segment above the intersection.

34  |  Get Started with ESPRIT


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

Working with Geometry   |  35


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

36  |  Get Started with ESPRIT


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

Working with Geometry   |  37


38  |  Get Started with ESPRIT
Working with Features

Features are an integral component to the machining Types of Features........................... 40


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


Types of Features
When a feature is created, it is classified as one of the following:

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

40  |  Get Started with ESPRIT


Creating and editing features
Features are created using the commands on the Features toolbar. To display the toolbar, click
Features on the Smart tool bar.

Two toolbars display: Create Features and Edit Features.


Creating features
Features are created from commands on the Create Features toolbar.

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

Working with Features   |  41


Editing features
The Features tool bar also displays commands you can use to edit features.

Insert Point: Inserts a point in an existing PTOP feature.


New Start: Changes the start location on a chain feature to any element defined in the original
chain.
Remove from PTOP Feature: Removes a point from a PTOP feature.
Move Back: Removes any number of elements, from last to first, on an existing chain or PTOP
feature. This command is available only when the Manual Chain function is active.
Modify Sharp Corner: Places arcs on corners (non-tangent junctions) of a chain feature. Arcs
can be applied to the entire chain or any portion of a chain.
Modify Internal/External Corners: Analyzes a chain or EDM feature to find and identify all
corners, then automatically applies a user-defined corner style to those corners. A corner style can
be applied to all corners, internal corners only, external corners only, clockwise corners, or counter
clockwise corners.
Find Shortest Path: Optimizes the travel distance between points in a PTOP or Hole feature.
Reverse: Reverses the direction of a curve, chain feature, or PTOP feature.
Command s to edi t EDM f eatures

Several commands on the Edit Features toolbar are designed specifically for EDM features.
Taper Change - Inserts a pivot or gradual taper change into a draft conic feature.
Add Match Line - Adds a new synchronization line to a 4-axis ruled feature.
Remove Match Line - Deletes a synchronization line from a 4-axis ruled feature.
Add Slug Retention Profile - Adds small slots or grooves to an EDM die feature to prevent a slug
from staying in the die during a punching operation.
Remove Slug Retention Profile - Removes slug retention profiles from EDM die features.
Add Extra Cut-off - Adds an extra break point to an existing EDM feature at a user-defined
location and distance.
Remove Extra Cut-off - Removes an extra break point that was previously added to an EDM
feature.
Add Thread at Angle - Adds a tilted thread line to a 4-axis ruled feature.
Remove Thread at Angle - Removes a tilted thread line from a 4-axis ruled feature.

42  |  Get Started with ESPRIT


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

Working with Features   |  43


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

44  |  Get Started with ESPRIT


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.
All dimensions in this lesson are in millimeters. Make sure “System Unit” on the Tools menu is set
to “Metric”.
If you would like to review and simulate the machining operations from this lesson, the completed
ESPRIT file is available in the folder “completed_parts”.

Import a CAD drawing


You will start by opening an AutoCAD file in ESPRIT. This drawing has part geometry that you will
use to create features. There is other geometry that you do not need, such as the drawing border
and title section. You will control the display of the geometry with layers.
On the Standard toolbar, click Open.

Browse and select the following file: drawing.dxf


In the dialog, click Options and make sure ‘File Unit’ is Metric.
Click OK to close the Options dialog.
Click Open.

Working with Features   |  45


If the Feature Manager is not displayed, press F2.
If the Property Browser is not displayed, press Alt+Enter (if necessary, drag the Property Browser
below the Feature Manager).

Turn of f layer s to hide element s


This drawing already has layers that were created in AutoCAD. When you imported the drawing,
you imported the layers as well.
Layers let you hide and show different aspects of your drawing. When elements of any type are
placed on a layer, you can turn off that layer to hide all elements on that layer. The elements
are temporarily hidden, not deleted. You can turn the layer back on at any time to show the
elements.
The CAD drawing has elements that you do not need for machining operations, such as the
drawing border and title box. You can hide these elements so you only see the geometry for the
part.
On the ‘Layers and Planes’ toolbar, click the Layers icon.

46  |  Get Started with ESPRIT


Uncheck all layers except ‘Default’, ‘Visible (ISO)’, and ‘Hidden (ISO)’.

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. All new elements are created on the active layer. When a new layer is
created, it is automatically set as the active layer.
• In the Layers dialog, click New
• For the layer name, type ‘Features’ and click OK
• Close the dialog

Working with Features   |  47


Position the part for machining
The origin point in the AutoCAD drawing is not located on the part geometry. 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.
• On the Edit menu, 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


Draw dimensions
This drawing does not have any dimensions. You will draw some dimensions on the top view of the
part to see the depths of the pockets and the holes. You can then use those values to add depth to
the features you create.

On the Tools menu, click Dimensioning.

• 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 Smart toolbar, click Dimensioning.

• Click Dimension
• In the Status area, 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, add dimensions for the depths of the pockets
• Press the ESC key to exit Dimension mode
• In the Status area, enable SNAP mode

50  |  Get Started with ESPRIT


Create 3D features from a 2D drawing
When a machine shop receives a drawing from a customer, it is useful to be able to use the
geometry in the drawing to create 3-dimensional features that can be machined.
ESPRIT lets you create features on 2-dimensional geometry and add 3-dimensional properties to
them.

Create a hole feature


On the Smart toolbar, click Features.

Click Holes.

• 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


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.

• In the Project Manager, select the Hole feature


• In the Property Browser, 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


Create chain features for t he pocket
You will create three features for the pocket: one for the closed boundary of the pocket, one
for the rectangular island, and one for the circular island. For features that define a pocket, the
cutting side is important because it controls where material is removed (on the inside or outside
of the chain). Cutting side is based on the direction of the feature and can be set to Left, Right, or
Center.
• 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 counter-
clockwise direction

Working with Features   |  53


• 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, 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


Add dept h to t he chain features
When several elements are selected, only the properties
that are common to all the elements can be edited in the
Property Browser. Since the features for the pocket all
share the same depth, you can update the depth for all
three features at one time.
• In the Feature Manager, 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. You can edit
the sub-elements of a feature to define edges as open or closed.
• 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


• On the View menu, click Masks
• Select ‘Geometry’ to hide the display of
the geometric elements (do not close the
dialog yet)

• In the status area, make sure SUB-ELEMENTS mode is enabled


• In the work area, 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, change the attribute for ‘Open Edge’ to ‘True’
• In the same way, select the other sub-elements on the outer edge and change the ‘Open Edge’
attribute to ‘True’

56  |  Get Started with ESPRIT


• Change the view to ‘Isometric’
• You can see that the open edges are displayed as dashed lines
• In the Masks dialog, 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. This chain defines an open
profile with the start point and the end point in different
locations. 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.
• 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, click Cycle Stop to create the
feature

• Change the cutting side to Right


• Change the depth to 24

Working with Features   |  57


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.
• 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.

58  |  Get Started with ESPRIT


Milling on a Standard Mill

ESPRIT has very strong capabilities in 2.5D milling, providing SolidMill Machining Technology
both ease-of-use and a high level of control over every aspect 60
of a milling operation. Saving Machining Technology.. 64
The intent of this project is to teach you the process for Feeds and Speeds. . ............................ 64
creating standard milling operations using the standard milling
Milling Clearances............................ 66
technology in ESPRIT.
Depths of Cut.. ...................................... 68
For this project, you will learn how to use the commands on
the SolidMill Traditional toolbar to mill a part on a 2-1/2 axis SolidMill Traditional Machining
mill. Cycles...................................................... 70
Prerequisites.. ......................................71
Open the part file............................71
Create a milling tool.....................72
The Tool Manager...............................72

Create milling features.. ............. 76


Create a stock model....................83
Remove excess material.. ........... 85
Cut the pockets and slot. . ......... 92
Mill and drill the holes.............. 99
You will learn: Simulate milling operations. . . 103
• 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

Milling on a Standard Mill   |  59


SolidMill Machining Technology
ESPRIT has machining technology that is designed specifically for 2-axis through 5-axis mills. This
technology is called SolidMill.
SolidMill technology lets you define the physical properties of your milling machine, 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. This
makes it easy to enter machining parameters and view the part model at the same time. 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.

The technology for a machining cycle will not open unless a valid feature is selected first.
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 interface is organized in three main areas:
• Toolbar area
• Vertical tabs
• Parameters area

60  |  Get Started with ESPRIT


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


Saving Machining Technology
Machining technology settings can be easily saved as a separate *.prc (process) file and used over
and over for the machining of similar parts. To save the technology for a machining cycle, click Save
on the drop-down menu. Enter a name for the file, browse to the location where you want to save
the file, and click Save.

After a technology file has been saved, it can be loaded in a technology page. Click 'Open' on the
drop-down menu, browse to the file, and click Open.
XX The type of technology in the file must match the machining cycle. For example, you can only
load Pocketing technology into a Pocketing cycle. For this reason, it is important to name the
saved technology file with the type of technology in 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. The column on the left is for actual feed and speed values, while the
column on the right is used for chip load programming. If you enter a value in one column, the
value in the next column is automatically calculated. This allows you to "fine tune" your feed and
speed values.

Cut Sp e ed

You can use 'Cut Speed RPM' (Revolutions Per Minute) or 'Cut Speed SPM' (Surface feet/meters Per
Minute). Cut speed is defined as the distance in feet or meters that the edge of the rotating tool
travels per minute. Cut speed is affected by the tool diameter. At a fixed number of RPMs, a larger
tool diameter results in a greater cutting speed.

64  |  Get Started with ESPRIT


When a value is entered in 'Cut Speed RPM', the system takes that value and the tool diameter and
calculates and displays the value for 'Cut Speed SPM'. 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. If you set Cut Speed SPM, the system takes that value
and the tool diameter and calculates the Cut Speed RPM. 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 , PT

These values are also interactive. Feed rate is defined as units (inch/millimeter) per minute (PM) or
per tooth (PT). In general terms, the feed rate is the speed at which the cutter moves with respect
to the work material. XY Feedrate allows you to specify the feed rate for movement in the XY
plane.
To calculate the feed rate PT (per tooth) from the feed rate PM (per minute), the system uses the
following formula:
PT = PM / (Number of Flutes * RPM)
Going the other way, 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.
There are three types of moves possible in the XY plane. These moves are represented by the
following examples of NC code. The value you enter for XY Feedrate determines the feed rate for
these three types of moves.
Type 1: N15 G01 X_ Y_
Type 2: N15 G01 X_
Type 3: N15 G01 Y_
Z Fe edrat e PM , PT

Z Feedrate allows you to specify the feed rate for moves along the tool axis. These moves are
represented by the following examples of NC code. The value you enter for Z Feedrate determines
the feed rate for these four types of moves.
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. When set to Yes, the feed rate is adjusted on arcs to maintain
the feed rate at the edge of the tool where it contacts the material. The feed rate increases around
exterior arcs and decreases around interior arcs in the NC code output. The Max Feedrate setting is
used to limit the increase in feed rate.

Milling on a Standard Mill   |  65


M a x Fe e d r at e PM , 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.
Use Fe ed and Sp e ed K B

This option can be set to Yes or No. When set to Yes, feed and speed values from the
KnowledgeBase will be inserted automatically.
Before setting this option to Yes, 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. 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. The Type of Cut
selected on the operation page also affects the inserted speed and feed values.
Milling Clearances
Parameters that control tool clearances during milling are located on the Links tab. Clearances
define how you want to position the tool when it makes a rapid move from one location to
another.

ESPRIT lets you define two separate distances for retract moves: Clearance and Full Clearance.
Once you define the two distances, you can use them to control the heights of retract moves.
• Full Clearance: This is an absolute value, measured from the origin of the coordinate system.
ESPRIT supports two types of coordinate systems: global (system default) and local (user
defined).
• Clearance: This is a relative value, measured from the top of the feature or the starting depth.
This is usually the top of the workpiece, but other situations may apply. Sometimes the top of
the feature is below the top of the work piece (for example, holes in the floor of a pocket). 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


negative (-) value. In that case, clearance is measured from the starting depth since it is above
the feature.
Both methods of measurement have advantages. When you know the heights of specific obstacles
on the work table, such as clamps and fixtures, you can use Full Clearance to make the tool retract
to a safe height that will always avoid those obstacles. To save time, you can set a minimum retract
height in Clearance that keeps the tool as close to the work piece as possible.
In addition to the retract distances, ESPRIT lets you control the behavior of the tool between
separate machining operations and between sections of a single operation.
• 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.
• Retract Plane: This setting establishes the plane position of the tool as it rapids between two
sections of a cutting operation (for example, when the tool needs to move between two pocket
areas in a Pocketing operation).
Return Plane and Retract Plane share the same four options. However, you can use a different
option for each.
XX The Return Plane is always used. Whether the Retract Plane is used depends on the areas that
are being machined. If you are not sure about when the retract plane is used, it is a good idea
to set the retract plane and return plane to the same option.
O pt ions for Retur n Plane and Ret rac t Plane

Clearance: The tool retracts to the Clearance distance, measured from the Starting Depth. See
"Depths of Cut". When the tool will encounter no obstacles during repositioning, this is a good
choice.

Initial Clearance: The value for Initial Clearance is specified on the tool page for the selected tool.
The distance is an absolute value, always measured from ESPRIT origin P0. When the tool must
avoid all obstacles (such as fixtures and clamps) while moving to the next position, this is a good
choice.

Milling on a Standard Mill   |  67


Full Clearance: The tool retracts to the distance entered in Full Clearance. If you are outputting
from World coordinates, this value is measured from P0. If you are outputting from a local
coordinate system, this value is measured from the origin of the Work Coordinate used. When the
tool must avoid vertical obstacles on the work piece between operations, this is a good choice.

Partial Depth: The tool retracts to the Clearance distance measured from the tool location at the
time of the retract. When you know the tool will be repositioning to a lower plane, this is a good
choice.

Depths of Cut
The depths of cutting passes are controlled by the Depth settings on the Strategy tab. The depth
settings let you control the z-level where the tool will start cutting, the depth of each incremental
pass, and the depth of the final cutting pass.

68  |  Get Started with ESPRIT


• Total Depth: This value establishes the bottom Z level for cutting passes. This value is measured
from the selected feature. A positive value cuts below the selected feature, a negative value cuts
above.
• Incremental Depth: This value controls the distance between each Z-level cutting pass. The
values for Total Depth and Incremental Depth are used to determine the number of depth
passes. 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.
• Starting Depth: This value establishes the top Z level for cutting passes, measured from the
selected feature. The first incremental depth pass is measured from this top Z level. A positive
value cuts below the selected feature, a negative value cuts above.
• Retract for IDepth: This value controls the retract position of the tool before and after each
incremental pass. Since this setting controls a tool retract distance, it shares the Full Clearance,
Initial Clearance, and Partial Depth options that are used for clearances. You can also use the
None option to have the tool feed between incremental passes without retracting. 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, whichever is
higher.
• 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, this setting does not
apply.
• Through Depth (Pocketing only): This value is used only when a pocket has no floor. Enter a value
beyond the depth of the pocket so the tool can cut completely through. When a value is entered,
the operation cuts to the total depth plus the distance for the through depth.

Milling on a Standard Mill   |  69


SolidMill Traditional Machining Cycles
All SolidMill Traditional machining cycles are displayed on the SolidMill Traditional toolbar and on
the Machining menu under SolidMill Traditional. To display the SolidMill Traditional toolbar, click
'Switch to SolidMill' on the Smart toolbar and then click SolidMill Traditional.

Facing - Removes a flat portion of stock material based on a feature that matches the stock
perimeter. 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. 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.
Pocketing - Removes material inside a closed boundary. Within a single pocketing operation,
you have the option to create separately definable phases for roughing, wall finishing, and floor
finishing passes that each let you use a different tool. When a pocket or face profile feature is
chosen, the operation automatically finds any subordinate islands within the feature boundary.
Contouring - Creates vertical or tapered cuts along the contour of a selected profile. Within
a single contouring operation, you have the option to create separately definable phases for
roughing and finishing. The same tool is used for both roughing and finishing, although you can
define different incremental depths for finishing passes as well as different speeds and feeds.
Rest Machining - Creates an operation to remove material remaining from previous operations.
A rest machining operation can be applied to any existing SolidMill Traditional operation. The
previous operation becomes the "parent" operation and the rest machining operation applied to it
becomes the "child" operation. 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.
Drilling - Creates a drilling operation. Several types of drilling cycles are supported, including
canned cycles.
Spiraling - Creates either spiral or helical cutting passes based on the selection of a feature with
a circular shape or a PTOP feature.
Threading - Creates a standard threading or single-point threading operation using basic milling
technology.
Manual Milling - Creates rapid or feed moves based on manually selected elements or
coordinate locations. Manual Milling creates a tool path on the centerline of the tool without
compensation.
Wire Frame Milling - Creates a milling operation based on wire frame geometry. This command
lets you create a simple freeform milling operation from planar geometry. Two separate profiles
are used. One profile is swept along the other to create a 3-dimensional shape for the toolpath.
Engraving - Engraves text or chain features, with multiple options to control the font, size, and
orientation of the text. Three engraving strategies are available: centerline contouring, V carving,
and concentric pocketing.

70  |  Get Started with ESPRIT


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.
All dimensions in this lesson are in millimeters. Make sure “System Unit” on the Tools menu is set
to “Metric”.
If you would like to review and simulate the machining operations from this lesson, the completed
ESPRIT file is available in the folder “completed_parts”.

Open the part file


On the Standard toolbar, click Open.

Browse and select the following file: milled_part.esp.


Set the view to 'Isometric'.

If the Project Manager is not displayed, press F2.

Milling on a Standard Mill   |  71


Create a milling tool
This file already contains several types of tools, such as end mills, drills, and even a custom mill for
cutting the milled hole.
You will learn how to create a face mill that will be used to remove the stock at the top of the part.
Milling tools can be created from the Tool Manager or from commands on the Milling Tools
toolbar.

ESPRIT provides an extensive list of pre-defined milling tools. If you use a very specific type of tool
that is not on the list, you can create a Custom Mill from geometry you define.
Instructions on how to create a custom mill are provided in ESPRIT Help.
The Tool Manager
All cutting tools are managed on the Tools tab of the Project Manager. The Tool Manager lets you
create, edit, copy, rename, and delete tools. You can also transfer tools between the Tool Manager
and the KnowledgeBase.
The Tool Manager displays all the available tools in the current document. Tools are grouped
by where they are mounted on the machine: on a milling head or a lathe turret (for a mill-turn
machine).

Tools in the list can be sorted on any column and the user can choose which columns to display
using the Field Chooser. These options are available by right-clicking on any column heading.

72  |  Get Started with ESPRIT


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, click Milling Tools.

Click Face Mill.

On the General tab:


• Set 'Tool ID' to 'FM 60'
• Set 'Tool Number' to 1

Milling on a Standard Mill   |  73


On the Machine tab:
• Set 'Movement X, 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 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


Create milling features
Milling features have machining properties that help to automate milling operations. These
properties include depth, draft, cutting side, and whether material is removed on the inside or
outside of the feature. These properties assist the user because SolidMill technology is designed to
use these properties each time a milling operation is created. If the feature is modified to change
any of the machining properties, such as a change in the depth property, any milling technology
that is applied to that feature can be updated quickly by simply rebuilding the operation.
When features are created on a solid model, ESPRIT uses automatic feature recognition to analyze
the part geometry and automatically create the appropriate features for milling operations. The
user is not limited to selecting only the solid model. The user can also select sub-elements of
a solid model, such as faces and face loops, to create features on a specific portion of the solid
model.

Set t he work plane


When automatic feature recognition is used, the direction of the W axis of the active work plane
controls the direction of feature recognition. This allows you to create features automatically on
different sides of a part.
Make sure the work plane is set to 'XYZ'.

Recognize t he pocket s
In the status area, make sure HI mode and SUB-ELEMENTS mode are active.

On the Smart toolbar, click Create Features.

Pocket Feature Recognition uses the 'Maximum Diameter' parameter located in the Feature
Parameters dialog to recognize cylindrical pockets. Any cylinder with a diameter greater than the
'Maximum Diameter' will be recognized as a pocket.

76  |  Get Started with ESPRIT


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


Rename t he pocket features
Features for the pockets and island were created automatically and placed in a folder in the
Feature Manager.
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
• 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


• 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


Create a hole feature for t he milled hole
It is more efficient to pre-drill the milled hole before applying a milling operation. To do this, you
can create a simple Hole feature that matches the size of your largest drill.
• Click Holes
• Set 'Max Diameter' and 'Min Diameter' to 42
• Click OK
• Press Alt+Enter to display the Property Browser
• In the Feature Manager, select the new hole feature
• In the Property Browser, change the value for the Depth
property to 38.1
• Change the value for the Diameter property to 30 and
press Enter
• Close the Property Browser

82  |  Get Started with ESPRIT


Create a stock model
Stock models for milling operations are created in Simulation Parameters on the Simulation
toolbar.
Stock models are created as solid models that aid in the visualization of material removal during
the simulation process. Stock models can be defined in a variety of ways: from an existing solid
model, from a feature, from an external file, and from points that define a block.
In this lesson, you will create the stock model from a chain feature that defines the shape of the
boundary.

On the Smart toolbar, click Simulation.

Click Simulation Parameters.

• 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


• Set 'Indexing' to 'None'
• Click Add
• Click OK
• To view the new stock model, click Single Step
• Click Stop to exit simulation mode

84  |  Get Started with ESPRIT


Remove excess material
In this project, the part is cut from standard rectangular stock. The first thing you need to do is
remove the excess material from the top and around the sides of the part.
To do this, you will first create a facing operation to quickly remove as much stock as possible from
the top of the part. 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.

Face t he top of t he par t


For this facing operation, there is an island on the face that must be avoided. The Facing
command lets you select and avoid islands and pocketed areas.
This operation will start slightly below the selected feature and cut at incremental depths of
8mm in a simple back and forth tool motion. A stock allowance of 0.5 mm will remain on the
walls of the island after the operation is complete. No stock allowance will remain on the floors.
XX As you enter values on the technology page you can use the Tab key to move from one
parameter to the next. Be careful not to press the Enter key. Pressing the Enter key will apply
the current settings to the selected feature.
In the Feature Manager, select the feature 'Stock Profile'.
On the Smart toolbar, click SolidMill Traditional.

Click Facing.

• On the dropdown menu, click 'System Default All' to reset all the technology parameters to
the system default settings

Milling on a Standard Mill   |  85


• 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, click
Help.
• Set 'Include Islands' to
'Yes'
• Set 'Stock Allowance
Walls' to 0.5
• Set 'Total Depth' to 15
• Set 'Incremental Depth'
to 8
• Set 'Starting Depth' to -1

86  |  Get Started with ESPRIT


• 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


Create a simple 3 D milling operat ion
For this operation, you will use two existing features. The 'Wireframe Drive Curve' defines the
curved profile for the walls around the island on the face. The 'Wireframe Basic Curve' feature is
located on the top face of the island and defines the path the profile will follow.
• Select the feature 'Wireframe Basic Curve'
• Click Wire Frame Milling
• On the drop-down menu, click Open
• Open the following technology file: Processes\M1-Wire_Frame_Milling.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


• 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, you will first rough the profile with a 30mm end mill that
will leave 0.5 mm stock on the walls and then finish with a 20mm end mill. Because the roughing
and finishing operations use very different settings, you will create two separate Contouring
operations.
• Select the profile feature on the boundary of the part
• Click Contouring
• Open the file: M2-Contour_Rough.prc
• Click the Strategy tab
• Notice that there will be 1 rough pass and no finish pass. 'Stock Allowance Walls' is set to 0.5
and 'Incremental Depth' is set the same as the diameter of the tool.
• Click OK

90  |  Get Started with ESPRIT


• With the same feature selected, click Contouring
• Open the file: M3-Contour_Finish.prc
• On the Strategy tab, 1 rough pass is generated with no stock allowance
• Click OK

Milling on a Standard Mill   |  91


Cut the pockets and slot
The part in this project contains two pockets and a slot. ESPRIT offers two types of pocketing
operations that you will use to cut each pocket: Trochoidal and Traditional.

Rough t he medium pocket


To mill the medium pocket, you will first remove as much material as possible as quickly as
possible with a Pocketing operation. A stock allowance of 0.5mm will remain on the walls and
floors of the pocket.
• Inside the 'Pocket' feature group, select the feature 'Medium Pocket'
• Click Pocketing
• Open the file: M4-Rough_Pocket.prc
• On the Strategy tab, 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.
• Click OK

92  |  Get Started with ESPRIT


Notice that the tool path starts in the largest area of the pocket and spirals outward until it
reaches an obstacle. Then the tool path changes to adjustable curves that adapt to the shape of
the pocket.

Finish t he medium pocket


You will again use a Pocketing operation to first finish the walls and then the floors of the pocket.
• Select the feature 'Medium Pocket'
• Click Pocketing
• Open the file: M5-Finish_Pocket.prc
• On the General tab, notice that 'Rough Pass' is set to 'No' and both 'Wall Finish Pass' and 'Floor
Finish Pass' are set to 'Yes'. The same tool will be used for all finish passes.
• Passes Order is set to 'Walls then Floors'. This means that all walls will be cut first, then all
floors.

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
• Click OK

94  |  Get Started with ESPRIT


Milling on a Standard Mill   |  95
Remove material in t he corner s
To remove any material remaining in the corners, you will apply a Rest Machining operation.
• Select the feature 'Medium Pocket'
• Click Rest Machining
• Open the file: M6-Corner_Finish.prc
• On the Strategy tab, 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,
between a wall and an island). Corner clearing is applied when there is only one exposed edge
(corners).
• Click OK

96  |  Get Started with ESPRIT


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.prc
• Click OK

Milling on a Standard Mill   |  97


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

98  |  Get Started with ESPRIT


Mill and drill the holes
This part has different types of holes, including a milled hole. For this project, you will create
drilling and spiraling operations depending on the type and size of the hole.

Pre- drill and mill t he large hole


The milled hole has a diameter of 42 mm. You will cut this hole in two steps. First, you will drill
the hole with a 30mm drill. Then, you will create a Spiraling operation to mill the upper diameter
to a depth of 30mm.
• Select the Hole feature for the milled hole
• Click Drilling
• Open the file: M9-Drill_Milled_Hole.prc
• Click OK

Milling on a Standard Mill   |  99


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

100  |  Get Started with ESPRIT


Drill t he holes
• In the Feature Manager, 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


• Right-click on the feature 'Countersink'
• Open the file: M13-Countersink.prc
• Again, right-click on the feature 'Countersink' and open the file: M14-Drill_Countersink.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


Simulate milling operations
Operations are simulated in the same order as they are listed in the Operation Manager.
On the Smart toolbar, click Simulation.

• Click 'Run' to start the simulation .


• Click 'Pause' to temporarily stop the simulation .
• Click 'Run' again to restart the simulation .
• When the simulation is finished, click 'Stop' .

Milling on a Standard Mill   |  103


S imulate wit h Stock Automat ion
When you simulated the operations, you simulated all of them from the beginning and the
simulation started with the initial stock defined in Simulation Parameters.
But what if you want to simulate only one operation without simulating all the operations before
them?
In that case, you can use Stock Automation. Stock Automation will start the simulation of one or
more operations with the previous stock already removed. Stock Automation also displays icons
next to each operation in the Operation Manager to let you know whether the stock has been
calculated.
• 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.
• Select 'Stock' and click OK.

• On the Tools menu, click Options.


• On the Machining tab, select 'Enable Stock Automation' and click OK.
• Notice that the display in the Operation Manager changes to show the status of the stock for
each milling operation. For details on what each icon means, open ESPRIT Help (press F1) and
look for 'Stock Automation' in the index.

104  |  Get Started with ESPRIT


• Select any operation in the Operation Manager and click Run.
• The simulation starts with the calculated stock from all previous operations.
• Click Stop to exit the simulation.

Milling on a Standard Mill   |  105


106  |  Get Started with ESPRIT
Turning on a Standard Lathe

A standard lathe permits movement within a single plane SolidTurn Machining Technology
defined by the Z and X axes—the Z axis being parallel to the 108
stock and the X axis perpendicular. In order for ESPRIT to Saving Machining Technology....111
accommodate both standard milling and standard turning
Feeds and Speeds. . ..............................111
operations, the global axis labeled “X” is the spindle axis (the Z
axis). The global axis labeled “Y” is the lathe X axis. Feature Extensions. . ..........................114

The intent of this project is to teach you the process for SolidTurn Machining Cycles. . .. 115
creating basic lathe operations using the lathe machining Commands for part transfers... 116
technology in ESPRIT. Commands for machine-specific
In this lesson you will create machining operations to cut a functions. . ................................................ 116
part on a standard 2-axis lathe. Prerequisites.. .....................................117
Open the part file...........................117
Create a turning tool................... 118
The Tool Manager.............................. 118

Create turning features.. .............121


Create lathe stock. . .........................131
Rough the face and the OD.....133
Drill on the center line. . ............137
Rough and finish the groove on
the OD.................................................... 138
You will learn:
• About SolidTurn machining technology and machining Contour the OD............................... 140
cycles Rough and finish the ID. . ............141
• How to create a turning tool
Groove the ID. . .................................. 142
• How to create features for turning operations
• How to create lathe stock Thread the ID.....................................143
• Roughing techniques on the face, OD, and ID of the part Perform the cutoff.. ...................... 144
• Center drilling Simulate turning operations.. 146
• Grooving on the OD and the ID
• Finish contouring
• Threading on the ID
• Simulation with Stock Automation

Turning on a Standard Lathe   |  107


SolidTurn Machining Technology
ESPRIT has machining technology that is designed specifically for lathes. This technology is called
SolidTurn.
SolidTurn technology lets you define the physical properties of your lathe machine, create turning
tools and lathe stock, create specialized turning features and turning operations, 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 technology for SolidTurn machining cycles is displayed on a tab in the Project Manager. This
makes it easy to enter machining parameters and view the part model at the same time. 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.

XX The technology for a machining cycle will not open unless a valid feature is selected first.
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


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 entry
and exit moves, 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
Passes’ on the Strategy tab is set to ‘No’, the Finish tab will not display because those parameters
are unnecessary for the operation.

Turning on a Standard Lathe   |  109


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.
For example, if the stock type for a roughing operation is changed from ‘Automation’ to ‘Diameter’,
the parameter ‘Stock Diameter’ displays to let the user define the diameter.

XX 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.
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.

110  |  Get Started with ESPRIT


Saving Machining Technology
Machining technology settings can be easily saved as a separate *.prc (process) file and used over
and over for the machining of similar parts. To save the technology for a machining cycle, click Save
on the drop-down menu. Enter a name for the file, browse to the location where you want to save
the file, and click Save.

After a technology file has been saved, it can be loaded in a technology page. Click Open on the
drop-down menu, browse to the file, and click Open.
XX The type of technology in the file must match the machining cycle. For example, you can only
load Roughing technology into a Roughing cycle. For this reason, it is important to name the
saved technology file with the type of technology in 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. If you enter a value in one column, the value in the next column is
automatically calculated. This allows you to “fine tune” your feed and speed values.

Sp e ed

You can use Speed RPM (Revolutions Per Minute) or Speed CSS (constant surface speed) to control
the speed of the spindle.

Turning on a Standard Lathe   |  111


When a value is entered in ‘Speed RPM’, the system takes that value and the reference diameter
and calculates and displays the value for ‘Speed CSS’ (in surface feet/meters per minute). 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. If you set Speed CSS, the system takes that value and the
reference diameter and calculates the Speed RPM (in revolutions per minute). 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 , PR

These values are also interactive. Feed rate is defined as units (inch/millimeter) per minute (PM)
or per revolution (PR). In general terms, the feed rate is the speed at which the cutter moves with
respect to the work material.
To calculate the feed rate PR (per revolution) from the feed rate PM (per minute), the system uses
the following formula:
PR = PM / RPM
Going the other way, 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, this value is
set to the value of ‘Bar Diameter’ in Machine Setup.
If you are machining a constant diameter, enter the approximate diameter at the machining
location. For diameters that are not constant, enter an average diameter.
Sp e ed Uni t

Speed Unit controls whether the value for Speed RPM or Speed CSS is used.
Fe ed Uni t

Feed Unit controls whether the value for Feedrate PM or Feedrate PR is used. ‘Per Minute’ uses
the value for Feedrate PM. ‘Per Revolution’ uses the value for Feedrate PR.
Transver se Fe edrat e %

This setting is available only for Roughing, Balanced Roughing, 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. Tool movement in the main cut direction uses the programmed
feed rate.

112  |  Get Started with ESPRIT


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, it will be overwritten at the next
slope angle change if the transverse feed rate is not 100%. The transverse feed rate is always
calculated using the initial feed rate. It does not use the feed rate the user has inserted.
M a ximum RPM

This value is applied only when Speed Unit is set to CSS. By default, this value is the same as the
‘Max RPM’ that is defined for the spindle in Machine Setup.
This value controls the maximum revolutions per minute allowed for the spindle. A machining
operation will not be allowed to exceed this limit.
Spindl e Rang e

This setting is used for RPM cutting. In general, set Spindle Range to ‘Off’ for CSS cutting. 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. For synced operations, you can specify which operation controls the spindle speed.
You can set spindle priority for more than one operation. Spindle priority can also be set on the
operation page.
Use Fe ed and Sp e ed K B

This option can be set to Yes or No. When set to Yes, feed and speed values from the
KnowledgeBase will be inserted automatically.
Before setting this option to Yes, 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


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 inserted speeds and feeds are affected by the “Tool
Material” specified on the tool page of the same Tool ID. The Type of Cut selected on the operation
page also affects the inserted speed and feed values.
Feature Ex tensions
When features are created for turning operations, they are created on the profile of the finished
part. However, there are many times when the tool needs to be positioned outside the feature to
avoid stock material that has not been removed yet. There are also times when the user wants the
tool to continue cutting past the end point of a feature. In ESPRIT, there is no need to modify the
features to obtain the correct tool path.
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. The feature itself is
not modified, only the reference path for the tool path.

A distance can be entered to extend the starting element or ending element of the feature. The
start or end point is extended tangent to the feature. A positive or negative value can be entered.
Entering a negative value has the same effect as making the feature shorter.
XX When a canned cycle is used, lead-in and lead-out moves are disabled. In this case, you can use
the Feature Extension settings to extend the profile for the canned cycle for a safe start.

114  |  Get Started with ESPRIT


SolidTurn Machining Cycles
All SolidTurn machining cycles are displayed on the SolidTurn toolbar and on the Machining menu
under SolidTurn. To display the SolidTurn toolbar, click ‘Switch to SolidTurn’ on the Smart toolbar
and then click SolidTurn.

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

Turning on a Standard Lathe   |  115


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

116  |  Get Started with ESPRIT


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.
All dimensions in this lesson are in millimeters. Make sure “System Unit” on the Tools menu is set
to “Metric”.
If you would like to review and simulate the machining operations from this lesson, the completed
ESPRIT file is available in the folder “completed_parts”.

Open the part file


On the Standard toolbar, click Open.

Browse and select the following file: turned_part.esp.


Click Open.
If the Project Manager is not displayed, press F2.

Turning on a Standard Lathe   |  117


Create a turning tool
This file already contains several tools for turning and drilling. You will learn how to create a
grooving insert that will be used to cut the groove on the OD of the part.
Turning tools can be created from the Tool Manager or from commands on the Turning Tools
toolbar. SolidTurn users can create both milling tools (for drilling and mill-turn work) and turning
tools.

When a tool is created in the Tool Manager, 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. The Tool Manager lets you
create, edit, copy, rename, and delete tools. You can also transfer tools between the Tool Manager
and the KnowledgeBase.
The Tool Manager displays all the available tools in the current document. Tools are grouped by
turret.

The user can choose which columns to display using the Field Chooser. Right-click on any column
heading and then select Field Chooser to view a list of options.
Tools can also be unmounted or moved from one turret to another. To move or copy a tool, right-
click on the tool and select Copy To or Move To. If you choose Unassigned, the tool is unmounted
from its current location.

118  |  Get Started with ESPRIT


Create a groove tool
In the Project Manager, click the Tools tab.
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


Click the Holder tab.
• Holder Type = Grooving
• Style = AS Side Mount
• Shank AxB = 20 - 20.00 x
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, Y, Z’ is set to
‘Home’.
Set ‘Tool Shift X, Z, Y’ to -30,
10, 0.
Click OK to create the new tool
in Station 6.

120  |  Get Started with ESPRIT


Create turning features
Standard turning operations use chain features and PTOPs to define the cutter path.
For simple 2-axis work, you only need to create chain features on the inner and outer part profiles.
For multiple-axis work, you must create chain features on the upper and lower sides of the part
profile because they correspond to upper and lower turrets.
In this project, you will use the Turning Profiles command to create features for turning operations.
The Turning Profiles command analyzes the shape of a selected solid model, surface, or STL model
to find internal and external profiles. ESPRIT rotates the part around the x-axis to find the OD
profile, ID profile or projections of the front face or back face. The calculated profile can be created
as a chain feature or as individual geometric elements.

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. The Turning
Profiles command lets you select solid models or solid faces.
Set the view to ‘Front Isometric’.

In the status area, make sure HI mode and SUB-ELEMENTS mode are active.

On the Smart toolbar, click Create Features.

Click Turning Profiles.

Use HI mode to select the front face of the part (when you first click on the part, the entire solid
model highlights. Right-click to select the next available element. When the face highlights, click
the left mouse button to confirm the selection).

Turning on a Standard Lathe   |  121


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


Change the view to ‘Top’ and zoom the view so that you can select the elements that form the
groove on the OD.
Click Auto Chain.

Select end point (1) as the starting element.


Select segment (2) as the next element in the chain (be careful to select the segment, not the
midpoint).
Select end point (3) as the ending element.
Click Cycle Stop (when a chain is created with an open shape, Cycle Stop must be used to end the
selection process).

Rename ‘3 Chain’ to ‘OD Groove’.

Turning on a Standard Lathe   |  125


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

126  |  Get Started with ESPRIT


Create a contouring profile
You will create this chain feature using a combination of the Manual Chain and Auto Chain
commands. This profile will go over the groove on the OD, since the groove and the OD will be
cut with different machining operations.
• 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.
• Click Cycle Stop
• Rename ‘5 Chain’ to ‘OD Finish’

Turning on a Standard Lathe   |  127


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

128  |  Get Started with ESPRIT


Create a drilling feature
You will create a PTOP feature for the drilled hole on the front face of the part.
• 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 profiles on t he ID
When the Auto Chain command is used, the geometry that defines the chain can be selected
before or after the command is run. When the geometry is selected first, you do not need to
click Cycle Stop. The chain is created automatically.
• 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


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. Stock models for turning operations can be created in
Simulation Parameters or defined in Machine Setup. The stock model in SolidTurn Machine Setup
can be defined as a solid bar, a tube, or as a casting.

Display t he lat he stock


Lathe Stock Automation maintains awareness of the state of lathe stock at any moment during
the machining process. The current operation calculates the stock material based on any
previous turning operations or the initial stock defined in Machine Setup or Simulation.
After any turning operation is created, ESPRIT updates the knowledge of the stock. That
knowledge can then be used to calculate the stock for any subsequent turning operations. The
visibility of the lathe stock on the screen is controlled through the Masks dialog.
• 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


Define t he bar stock in Machine Setup
You can see that the diameter of the default stock is too small. You will define the stock in
Machine Setup as a solid bar with a diameter of 60 mm. The length of the bar stock and the part
stock are the same.
On the Smart toolbar, click Common Machining.

Click Machine Setup.

• 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


Rough the face and the OD
You will start by removing the excess material on the front face and the OD of the part. 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.

Rough t he face
In the Feature Manager, select ‘Front Face’.
On the Smart toolbar, click SolidTurn.

Click Roughing.

• On the drop-down menu, click Open


• Open the following technology file: Processes\T1-Face_Rough.prc

Turning on a Standard Lathe   |  133


Click the Strategy tab.
Notice that ‘Type of Work’ is set to ‘Face’ and that ‘Finish Pass’ is set to ‘No’. Only rough passes
will be generated. 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 the Rough tab.
Notice that Stock Type is set to Automation to allow the system to automatically calculate the
stock for you. Under ‘Passes’ you can see that this operation uses a constant depth of cut of 2
mm.
For detailed information on all the settings for Roughing, click Help.

134  |  Get Started with ESPRIT


Click OK.
Notice that the lathe stock is automatically updated. Each time an operation is applied, the stock
is updated so that the next operation will not create cutting passes in areas where material has
already been removed.

Rough t he OD
Select the feature ‘OD Rough’ and click Roughing .
On the drop-down menu, click Open.
In the same Processes folder, open the file: T2-OD_Rough.prc.
The OD Rough operation uses the same roughing tool as the Face Rough operation. ‘Type of
Work’ is now set to OD. On the Rough tab, Depth Variation is now set to ‘Even Steps’ instead of a
constant depth of cut.
Click OK.

Turning on a Standard Lathe   |  135


Rough t he undercut area on t he OD
Select the feature ‘OD Undercut’ and click Roughing .
Open the file: T3-OD_Rough_Undercut.prc.
On the Strategy tab, notice that ‘Undercutting Mode’ is set to ‘Below’. ESPRIT will recognize and
cut any undercut areas located below the tool. Any undercut areas in front of the tool will be
ignored.
On the Rough tab, a constant depth of cut of 0.5 mm is used for this operation.
Click OK.

136  |  Get Started with ESPRIT


Drill on the center line
Select the PTOP feature and click Drilling.

Open the file: T4-Center_Drill.prc.


This is a standard drilling cycle that uses a 21 mm drill to a depth of 52 mm.
Click OK.

Turning on a Standard Lathe   |  137


Rough and finish the groove on the OD
Select the feature ‘OD Groove’ and click Grooving.

Open the file: T5-OD_Groove.prc.


On the Strategy tab, notice that a rough pass and a finish pass will be created in the same
operation.

On the Rough tab, the groove will be cut with multiple plunge moves using the ‘Smart’ step over
mode. For more information on these settings, click Help.

138  |  Get Started with ESPRIT


On the Finish tab, the ‘Finish Mode’ will create 2 finish passes, starting at each side of the groove
and retracting at the middle.
Click OK.

Turning on a Standard Lathe   |  139


Contour the OD
Select the feature ‘OD Finish’ and click Contouring.

Open the file: T6-OD_Finish.prc.


Click OK.
The OD of the part is now complete and you are ready to start working on the ID.

140  |  Get Started with ESPRIT


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

Turning on a Standard Lathe   |  141


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.
Select the file ‘T8-ID_Groove.prc’ and click Open.

142  |  Get Started with ESPRIT


Thread the ID
Select the feature ‘ID Thread’ and click Threading.

Open the file: T9-ID_Thread.


On the Thread tab, ‘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. When ‘Thread Definition’ is set to ‘From Database’, the thread
parameters are imported from a database.
Click OK.

Turning on a Standard Lathe   |  143


Perform the cutoff
Select the feature ‘Back Face’ and click Cutoff.

On the drop-down menu, click ‘System Default All’ to set all the parameters to the system defaults.
• 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.
• Set Stock ‘Type’ to ‘Automation’
• Set ‘Rough to Diameter’ to -1 so that the tool will cut slightly below the center line
Click OK.

Turning on a Standard Lathe   |  145


Simulate turning operations
The details of the machine, including spindles and turrets, are already defined in Machine Setup.
You can now simulate the complete movement of the operations, the part and the machine to see
how the operations you just created work together.
Operations are simulated in the same order as they are listed in the Operation Manager.
On the Smart toolbar, click Simulation.

• Click ‘Run’ to start the simulation .


• Click ‘Pause’ to temporarily stop the simulation .
• Click ‘3/4 Section’ so that you can see the simulation on the inside of the stock .
• Click ‘Run’ again to restart the simulation .
• When the simulation is finished, click ‘Stop’ .

146  |  Get Started with ESPRIT


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

Turning on a Standard Lathe   |  147


• On the Tools menu, click Options.
• On the Machining tab, select ‘Enable Stock Automation’ and click OK.
• Notice that the display in the Operation Manager changes to show the status of the stock for
each turning operation. For details on what each icon means, open ESPRIT Help (press F1) and
look for ‘Stock Automation’ in the index.

• Select any operation in the Operation Manager and click


Run.
• The simulation starts with the calculated stock from all
previous operations.
• Click Stop to exit the simulation.

148  |  Get Started with ESPRIT


Burning on a 2-axis Wire EDM

ESPRIT offers a complete tool set for a range of wire EDM SolidWire Machining Technology
machines. The unique cutting technology and methodologies 150
for each manufacturer are integrated into specialized Saving Machining Technology.154
technology pages. This gives you full control over the
EDM Machine Types........................ 155
advanced features and unique functionality of the leading
machines on the market. Machining strategies for dies and
punches. . .................................................. 155
The intent of this project is to teach you the process for
Cutting planes. . ................................... 156
creating 2-axis wire EDM (Electrical Discharge Machine)
operations using the standard wire EDM technology in ESPRIT. Cut strategies for lands and tapers
157

SolidWire Gold Machining Cycles


159
Prerequisites.. ...................................160
Open the part file.........................160
Set the EDM Machine Type. . .... 161
Create EDM features.. ................... 161
Create a stock model..................166
Contour the group of holes. . ..169
Contour the die openings. . ........171
Sort EDM operations. . ..................174
Simulate wire EDM operations .176
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

Burning on a 2-axis Wire EDM   |  149


SolidWire Machining Technology
ESPRIT has machining technology that is designed specifically for 2-axis through 5-axis wire EDM,
including machines equipped with a rotary axis. This technology is called SolidWire.
SolidWire technology lets you define the physical properties of your wire EDM, create stock
models, create specialized EDM features with automatic feature recognition, create wire EDM
operations, 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. This
makes it easy to enter machining parameters and view the part model at the same time. The user
can also click on any of the other tabs in the Project Manager to make it easier to select features.

XX The technology for a machining cycle will not open unless a valid feature is selected first.
The way that machining parameters are organized for all SolidWire 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

150  |  Get Started with ESPRIT


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. All EDM machine types use the same interface to
group machining parameters in a consistent way.
• The General tab contains all the general information about the operation such as the operation
name, the machining strategy, information about the workpiece, cut-off moves, and a comment
area.
• 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,
such as optimized wire path, taper information, and control over machine functions

Burning on a 2-axis Wire EDM   |  151


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.

To make the selection of parameters easier, the interface shows the user only what is needed
based on the current input. For example, if the selected feature has a land depth, the ‘Land Cut’
parameters display on the Cut Data tab.

152  |  Get Started with ESPRIT


If the feature has taper only, the ‘Land Cut’ settings 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.

Burning on a 2-axis Wire EDM   |  153


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.

Saving Machining Technology


Machining technology settings can be easily saved as a separate *.prc (process) file and used over
and over for the machining of similar parts. To save the technology for a machining cycle, click Save
on the drop-down menu. Enter a name for the file, browse to the location where you want to save
the file, and click Save.

After a technology file has been saved, it can be loaded in a technology page. Click ‘Open’ on the
drop-down menu, browse to the file, and click Open.
XX The type of technology in the file must match the machining cycle. For example, you can only
load Pocketing technology into a Pocketing cycle. For this reason, it is important to name the
saved technology file with the type of technology in the file.

154  |  Get Started with ESPRIT


EDM Machine Types
Before you create SolidWire operations, you must first select the type of EDM you are using. The
machine type you choose determines the options that are available on the operation technology
pages.
The EDM machine type is selected from the Tools menu.

A dialog displays all the machine types available in ESPRIT. If your machine type is not shown on
the list, select ‘Generic’.

XX After machining operations are created, the machine type cannot be changed. All existing
operations must be deleted before the user is allowed to change the machine type.
Machining strategies for dies and punches
A single EDM operation generates a separate operation for the rough cut, each skim cut, each cut-
off, 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, especially important when you are cutting multiple work
pieces or work pieces that require multiple cuts.

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The ‘Strategy’ parameter lets you choose the order in which these cutting passes are created.

The following strategies are available:


• [Rough][Skim]: The rough cut for each selected feature is performed first, then all skim cuts for
each feature. If a cut-off strategy is selected, the cut-off distance is applied to the rough cut and
no retract takes place.
• [Rough][Cut-off][Skim]: This strategy is generally used when the thread point and retract are
inside the feature (a die).The rough cut for each selected feature is performed first, then the
cut-off, then all skim cuts. The cut-off strategy can insert a stop or optional stop code before the
cut-off move for parts that are run unattended.
• [Rough][Skim][Cut-off]: This strategy is generally used when the thread point and retract are
outside the feature (a punch). The rough cut for each feature is performed first, then all skim
cuts for each feature, then all cut-offs.
Cut ting planes
Parameters that control the heights of cutting planes are shown on the General tab. These plane
heights are automatically loaded from the feature properties.
If a chain feature is selected as input, 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.
If an EDM feature is selected as input, these properties are contained in the feature and are loaded
automatically in the technology page. For this reason, it is recommended to use EDM features.

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• 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. The taper is taken from this position. 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).
• 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, a rough pass and skim cuts, or skim cuts only.
When a feature contains both a taper and a land, separate strategies can be defined for each type
of cut. Up to 9 skim cuts can be created after the rough cut.

XX Although a rough cut is included in each strategy, you can use the ‘Suppress Rough’ parameter
to output only skim cuts.
ESPRIT also provides the SolidWire Expert System for several types of machines. The Expert
System is a database that lets you view and choose cutting data before it is inserted on a SolidWire
technology page. The Expert System is launched from a button located on the contouring and
pocketing technology pages.

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The Expert System has two sets of data: a default (Master) database and a User Custom Database.
You can select data from either database. The Default Database contains manufacturer-
recommended data that cannot be changed. The User Custom Database contains data that is set
up by the user.

XX Charmilles machines use their own CT-Expert System provided by AgieCharmilles.


Details about how to set up and use data in the Expert System are provided in ESPRIT Help. Press
F1 to display the Help window and look for ‘Expert System’ in the index.

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SolidWire Gold Machining Cycles
All SolidWire Gold machining cycles are displayed on the SolidWire Gold toolbar and on the
Machining menu under SolidWire Gold. To display the toolbar, click ‘Switch to SolidWire’ on the
Smart toolbar and then click SolidWire.

Part Setup - Part setup is the first step for every machining process. Part Setup controls which
codes are output when SolidWire operations are converted to NC code. Part Setup also defines the
initial position of the wire.
EDM Drilling - 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. 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.
Contouring - This versatile machining cycle supports any number of straight or tapered rough
and skim cuts. Strategies for all styles of EDM machining such as punch, die, multi-cavity parts, and
unattended machining are included. Between cuts ESPRIT automatically handles all the necessary
wire-cut and wire-thread instructions.
Pocketing - 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. When the size of the work
piece makes it difficult to handle slugs efficiently, this no-core pocket machining cycle erodes away
all the material inside a cavity without creating a slug.
Manual EDMing - Creates a 2-axis wire EDM contouring operation using any combination of
rapid or feed moves along manually selected geometric elements.
Taper Change - This command simplifies the process of inserting a gradual taper between
selected sub-elements in a draft conic feature. It is easier to apply a constant taper using the
Property Browser. Simply select one or more sub-elements in a draft conic feature and change the
Draft property. However, if the group of sub-elements includes isometric corners, you must use
the Taper Change command to insert the taper.
Advanced Operation Sorting - Sorts a group of SolidWire operations according to user-defined
criteria. This command offers a range of automatic sorting options to help optimize machining
time.

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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.
All dimensions in this lesson are in millimeters. Make sure “System Unit” on the Tools menu is set
to “Metric”.
If you would like to review and simulate the machining operations from this lesson, the completed
ESPRIT file is available in the folder “completed_parts”.

Open the part file


On the Standard toolbar, click Open.

Browse and select the following file: wire_part.esp.


Set the view to ‘Isometric’.

If the Project Manager is not displayed, press F2.

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Set the EDM Machine Type
For this lesson, you will use the technology for a generic machine.
• On the Tools menu, click EDM Machine Types...
• Make sure Generic is selected and click OK.

Create EDM features


When you have a large number of shapes to cut, you can save time by creating features as a group
and then applying a machining cycle to all of them at once.
You will create draft conic features for the die openings and the holes. Instead of creating features
one at a time, you can create all the features at once using the face propagation capabilities in
ESPRIT.

Set t he work plane


When an EDM feature is created, the orientation of the feature is based on the current work
plane. 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 height of the UV and XY
planes are measured from the origin of the plane.
For this lesson, make sure the current work plane is set to XYZ.

Create a group of hole features


You will use Draft Feature Recognition to create the hole features. 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. You will also automatically place
the new features into a feature group.
Select the solid model.
On the Smart toolbar, click Features.

Click Draft Features.

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• 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

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• 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.

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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’

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• 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’

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Create a stock model
Stock models for wire EDM operations are created in Simulation Parameters on the Simulation
toolbar.
Stock models are created as solid models that aid in the visualization of material removal during
the simulation process. Stock models can be defined in a variety of ways: from an existing solid
model, from a feature, from an external file, and from points that define a block.
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.
To automatically select all the connected segments that form the profile of the part, you will hold
down the Shift key during the selection process.
• Hold down the Shift key and select a segment in the outer profile
• Click Auto Chain

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On the Smart toolbar, click Simulation.

Click Simulation Parameters.

• 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

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• Click Add
• Click OK

• To view the new stock model, click Single Step


• Click Stop to exit simulation mode

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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, you only need
to define a few machining parameters.

On the Smart toolbar, click SolidWire.

In the Feature Manager, select the ‘Hole Group’ folder.


Click Contouring.

• Make sure ‘Strategy’ is set to [Rough][Skim]


• Click the Cut Data tab
• set ‘Strategy’ to ‘Rough and 1 Skim’
• Click OK

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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. If you change
the parent operation, the child operations will be
updated automatically.
You can also treat the child operations as
independent operations by changing some of
the technology settings. However, if any of those
settings are updated later in the parent operation,
the parent will override the children.

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Contour the die openings
You will again create a Contouring operation to cut all the rectangular openings. Then you will
create a Contouring operation for the triangular opening.
To make it easier to apply a single operation to all the rectangular die openings, you can move the
feature for the triangular die opening out of the feature group.

• 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


• 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

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• Select the ‘Die’ feature for the triangular opening
• Click Contouring
• Click the Cut Data tab
• Set ‘Strategy’ to ‘Rough and 1 Skim’
• Click OK

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Sort EDM operations
SolidWire operations are added to the Operation Manager in the same order as they are created.
This is typically not the optimum order in which you will want to cut the final part.
ESPRIT offers several methods for sorting SolidWire operations in the Operation Manager.
• 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.
The Advanced Operation Sorting command gives you plenty of options for sorting operations to
optimize cutting time. You can sort operations by type of cut or by cavity and then optimize the
cutting path between operations.
The operations you created in this project are currently sorted by feature. You will use Advanced
Operation Sorting to sort the operations by type of cut so that all the roughs are performed first.
Then you will practice optimizing the cutting path using different optimization methods.

• Click the Operations tab in the Project Manager.


• 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

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• 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

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Simulate wire EDM operations
When SolidWire operations are simulated, 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. For this project, you will manually remove the
slugs.

On the Smart toolbar, click Simulation.

• Click Simulation Parameters


• Uncheck ‘Automatic Slug Removal’ and click OK

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• Click ‘Run’ to simulate all the operations .

• 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

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