ALPHACAM 3D Machining 2020

ALPHACAM 2020
3D MACHINING
Copyright
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Alphacam 2020
3D Machining
Contents
Copyright ..................................................................................................................................... i
Conventions used in this manual........................................................................................... xxii
Recommended Operating Systems and Hardware for Alphacam ..................................... xxiii

Supported Operating Systems ............................................................................................... xxiii
Alphacam Minimum Specifications ......................................................................................... xxiii
Hexagon Customer Portal ...................................................................................................... xxiv
ALPHACAM esupport .............................................................................................................. xxv
Introduction .................................................................................................................................. 1
Objective ..................................................................................................................................... 1
3D Machining Strategies ............................................................................................................. 1

3D Machining Strategies – 3 Axis Type ..................................................................................... 1
Type Selection Dialogue............................................................................................................. 3
Type Dialogue (Essential) ....................................................................................................... 3
Z Contour Roughing Theory ....................................................................................................... 4

General ....................................................................................................................................... 5
Type ............................................................................................................................................ 6
Close Open Pockets (Contour option) .................................................................................... 7
Smoothing Radius (Waveform option) .................................................................................... 7
Back Pass Retract (waveform option)..................................................................................... 7
Use Max Feed on Back Pass (Waveform option) ................................................................... 7
Cutting Type ............................................................................................................................ 8
High Speed Cornering ............................................................................................................ 8
Take Account Previous Machining.......................................................................................... 9
Material Selection.................................................................................................................... 9
Levels and Cuts ........................................................................................................................ 10
Material Top and Bottom ....................................................................................................... 10
Intermediate Slices................................................................................................................ 11
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Include Flat Areas as Additional Z Levels ............................................................................. 11

Approach Type ...................................................................................................................... 12
Slope Angle ........................................................................................................................... 12
Maximum Plunge Depth ........................................................................................................ 12
Cutting Order......................................................................................................................... 13
Prismatic Geometry............................................................................................................... 13
Machining Data......................................................................................................................... 14
Chord Tolerance ................................................................................................................... 14
Adaptive Feed Rates ............................................................................................................ 15
Trochoidal for Full-Width Moves ........................................................................................... 16
Links ...................................................................................................................................... 16
Link Type............................................................................................................................... 17
XY Standoff ........................................................................................................................... 17
Feed When Plunging ............................................................................................................ 17
Avoid Rollover ....................................................................................................................... 17
#1 Z Contour Roughing Example ............................................................................................. 18

Auto Set Material dialogue options ........................................................................................... 19
First stage Roughing ................................................................................................................ 21
Select tool ............................................................................................................................. 21
General ................................................................................................................................. 22
Levels and Cuts .................................................................................................................... 23
Machining Data ..................................................................................................................... 24
Tool Data............................................................................................................................... 25
Prismatic Geometry note first stage ......................................................................................... 27
Second Stage Roughing........................................................................................................... 27
Make your drawing clearer .................................................................................................... 27
Create the Side Work Plane ................................................................................................. 28
Create the second roughing tool path ................................................................................... 28
General ................................................................................................................................. 29
Levels and Cuts .................................................................................................................... 30
Prismatic Geometry note second stage ................................................................................... 31
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3D Finish Machining Theory ..................................................................................................... 32

Multi-Processing of 3D Machining Operations ......................................................................... 32
Finish Machining Strategy Options ........................................................................................... 34
3D Solid Machining Accuracy ................................................................................................... 35
Width of Cut .......................................................................................................................... 35
Cusp Height .......................................................................................................................... 35
Cusp Height table.................................................................................................................. 36
Chord Tolerance Along Cut .................................................................................................. 36
Facet Tolerance .................................................................................................................... 36
Lead In/Out Links ..................................................................................................................... 37
Contact Angles ......................................................................................................................... 38
Corners ..................................................................................................................................... 40
Machining Styles ........................................................................................................................ 41
Example Files ............................................................................................................................. 43
#2 Along Intersection (Surface Machining cycle only) .......................................................... 43

General ..................................................................................................................................... 45
Tool Data .................................................................................................................................. 46
Selecting the items to machine ................................................................................................ 47
Step Length ........................................................................................................................... 48
#3 Parameter Line Machining (Surface Machining cycle only) ............................................. 51

General ..................................................................................................................................... 54
Machining Data......................................................................................................................... 55
Tool Data .................................................................................................................................. 56
Hints and Tips........................................................................................................................... 62
Extended Surfaces ................................................................................................................ 62
Create New Surfaces ............................................................................................................ 64
Working with multiple surface ............................................................................................... 65
#4 Machine Surface with Tool Side (Surface Machining cycle only) .................................... 66
General ..................................................................................................................................... 68
3D Lead-In/Out ......................................................................................................................... 69
Machining Data......................................................................................................................... 70
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Tool Axis ............................................................................................................................... 71

Chord Tolerance ................................................................................................................... 71
Tool Data .................................................................................................................................. 72
#5 Horizontal Z Contours .......................................................................................................... 74

General ..................................................................................................................................... 76
Lead-In/Out Links ..................................................................................................................... 77
Machining Data......................................................................................................................... 79
Mill Type ................................................................................................................................ 80
Finish Precision ..................................................................................................................... 81
Connect Aircut Length .......................................................................................................... 82
Additional options .................................................................................................................. 82
Prismatic Geometry Processing times on sample file ........................................................... 82
Cut Between Z Levels ........................................................................................................... 83
Cutting Order......................................................................................................................... 83
Advanced .................................................................................................................................. 84
Contact Angle Limits ............................................................................................................. 85
Finish Shallow Areas ............................................................................................................ 87
XY Step Over ........................................................................................................................ 87
Clip to Depth ......................................................................................................................... 87
Mill Type ................................................................................................................................ 88
Corners ................................................................................................................................. 88
Rest Finish ................................................................................................................................ 89
Tool Data .................................................................................................................................. 90
Select the items ........................................................................................................................ 91
Start Location ........................................................................................................................ 92
#6 Parallel ................................................................................................................................... 94
General ..................................................................................................................................... 96
Lead-In/Out Links ..................................................................................................................... 97
Machining Data......................................................................................................................... 99
Cut Spacing Uses ............................................................................................................... 100
Mill Type .............................................................................................................................. 100
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Finish Precision ................................................................................................................... 101

Facet Tolerance .................................................................................................................. 101
Cut Direction ....................................................................................................................... 102
Connect Aircut Length ........................................................................................................ 102
Step Direction...................................................................................................................... 103
Cut Between Z Levels ......................................................................................................... 103
Advanced ................................................................................................................................ 104
Exclude Flat Areas and Ignore External Edges .................................................................. 105
Corners ............................................................................................................................... 107
Perpendicular Lace ............................................................................................................. 108
Up Down Mill ....................................................................................................................... 109
Contact Angles ....................................................................................................................... 110
Tool Data ................................................................................................................................ 112
Select the items ...................................................................................................................... 113
#7 Projected Contours............................................................................................................. 115

Boundary Rules ...................................................................................................................... 117
Boundary Selection for Block Engraving ................................................................................ 118
General ................................................................................................................................... 119
Lead-In/Out Links ................................................................................................................... 120
Machining Data....................................................................................................................... 122
Cut Spacing Uses ............................................................................................................... 122
Tolerances .......................................................................................................................... 123
Machining Options .............................................................................................................. 123
Tool Data ................................................................................................................................ 124
Select the items ...................................................................................................................... 125
Boundary Selection for Face Machining................................................................................. 126
Extracting the Boundary Geometries .................................................................................. 126
Tool Directions .................................................................................................................... 128
Machining options ............................................................................................................... 131
Select the items ...................................................................................................................... 132
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#8 Radial Fan ............................................................................................................................ 134

Radial requirements ............................................................................................................... 134
Decorative application ............................................................................................................ 135
Boundary Rules ...................................................................................................................... 136
Boundary Selection for Radial Machining .............................................................................. 137
General ................................................................................................................................... 138
Lead-In/Out Links ................................................................................................................... 139
Machining Data....................................................................................................................... 141
Options ................................................................................................................................ 141
Angles ................................................................................................................................. 142
Tolerances .......................................................................................................................... 142
Tool Data ................................................................................................................................ 143
Select the items ...................................................................................................................... 144
Same Values, Different Centre Points .................................................................................... 146
#9 Radial Curved Pocket ......................................................................................................... 147

Blend Machining Application .................................................................................................. 148
Boundary Rules ...................................................................................................................... 149
Boundary Selection for Radial Machining .............................................................................. 150
Select the items ...................................................................................................................... 152
#10 Spiral .................................................................................................................................. 154

Worked Example .................................................................................................................... 156
General ................................................................................................................................... 158
Lead-In/Out Links ................................................................................................................... 159
Machining Data....................................................................................................................... 161
Cut Spacing Uses ............................................................................................................... 161
Spiral Options...................................................................................................................... 162
Tolerances .......................................................................................................................... 162
Options ................................................................................................................................ 162
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Select the items ...................................................................................................................... 170
#11 Rest Machining ................................................................................................................. 171

 Previous Tool ..................................................................................................................... 172
General ................................................................................................................................... 173
Lead-In/Out Links ................................................................................................................... 174
Machining Data....................................................................................................................... 176
Type .................................................................................................................................... 177
Steep/Shallow ..................................................................................................................... 178
Options ................................................................................................................................ 178
Tolerances .......................................................................................................................... 179
Mill Type .............................................................................................................................. 179
Tool Data ................................................................................................................................ 180
#12  Pencil Tracing ............................................................................................................... 181

General ................................................................................................................................... 183
Lead-In/Out Links ................................................................................................................... 184
Machining Data....................................................................................................................... 186
#13 Drive Curves ...................................................................................................................... 188

Using Geometries ................................................................................................................... 188
Using Toolpaths...................................................................................................................... 189
General ................................................................................................................................... 192
Lead-In/Out Links ................................................................................................................... 195
Tool Data ................................................................................................................................ 197
Worked Example using Toolpaths .......................................................................................... 199
Types .................................................................................................................................. 201
General ............................................................................................................................... 201
Levels and Cuts .................................................................................................................. 202
Machining Data ................................................................................................................... 203
Tool Data............................................................................................................................. 204
#14 Flat Area Offset ................................................................................................................. 213

General ................................................................................................................................... 215
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Lead-In/Out Links ................................................................................................................... 216

Machining Data....................................................................................................................... 218
Cut Spacing Uses ............................................................................................................... 218
Strategy ............................................................................................................................... 220
Options ................................................................................................................................ 224
Rest Finish .............................................................................................................................. 225
Worked Example ................................................................................................................. 226
#15 Helical Z ............................................................................................................................. 233

General ................................................................................................................................... 235
Lead-In/Out Links ................................................................................................................... 236
Machining Data....................................................................................................................... 238
Cut Spacing uses ................................................................................................................ 238
Tolerances .......................................................................................................................... 239
Cutting Order....................................................................................................................... 240
Options ................................................................................................................................ 240
Worked Example .................................................................................................................... 241
General ................................................................................................................................... 243
Lead-In/Out Links ................................................................................................................... 243
Machining Data....................................................................................................................... 244
#16 Cylindrical Parallel ............................................................................................................ 248

Axis of Revolution ................................................................................................................... 250
Faces to Machine ................................................................................................................... 251
General ................................................................................................................................... 252
Lead-In/Out Links ................................................................................................................... 253
Machining Data....................................................................................................................... 255
Cut Spacing uses ................................................................................................................ 255
Cutting limits........................................................................................................................ 256
Finish Precision ................................................................................................................... 256
Bi-Directional ....................................................................................................................... 257
Max to Min........................................................................................................................... 257
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Direction of Rotation ........................................................................................................... 258

Tool Offset from Centre Line............................................................................................... 259
#17 Cylindrical Profiling .......................................................................................................... 261

General ................................................................................................................................... 263
Tool Control ............................................................................................................................ 264
Lead-In/Out Links ................................................................................................................... 265
Machining Data....................................................................................................................... 267
Cut Spacing uses ................................................................................................................ 267
Options ................................................................................................................................ 268
Finish Tolerances ................................................................................................................ 268
Cut Between Values ........................................................................................................... 268
Direction .............................................................................................................................. 269
Cutting Order....................................................................................................................... 269
Tool Data ................................................................................................................................ 270
Axis Location .......................................................................................................................... 271
Part Selection ......................................................................................................................... 271
#18 Constant Cusp .................................................................................................................. 273

Constant Cusp step over ........................................................................................................ 274
Parallel step over .................................................................................................................... 274
General ................................................................................................................................... 278
Lead-In/Out Links ................................................................................................................... 279
Machining Data....................................................................................................................... 281
Cut Spacing Uses ............................................................................................................... 282
Mill Type .............................................................................................................................. 282
Tolerances .......................................................................................................................... 282
Options ................................................................................................................................ 283
Contact Angles ....................................................................................................................... 284
Tool Data ................................................................................................................................ 286
Worked Example .................................................................................................................... 287
Boundary creation .................................................................................................................. 291
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Tool Directions .................................................................................................................... 293

Add Boundary ..................................................................................................................... 294
Update the tool path ............................................................................................................ 295
Constant Cusp Tips............................................................................................................. 297
#19 Z (Enhanced Undercuts) .................................................................................................. 299

Tool paths generated with Horizontal Z .................................................................................. 299
Tool Paths Generated with Z (Enhanced Undercuts)............................................................. 300
General ................................................................................................................................... 302
Lead-In/Out Links ................................................................................................................... 303
Machining Data....................................................................................................................... 305
Cut Spacing Uses ............................................................................................................... 305
Options ................................................................................................................................ 306
Tolerances .......................................................................................................................... 307
Cutting Order....................................................................................................................... 307
Direction .............................................................................................................................. 307
Tool Data ................................................................................................................................ 308
Worked Example .................................................................................................................... 309
Tool Axis conversion .............................................................................................................. 317
3D Finish Machining tutorial example. .................................................................................. 320

Finish Machining Outline ........................................................................................................ 321
Tool Axis Conversion .............................................................................................................. 322

#20 Convert 3D work plane tool path to Vertical .................................................................... 323
#21 Convert 2 Axis tool path in work plane to Vertical ........................................................... 324
4 Axis XZ or YZ Rotation ........................................................................................................ 326
#22 Through Axis ................................................................................................................ 326
Parallel tool paths................................................................................................................ 326
#23 Helical Z tool paths in work plane ................................................................................ 327
5 Axis ...................................................................................................................................... 328
#24 XZ Rotation Confined with Boundary ........................................................................... 328
#25 Normal to Curve or Curves .......................................................................................... 329
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#26 XY Rotation Tool at Fixed Tilt Angle ............................................................................ 330

#27 Project through Point ................................................................................................... 331
#28 Project through Axis ..................................................................................................... 332
#29 Confine with Boundary ................................................................................................. 334
#30 Project through Guide Curves...................................................................................... 335
#31 Cut Spline or Polyline ....................................................................................................... 338
5 Axis Cut With side of tool .................................................................................................... 340
Model Examples ....................................................................................................................... 341

Bracket ................................................................................................................................... 341
Curved Block .......................................................................................................................... 341
Curved Recess ....................................................................................................................... 342
Helical Z .................................................................................................................................. 342
Male Form 1 ........................................................................................................................... 343
Mould Insert ............................................................................................................................ 343
Mould 1 ................................................................................................................................... 344
Mould 2 ................................................................................................................................... 344
Mould 3 ................................................................................................................................... 345
Mould 4 ................................................................................................................................... 345
Panel + Shape ........................................................................................................................ 346
Part Machined with lollipop cutter ........................................................................................... 346
Pipe ........................................................................................................................................ 347
Pocketed Plate ....................................................................................................................... 347
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Table of Images
FIGURE 1 - CUSTOMER SUPPORT PORTAL XXIV
FIGURE 2 - ESUPPORT PAGE XXV
FIGURE 3 - 3D MACHINING STRATEGY DROP DOWN 1
FIGURE 4 – 4 AXIS 3D MACHINING CYCLE LIST 2
FIGURE 5 - 5 AXIS 3D MACHINING CYCLE LIST 2
FIGURE 6 - 3 AXIS TYPE Z CONTOUR ROUGHING 4
FIGURE 7 – Z CONTOUR ROUGHING GENERAL TAB 5
FIGURE 8 - CONTOUR TYPE TOOL PATH 6
FIGURE 9 - LINEAR TYPE TOOL PATH 6
FIGURE 10 - SPIRAL TYPE TOOL PATH 6
FIGURE 11 - WAVEFORM TYPE TOOL PATH 6
FIGURE 12 - CLOSE OPEN POCKETS ACTIVE 7
FIGURE 13 - CLOSE OPEN POCKETS INACTIVE 7
FIGURE 14 - CUTTING DIRECTION 8
FIGURE 15 - HIGH SPEED CORNERING ON 8
FIGURE 16 - HIGH SPEED CORNERING OFF 8
FIGURE 17 - Z CONTOUR ROUGHING LEVELS AND CUTS OPTIONS 10
FIGURE 18 - Z CONTOUR ROUGHING WITH MANUAL UPPER AND LOWER CUTTING LIMITS 10
FIGURE 19 - ADDITIONAL Z PASSES INSERTED BETWEEN THE PROGRAMMED DEPTHS OF CUT 11
FIGURE 20 - Z CONTOUR ROUGHING TOOLING MACHINING DATA TAB 14
FIGURE 21 - CHORD TOLERANCE DESCRIPTION 14
FIGURE 22 - ADAPTIVE FEED RATE GRAPH 15
FIGURE 23 -  TROCHOIDAL ACTIVE 16
FIGURE 24 -  TROCHOIDAL INACTIVE 16
FIGURE 25 -  AVOID ROLLOVER INACTIVE 17
FIGURE 26 -  AVOID ROLLOVER ACTIVE 17
FIGURE 27 - AUTO SET MATERIALS DIALOGUE OPTIONS 18
FIGURE 28 - HANDRAIL PRIOR TO ADDING MATERIAL STOCK 20
FIGURE 29 - HANDRAIL WITH STOCK MATERIAL APPLIED 20
FIGURE 30 - Z CONTOUR ROUGHING TOOL SELECTION 21
FIGURE 31 - SELECTING Z CONTOUR ROUGHING 21
FIGURE 32 - Z CONTOUR ROUGHING GENERAL TAB 22
FIGURE 33 - Z CONTOUR ROUGHING LEVELS AND CUTS TAB 23
FIGURE 34 - Z CONTOUR ROUGHING MACHINING DATA TAB 24
FIGURE 35 - Z CONTOUR ROUGHING TOOL DATA TAB 25
FIGURE 36 - HANDRAIL MODEL SELECTED FOR Z CONTOUR ROUGHING 26
FIGURE 37 - APPLIED TOOLPATH 26
FIGURE 38 - TURN OFF TOOLPATHS AND MATERIAL 27
FIGURE 39 - CORRECT LINE FOR THE CREATION OF THE FRONT SIDE WORK PLANE 28
FIGURE 40 - WARNING DIALOGUE SHOWN WHEN NOT WORKING ON FLAT-LAND 28
FIGURE 41 - Z CONTOUR ROUGHING AUTO-UPDATE MATERIAL OPTION ACTIVE 29
FIGURE 42 - ALTER THE LOWER Z LIMIT FOR THE SECOND FACE 30
FIGURE 43 - SIMULATED SIDE MACHINING HIGHLIGHTING ONLY THE AREAS MACHINED 31
FIGURE 44 - WHERE TO SET THE BACKGROUND PROCESSING OPTION 32
FIGURE 45 - TOOL PATHS SHOWING THE PROCESSING MARKER 33
FIGURE 46 - <RCLICK> MENU FOR A PROCESSING TOOL PATH 33
FIGURE 47 – 3-AXIS STRATEGY SELECTION DIALOGUE 34
FIGURE 48 – 4-AXIS STRATEGY SELECTION DIALOGUE 34
FIGURE 49 - STEP OVER CALCULATED USING WIDTH OF CUT 35
FIGURE 50 - STEP OVER CALCULATED USING CUSP HEIGHT 35
FIGURE 51 - EXPLANATION OF CHORD TOLERANCE 36
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FIGURE 52 - LEAD IN/OUT LINKS EXPLANATION 37

FIGURE 53 - REFERENCE 30° ANGLE VALUE 38
FIGURE 55 - REFERENCE BOTH ANGLE VALUES 38
FIGURE 56 - CREATING A MACHINING STYLE FROM A SOLID MACHINING OPERATION 41
FIGURE 57 - <RCLICK> MENU ON A MACHINING STYLE TO APPLY 42
FIGURE 58 - ALONG INTERSECTION MACHINING EXAMPLE 43
FIGURE 59 - ALONG INTERSECTION TOOL SELECTION 44
FIGURE 60 - ALONG INTERSECTION STRATEGY 44
FIGURE 61 - ALONG INTERSECTION GENERAL TAB 45
FIGURE 62 - ALONG INTERSECTION TOOL DATA TAB 46
FIGURE 63 - ALONG INTERSECTION FIRST SURFACE SELECTION 47
FIGURE 64 - ALONG INTERSECTION SECOND SURFACE SELECTION 47
FIGURE 65 - ALONG INTERSECTION STEP LENGTH 48
FIGURE 66 - ALONG INTERSECTION START POINT 49
FIGURE 67 - ALONG INTERSECTION SELECTING THE DIRECTION INTO THE INTERSECTION 49
FIGURE 68 - ALONG INTERSECTION COMPLETED TOOLPATH 50
FIGURE 69 - PARAMETER LINE MACHINING EXAMPLE FILE 51
FIGURE 70 - FACES SELECTED FOR SURFACE EXTRACTION 52
FIGURE 71 - NEWLY EXTRACTED SURFACES 52
FIGURE 72 - PARAMETER LINE TOOL SELECTION 53
FIGURE 73 – PARAMETER LINES STRATEGY 53
FIGURE 74 - PARAMETER LINES GENERAL TAB 54
FIGURE 75 - PARAMETER LINES MACHINING DATA TAB 55
FIGURE 76 - PARAMETER LINES TOOL DATA TAB 56
FIGURE 77 - SURFACE SELECTION POINT DURING THE CYCLE CREATION 57
FIGURE 78 - START LOCATION FOR THE MACHINING 58
FIGURE 79 - SECOND POINT TO FIX THE DIRECTION OF CUT 58
FIGURE 80 - PARAMETER LINES TOOL PATH FOLLOWING THE U CURVE 59
FIGURE 81 - START THE MACHINING OF THE SECOND SURFACE FROM 60
FIGURE 82 - SELECTING THE SECOND POINT TO FIX THE DIRECTION OF CUT 60
FIGURE 83 - PARAMETER LINES TOOL PATH FOLLOWING THE SWEEP OF THE CURVE 61
FIGURE 84 - EXTEND SURFACE OPTION 62
FIGURE 85 - EXTEND SURFACE OPTIONS 62
FIGURE 86 - INCORRECT SURFACE EXTENSIONS 63
FIGURE 87 - POLYLINES FOR SURFACE CREATION 64
FIGURE 88 - SURFACE CREATION DIALOGUE 64
FIGURE 89 - BETTER QUALITY TOOLPATH 65
FIGURE 90 - MACHINE SURFACE WITH TOOL SIDE EXAMPLE FILE 66
FIGURE 91 - PARAMETER LINE TOOL SELECTION 67
FIGURE 92 – MACHINE SURFACE WITH TOOL SIDE STRATEGY 67
FIGURE 93 – MACHINE SURFACE WITH TOOL SIDE GENERAL TAB 68
FIGURE 94 - MACHINE SURFACE WITH TOOL SIDE 3D LEAD-IN/OUT 69
FIGURE 95 – MACHINE SURFACE WITH TOOL SIDE MACHINING DATA TAB 70
FIGURE 96 - TOOL AXIS CONTROL OPTIONS 71
FIGURE 97 - CHORD TOLERANCE OPTIONS 71
FIGURE 98 - CHECK FOULING OPTIONS 71
FIGURE 99 - MACHINE SURFACE WITH TOOL SIDE TOOL DATA 72
FIGURE 100 - MACHINE SURFACE WITH TOOL SIDE APPLIED TOOLPATH 73
FIGURE 101 - HORIZONTAL Z CONTOURS EXAMPLE FILE 74
FIGURE 102 - HORIZONTAL Z CONTOURS TOOL SELECTION 75
FIGURE 103 – HORIZONTAL Z CONTOURS STRATEGY 75
FIGURE 104 - HORIZONTAL Z CONTOURS GENERAL TAB 76
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FIGURE 105 - HORIZONTAL Z CONTOURS LEAD-IN/OUT LINKS TAB 77

FIGURE 107 - HORIZONTAL Z CONTOURS MACHINING DATA TAB 79
FIGURE 108 - HORIZONTAL Z CONTOURS CUT SPACING 79
FIGURE 109 - CUTTING TYPE OPTIONS 80
FIGURE 110 - CLIMB AND CONVENTIONAL MILLING EXPLANATION DIAGRAMS 80
FIGURE 111 - CHORD AND FACET TOLERANCE SETTINGS 81
FIGURE 112 - CHORD TOLERANCE EXPLANATION DIAGRAM 81
FIGURE 113 - CONNECT AIRCUT SETTINGS 82
FIGURE 114 - HORIZONTAL Z CONTOURS CYCLE SPECIFIC OPTIONS 82
FIGURE 115 - AUTOMATIC DEPTH OPTION SELECTED 83
FIGURE 116 - USER DEFINED DEPTH LIMITS WITH AUTO NOT ACTIVE 83
FIGURE 117 - CUTTING ORDER OPTIONS 83
FIGURE 118 - HORIZONTAL Z CONTOURS ADVANCED TAB 84
FIGURE 119 - CONTACT ANGLE OPTIONS 85
FIGURE 123 - HORIZONTAL Z CONTOURS SHALLOW AREA FINISHING OPTIONS 87
FIGURE 124 - SECONDARY ADVANCED CUTTING TYPE 88
FIGURE 125 - ADVANCED CORNER TECHNIQUES 88
FIGURE 126 - HORIZONTAL Z CONTOURS REST FINISH TAB 89
FIGURE 127 - HORIZONTAL Z CONTOURS TOOL DATA TAB 90
FIGURE 128 - HORIZONTAL Z CONTOURS SELECTING THE ITEMS TO MACHINE 91
FIGURE 129 - HORIZONTAL Z CONTOURS SETTING THE CYCLE START LOCATION 92
FIGURE 130 - HORIZONTAL Z CONTOURS TOOLPATH 93
FIGURE 131 - HORIZONTAL Z CONTOURS SIMULATED PROCESSING 93
FIGURE 132 - PARALLEL MACHINING EXAMPLE FILE 94
FIGURE 133 - PARALLEL TOOL SELECTION 95
FIGURE 134 – PARALLEL STRATEGY 95
FIGURE 135 - PARALLEL GENERAL TAB 96
FIGURE 136 – PARALLEL LEAD-IN/OUT LINKS TAB 97
FIGURE 138 - PARALLEL MACHINING DATA TAB 99
FIGURE 139 - CUT SPACING OPTIONS 100
FIGURE 140 - DIRECTION OF MACHINING OPTIONS 100
FIGURE 141 - CHORD AND FACET PRECISION OPTIONS 101
FIGURE 142 - CHORD TOLERANCE DESCRIPTION 101
FIGURE 143 - CUT DIRECTION OPTION 102
FIGURE 144 - CONNECT AIRCUT SETTING 102
FIGURE 145 - PARALLEL STEP DIRECTION DROP DOWN OPTIONS 103
FIGURE 146 - PARALLEL MACHINING DEPTH CONTROL OPTIONS 103
FIGURE 147 - PARALLEL ADVANCED TAB 104
FIGURE 148 - FLAT AREA AND EDGES OPTIONS 105
FIGURE 149 - NO ADVANCED OPTIONS SELECTED 105
FIGURE 150 - EXCLUDE FLAT AREAS ACTIVE 106
FIGURE 151 - IGNORE EXTERNAL EDGES ACTIVE 106
FIGURE 152 - VERTICAL CORNER TRANSFER OPTIONS 107
FIGURE 153 - PERPENDICULAR LACE OPTIONS 108
FIGURE 154 - PERPENDICULAR LACE PRIMARY BOUNDED 108
FIGURE 155- PERPENDICULAR LACE PRIMARY UNBOUNDED 108
FIGURE 156 - UP OR DOWN MILL OPTIONS 109
FIGURE 157 - PARALLEL CYCLE SET TO DOWN MILL 109
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FIGURE 158 - PARALLEL CYCLE SET TO UP MILL 109

FIGURE 162 - PARALLEL TOOL DATA TAB 112
FIGURE 163 - SELECTING THE ITEMS TO PARALLEL MACHINE 113
FIGURE 164 - PARALLEL APPLIED TOOLPATH 114
FIGURE 165 - PARALLEL SIMULATED PROCESSING 114
FIGURE 166 - PROJECTED CONTOURS EXAMPLE FILE 115
FIGURE 167 - PROJECTED CONTOURS TOOL SELECTION 116
FIGURE 168 - PROJECTED CONTOURS STRATEGY 116
FIGURE 169 - BOUNDARIES SET TO CENTRE 117
FIGURE 170 - BOUNDARIES SET TO THE OPPOSITE OF EACH OTHER 117
FIGURE 171 - BOUNDARIES SET TO THE SAME SIDE AS EACH OTHER 117
FIGURE 172 - PROJECTED CONTOURS BOUNDARY SELECTION FOR ENGRAVING 118
FIGURE 173 - PROJECTED CONTOURS GENERAL TAB 119
FIGURE 174 - PROJECTED CONTOURS LEAD-IN/OUT LINKS TAB 120
FIGURE 176 - PROJECTED CONTOURS MACHINING DATA TAB 122
FIGURE 178 - FINISH TOLERANCE OPTIONS 123
FIGURE 179 - PROJECTED CONTOURS TOOL DATA TAB 124
FIGURE 180 - PROJECTED CONTOURS SELECTED ITEMS TO MACHINE 125
FIGURE 181 - PROJECTED CONTOURS USED FOR BLOCK ENGRAVING IN ISO VIEW 125
FIGURE 182 - PROJECTED CONTOURS WORKED EXAMPLE 126
FIGURE 183 - EXTRACTION OF REQUIRED BOUNDARIES 126
FIGURE 184 - EXTRACTED BOUNDARY GEOMETRIES 127
FIGURE 185 - GHOST TOOLS AS EXTRACTED 128
FIGURE 186 - GHOST TOOLS SET TO CENTRE AS REQUIRED 128
FIGURE 187 - TOOL SELECTION FROM AN EXISTING CYCLE USING <RCLICK> OPTION 129
FIGURE 189 - PROJECTED CONTOURS BOUNDARY SELECTION FOR AREA MACHINING 130
FIGURE 190 - PROJECTED CONTOURS MACHINING OPTIONS 131
FIGURE 191 - PROJECTED CONTOURS ITEMS TO MACHINE 132
FIGURE 192 - PROJECTED CONTOURS INACTIVE OFFSET ISLANDS 133
FIGURE 193 - PROJECTED CONTOURS ACTIVE OFFSET ISLANDS 133
FIGURE 194 - RADIAL DECORATIVE SAMPLE FILE 134
FIGURE 195 – RADIAL TOOL SELECTION 135
FIGURE 200 - RADIAL BOUNDARY SELECTION 137
FIGURE 201 - RADIAL GENERAL TAB 138
FIGURE 202 - RADIAL LEAD-IN/OUT LINKS TAB 139
FIGURE 204 - RADIAL MACHINING DATA TAB 141
FIGURE 205 - RADIAL MACHINING OPTIONS 141
FIGURE 206 - RADIAL ANGLE OPTIONS 142
FIGURE 207 - FINISH TOLERANCE OPTIONS 142
FIGURE 208 - RADIAL TOOL DATA TAB 143
FIGURE 209 - RADIAL ITEMS TO MACHINE 144
FIGURE 210 - RADIAL CENTRE POINT LOCATION 144
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FIGURE 211 - RADIAL GENERATED DECORATIVE TOOLPATH 145

FIGURE 212 - RADIAL POCKET FINISHING EXAMPLE FILE 147
FIGURE 213 – RADIAL TOOL SELECTION 148
FIGURE 218 - RADIAL BOUNDARY SELECTION 150
FIGURE 219 - RADIAL MACHINING OPTIONS 151
FIGURE 220 - RADIAL ITEMS SELECTED FOR MACHINING 152
FIGURE 221 - RADIAL CENTRE LOCATION SET 152
FIGURE 222 - RADIAL APPLIED TOOLPATHS 153
FIGURE 223 - RADIAL CYCLE WHEN APPLIED TO INDIVIDUAL BOUNDARIES 153
FIGURE 224 - RADIAL CYCLE WHEN APPLIED TO ALL FOUR BOUNDARIES AT ONCE 153
FIGURE 225 - SPIRAL EXAMPLE FILE 154
FIGURE 226 - TOOL PATH RAPIDS TURNED ON 155
FIGURE 227 - EVALUATING THE SIZE OF THE AREA TO MACHINE 156
FIGURE 228 - SOLID MACHINING FINISHING SELECTION DIALOGUE 157
FIGURE 229 - SPIRAL GENERAL TAB 158
FIGURE 230 - SPIRAL LEAD-IN/OUT LINKS TAB 159
FIGURE 232 - SPIRAL MACHINING DATA TAB 161
FIGURE 234 - SPIRAL OPTIONS 162
FIGURE 235 - CHORD AND FACET FINISHING OPTIONS 162
FIGURE 236 - SPIRAL DIRECTION OPTIONS 162
FIGURE 237 - SELECTING THE SOLID TO MACHINE 163
FIGURE 238 - SETTING THE START POINT FOR THE SPIRAL CYCLE 164
FIGURE 239 - SPIRAL CYCLE APPLIED 164
FIGURE 240 - SELECTING THE FACE FOR BOUNDARY EXTRACTION 165
FIGURE 241 - EXTRACTED BOUNDARIES 165
FIGURE 243 - GHOST TOOLS SET TO CENTRE AS REQUIRED 166
FIGURE 245 - PROJECTED CONTOURS BOUNDARIES TO BLEND WITH THE SPIRAL 168
FIGURE 246 - PROJECTED CONTOURS MACHINING DATA OPTIONS 169
FIGURE 247 - PROJECTED CONTOURS ITEMS TO MACHINE 170
FIGURE 248 - SPIRAL AND PROJECTED CONTOURS WORKING TOGETHER. 170
FIGURE 249 - REST MACHINING EXAMPLE FILE 171
FIGURE 250 - REST MACHINING STRATEGY 172
FIGURE 251 - EDITING THE EXISTING REST MACHINING CYCLE 172
FIGURE 252 - REST MACHINING GENERAL TAB 173
FIGURE 253 - REST MACHINING LEAD-IN/OUT AND LINKS TAB 174
FIGURE 255 - REST MACHINING DATA TAB 176
FIGURE 256 - REST MACHINING TYPE OPTIONS 177
FIGURE 257 - PREVIOUS TOOL AUTO ACTIVE 177
FIGURE 258 - PREVIOUS TOOL AUTO NOT ACTIVE 177
FIGURE 259 - STEEP/SHALLOW ACTIVE 178
FIGURE 260 - REST MACHINING WIDTH OF CUT OPTION. 178
FIGURE 261 - REST MACHINING CUT BETWEEN Z LEVELS 178
FIGURE 262 - CHORD AND FACET FINISHING OPTIONS 179
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FIGURE 264 - REST MACHINING TOOL DATA TAB 180

FIGURE 265 - PENCIL TRACING SAMPLE FILE 181
FIGURE 266 - REST MACHINING STRATEGY 182
FIGURE 267 - EDITING THE EXISTING REST MACHINING CYCLE 182
FIGURE 268 - REST MACHINING GENERAL TAB 183
FIGURE 269 - REST MACHINING LEAD-IN/OUT AND LINKS TAB 184
FIGURE 271 - REST MACHINING DATA TAB 186
FIGURE 272 - EXTRA OPTIONS FOR PENCIL TRACING SETTINGS 186
FIGURE 273 - STEP OVER VALUE FOR EXTRA PASSES 187
FIGURE 274 - EXTRA PASSES SET TO 0 187
FIGURE 275 - EXTRA PASSES SET TO 3 187
FIGURE 276 - WAVES ADD-IN USED TO GENERATE DRIVE CURVES 188
FIGURE 277 - WAVES GEOMETRIES PROJECTED TO THE SOLID MODEL 188
FIGURE 278 - SIMULATED TOOLPATH 188
FIGURE 279 - 2D TOOLPATH USED AS A DRIVE CURVE 189
FIGURE 280 - DRIVE CURVES EXAMPLE FILE 190
FIGURE 281 – DRIVE CURVES SELECTING A 3MM BALL CUTTER FOR THE WORKED EXAMPLE 191
FIGURE 282 – DRIVE CURVES STRATEGY 191
FIGURE 283 – DRIVE CURVES GENERAL TAB 192
FIGURE 284 - DRIVE CURVES SPECIFIC REQUIREMENTS 193
FIGURE 285 - SELECT THE REQUIRED ITEMS 194
FIGURE 286 - GREEN TICK INDICATES CORRECT OPTIONS 194
FIGURE 287 – DRIVE CURVES LEAD-IN/OUT AND LINKS TAB 195
FIGURE 289 – DRIVE CURVES TOOL DATA TAB 197
FIGURE 290 - SELECT THE SOLID TO MACHINE 198
FIGURE 291 - DRIVE CURVES USING GEOMETRIES APPLIED TOOLPATH 198
FIGURE 292 - ENSURE THE TOOL DIRECTION IS CORRECT FOR A POCKET CYCLE 199
FIGURE 293 – DRIVE CURVES SELECTING A 3MM BALL CUTTER FOR THE WORKED EXAMPLE 200
FIGURE 294 - 2D POCKET CYCLE CREATION PROCESS 201
FIGURE 295 - 2D POCKETING STYLE OPTIONS 201
FIGURE 296 - 2D LEVELS AND CUTS OPTIONS 202
FIGURE 297 - MACHINING DATA WIDTH OF CUT OPTIONS TO SUIT THE FINISHED 3D MACHINING 203
FIGURE 298 - TOOL DATA OPTIONS 204
FIGURE 299 - SELECTING THE PROFILE TO APPLY THE POCKET TO 205
FIGURE 300 - APPLIED INITIAL 2D POCKET CYCLE 205
FIGURE 301 – DRIVE CURVES STRATEGY 206
FIGURE 302 - ENSURE THE TOOL PATHS OPTION IS SET 206
FIGURE 303 - SELECT THE PREVIOUS 2D POCKET AS THE DRIVE CURVE 207
FIGURE 304 – DRIVE CURVES USING TOOL PATHS 207
FIGURE 305 - DRIVE CURVES GENERAL OPTIONS 208
FIGURE 306 – DRIVE CURVES INITIAL CONVERTED TOOL PATH 209
FIGURE 307 - DRIVE CURVES USING TOOLPATHS ARE NOT EDITABLE 210
FIGURE 308 - USING UNDO TO STEP BACK 210
FIGURE 309 - ORIGINAL 2D POCKET CYCLE EDITED TO SUIT 211
FIGURE 310 - USE THE <RCLICK> MENU TO COPY THE OPERATION 211
FIGURE 311 - PROJECTED COPY CYCLE WITH ORIGINAL HIDDEN 212
FIGURE 312 - EDITED 2D TOOL PATH COPIED AND APPLIED TO THE SOLID 212
FIGURE 313 - FLAT AREA OFFSET EXAMPLE FILE 213
FIGURE 314 – FLAT AREA OFFSET STRATEGY 214
FIGURE 315 - FLAT AREA OFFSET GENERAL TAB 215
FIGURE 316 – FLAT AREA OFFSET LEAD-IN/OUT AND LINKS TAB 216
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FIGURE 318 - FLAT AREA OFFSET MACHINING DATA TAB 218
FIGURE 319 – USE WIDTH OF CUT FOR SPACING OPTIONS 218
FIGURE 320 - MACHINING METHOD 219
FIGURE 322 - POCKET STYLE OPTIONS TO MACHINE FLAT AREAS 220
FIGURE 323 – FLAT AREA CONTOUR STYLE MACHINING 220
FIGURE 324 – FLAT AREA LINEAR STYLE MACHINING 221
FIGURE 325 - CLOSE OPEN POCKETS ACTIVE 222
FIGURE 326 - CLOSE OPEN POCKETS INACTIVE 222
FIGURE 327 – FLAT AREA FINISH STYLE MACHINING 223
FIGURE 328 - REST FINISH TAB 225
FIGURE 329 - FLAT AREA OFFSET EXAMPLE FILE 226
FIGURE 330 – FLAT AREA SELECT A SUITABLE FLAT TOOL FOR MACHINING 227
FIGURE 331 – FLAT AREA OFFSET STRATEGY 227
FIGURE 332 – FLAT AREA OFFSET GENERAL OPTIONS 228
FIGURE 333 - FLAT AREA OFFSET MACHINING DATA OPTIONS 229
FIGURE 334 - SELECTING THE SOLID TO MACHINE 230
FIGURE 335 - FLAT AREA OFFSET TOOLPATH APPLIED 230
FIGURE 336 - USING SELECT FACES AND COLLISION DETECTION IN FLAT AREA OFFSET 231
FIGURE 337 - FLAT AREA OFFSET AVOID OPTION INACTIVE 232
FIGURE 338 - FLAT AREA OFFSET AVOID OPTION ACTIVE 232
FIGURE 339 - HELICAL Z EXAMPLE FILE 233
FIGURE 340 – HELICAL Z STRATEGY 234
FIGURE 341 – HELICAL Z GENERAL TAB 235
FIGURE 342 – HELICAL Z LEAD-IN/OUT AND LINKS TAB 236
FIGURE 344 – HELICAL Z MACHINING DATA TAB 238
FIGURE 345 - HELICAL Z CUT SPACING OPTIONS 238
FIGURE 346 - CHORD AND FACET OPTIONS 239
FIGURE 347 - HELICAL Z CUT BETWEEN OPTIONS 239
FIGURE 348 - CUTTING DIRECTIONS 239
FIGURE 349 - CUTTING ORDER 240
FIGURE 350 - HELICAL Z OPTIONS FOR MACHINING 240
FIGURE 351 - HELICAL Z EXAMPLE FILE 241
FIGURE 352 - HELICAL Z SELECT A SUITABLE TOOL FOR MACHINING 242
FIGURE 353 – HELICAL Z STRATEGY 242
FIGURE 354 – HELICAL Z GENERAL TAB 243
FIGURE 355 – HELICAL Z LEAD-IN/OUT AND LINKS TAB 243
FIGURE 356 – HELICAL Z MACHINING DATA TAB 244
FIGURE 357 - SELECTION PROMPT FOR MACHINING 244
FIGURE 358 - SELECT ONE YELLOW FACE THEN USE THE FACE SELECTOR OPTION 245
FIGURE 359 - HELICAL Z USING THE FACE SELECTOR 245
FIGURE 360 – HELICAL Z SELECTING THE START LOCATION 246
FIGURE 361 - SHADED VIEW SHOWS NO TOOLPATH 246
FIGURE 362 - UNSHADED SHOWS THE TOOLPATH INSIDE THE SOLID MODEL 247
FIGURE 363 – CUT INNER SURFACES OPTION SWITCHED ON 247
FIGURE 364 - CYLINDRICAL PARALLEL SAMPLE FILE 248
FIGURE 365 – CYLINDRICAL PARALLEL STRATEGY 249
FIGURE 366 - SELECTING THE CORRECT AXIS TYPE 249
FIGURE 367 - CYLINDRICAL PARALLEL AXIS OF ROTATION 250
FIGURE 368 - SELECTING THE FACES TO MACHINE 251
FIGURE 369 – CYLINDRICAL PARALLEL GENERAL TAB 252
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FIGURE 370 – CYLINDRICAL PARALLEL LEAD-IN/OUT AND LINKS TAB 253

FIGURE 372 - CYLINDRICAL PARALLEL MACHINING DATA TAB 255
FIGURE 373 - CYLINDRICAL PARALLEL SECONDARY WIDTH OF CUT OPTIONS 256
FIGURE 374 - CYLINDRICAL PARALLEL ANGLE LIMIT OPTIONS 256
FIGURE 376 - MAX TO MIN ACTIVE START POINT LOCATION 257
FIGURE 377 - MAX TO MIN NOT ACTIVE START POINT LOCATION 257
FIGURE 378 - CYLINDRICAL PARALLEL MACHINING LIMIT SETTINGS 258
FIGURE 379 - GRAPHIC REPRESENTATION OF THE WORKING LIMIT 258
FIGURE 380 - TOOL OFFSET FROM CENTRE SET TO ZERO 259
FIGURE 381 - TOOL OFFSET FROM CENTRE WITH AN APPLIED VALUE 259
FIGURE 382 - CYLINDRICAL PARALLEL SHOWN IN SIMULATION 260
FIGURE 383 - CYLINDRICAL PROFILING SAMPLE FILE 261
FIGURE 384 – CYLINDRICAL PARALLEL STRATEGY 262
FIGURE 385 - SELECTING THE CORRECT AXIS TYPE 262
FIGURE 386 – CYLINDRICAL PROFILING GENERAL TAB 263
FIGURE 387 - CYLINDRICAL PROFILING TOOL AXIS CONTROL OPTIONS 264
FIGURE 388 - TOOL CONTROL TOOL TIP 264
FIGURE 389 – CYLINDRICAL PROFILING LEAD-IN/OUT AND LINKS TAB 265
FIGURE 391 - CYLINDRICAL PROFILING MACHINING DATA TAB 267
FIGURE 392 - CYLINDRICAL PROFILING CUT SPACING OPTIONS 267
FIGURE 393 – CYLINDRICAL PROFILING OPTIONS FOR MACHINING 268
FIGURE 395 – CYLINDRICAL PROFILING CUT BETWEEN OPTIONS 268
FIGURE 396 - CUTTING DIRECTIONS 269
FIGURE 397 - CUTTING ORDER 269
FIGURE 399 - CYLINDRICAL PROFILING AXIS LOCATION CHOICE 271
FIGURE 400 - CYLINDRICAL PROFILING PART SELECTION 271
FIGURE 401 - CYLINDRICAL PROFILING START POINT SETTING 272
FIGURE 402 - TOOLPATH SHOWN IN SIMULATION 272
FIGURE 403 - CONSTANT CUSP SAMPLE FILE 273
FIGURE 404 – CONSTANT CUSP STEP OVER 274
FIGURE 405 - PARALLEL STEP OVER 274
FIGURE 406 - CONSTANT CUSP STEP OVER OVERLAID ON THE PARALLEL STEP OVER 275
FIGURE 407 - PROJECTED CONTOURS TOOLPATH 276
FIGURE 408 - CONSTANT CUSP TOOLPATH 276
FIGURE 409 - CONSTANT CUSP STRATEGY 277
FIGURE 410 – CONSTANT CUSP GENERAL TAB 278
FIGURE 411 – CONSTANT CUSP LEAD-IN/OUT AND LINKS TAB 279
FIGURE 413 - CONSTANT CUSP MACHINING DATA TAB 281
FIGURE 417 - PARALLEL MACHINING DEPTH CONTROL OPTIONS 283
FIGURE 418 - CONSTANT CUSP EXTRA OPTIONS 283
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FIGURE 423 - CONSTANT CUSP EXAMPLE FILE 287

FIGURE 424 – CONSTANT CUSP SELECTING A SUITABLE TOOL 287
FIGURE 425 - CONSTANT CUSP STRATEGY 288
FIGURE 426 - CONSTANT CUSP TOOLING INFORMATION DIALOGUE OPTIONS 288
FIGURE 427 – CONSTANT CUSP LEAD-IN/OUT AND LINKS TAB 289
FIGURE 428 - CONSTANT CUSP MACHINING DATA OPTIONS 289
FIGURE 429 - SELECTION PROMPT FOR [ALL] SOLIDS 290
FIGURE 430 - CONSTANT CUSP APPLIED TOOLPATH 290
FIGURE 431 - CONSTANT CUSP FACE SELECTION FOR BOUNDARIES 291
FIGURE 432 - CONSTANT CUSP GENERATED BOUNDARIES 292
FIGURE 434 - GHOST TOOLS AS REQUIRED 293
FIGURE 435 - CONSTANT CUSP CYCLE EXPANDED TO SHOW MORE DETAILS 294
FIGURE 436 - <RCLICK> OPTIONS TO ADD BOUNDARIES TO THE EXISTING CYCLE 294
FIGURE 437 - SELECT ONLY THE SQUARE IN THIS EXAMPLE 294
FIGURE 438 - AFTER ADDING THE NEW BOUNDARY, YOU NEED TO UPDATE THE TOOLPATH 295
FIGURE 439 - <RCLICK> MENU UPDATE OPTION 295
FIGURE 440 – CONSTANT CUSP MODIFIED TOOLPATH USING BOUNDARIES 296
FIGURE 441 - EXTRACTED SURFACE 297
FIGURE 442 - EXTEND SURFACES OPTIONS 298
FIGURE 443 - EXTENDED TOOLPATH WITH NEW BOUNDARY 298
FIGURE 444 - EXAMPLE OF HORIZONTAL Z 299
FIGURE 445 - GENERATED TOOLPATH 299
FIGURE 446 – Z (ENHANCED UNDERCUTS) INITIAL TOOLPATH SEEN IN XZ VIEW 300
FIGURE 447 - Z (ENHANCED UNDERCUTS) INITIAL TOOL PATH IN ISO VIEW 300
FIGURE 448 – Z (ENHANCED UNDERCUTS) STRATEGY 301
FIGURE 449 – Z (ENHANCED UNDERCUTS) GENERAL TAB 302
FIGURE 450 – Z (ENHANCED UNDERCUTS) LEAD-IN/OUT AND LINKS TAB 303
FIGURE 452 - Z (ENHANCED UNDERCUTS) MACHINING DATA TAB 305
FIGURE 453 - Z (ENHANCED UNDERCUTS) CUT SPACING OPTIONS 305
FIGURE 454 - Z (ENHANCED UNDERCUTS) OPTIONS FOR THE CYCLE 306
FIGURE 455 - Z (ENHANCED UNDERCUTS) Z LIMITING OPTIONS 306
FIGURE 457 - Z (ENHANCED UNDERCUTS) AREA ORDERING OPTIONS 307
FIGURE 458 - Z (ENHANCED UNDERCUTS) DIRECTION OF CUT OPTIONS 307
FIGURE 460 - Z (ENHANCED UNDERCUTS) EXAMPLE FILE 309
FIGURE 461 - Z (ENHANCED UNDERCUTS) SELECTING A SUITABLE TOOL FOR MANUFACTURE 310
FIGURE 462 – Z (ENHANCED UNDERCUTS) STRATEGY 310
FIGURE 463 - Z (ENHANCED UNDERCUTS) BOUNDARY SELECTION PROMPT 311
FIGURE 464 - Z (ENHANCED UNDERCUTS) TOOLING INFORMATION DIALOGUE OPTIONS 311
FIGURE 465 - Z (ENHANCED UNDERCUTS) LEAD-IN/OUT LINKS 312
FIGURE 466 - Z (ENHANCED UNDERCUTS) MACHINING DATA OPTIONS 312
FIGURE 467 - Z (ENHANCED UNDERCUTS) SELECTION OPTIONS 313
FIGURE 468 - Z (ENHANCED UNDERCUTS) SETTING THE START POINT FOR MACHINING 313
FIGURE 469 - Z (ENHANCED UNDERCUTS) APPLIED INITIAL TOOL PATH THAT WILL NEED EDITING314
FIGURE 470 - Z (ENHANCED UNDERCUTS) TOOLPATHS MARKED FOR DELETION 315
FIGURE 471 - Z (ENHANCED UNDERCUTS) FINAL REQUIRED TOOLPATHS 315
FIGURE 472 - USING THE <RCLICK> MENU TO USE TOOL AXIS CONVERSION 316
FIGURE 473 - TOOL AXIS CONVERSION OPTIONS DIALOGUE 317
FIGURE 474 - SURFACE OPTION SELECTED TO ADJUST THE CURRENT 3 AXIS TOOL PATH 318
FIGURE 475 - Z (ENHANCED UNDERCUTS) TOOLPATH USING TOOL AXIS CONVERSION 318
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FIGURE 476 - Z (ENHANCED UNDERCUTS) FINISHED CONVERTED TOOL PATH 319

FIGURE 477 - EXAMPLE FILE FOR PRACTICE 320
FIGURE 478 - EXPLANATION OF TOOL AXIS CONVERSION DIALOGUE 322
FIGURE 479 - SPIRAL CYCLE CREATED IN A WORK PLANE 323
FIGURE 480 - SPIRAL CYCLE CONVERTED TO A 3 AXIS TOOLPATH NOT ON A WORK PLANE 323
FIGURE 481 - 2D POCKET CYCLE APPLIED ON A WORK PLANE 324
FIGURE 482 - 2D POCKET CYCLE CONVERTED FROM A WORK PLANE TO VERTICAL 325
FIGURE 483 - PARALLEL STRATEGY AS APPLIED 326
FIGURE 484 - TOOL AXIS CONVERSION AT THE CENTRE OF THE CIRCLE 326
FIGURE 485 - Z ENHANCED UNDERCUTS CONVERTED TO VERTICAL THROUGH AN AXIS 327
FIGURE 486 - INITIAL HORIZONTAL Z TOOLPATH 328
FIGURE 487 - TOOLPATH ALTERED USING A BOUNDARY TO PREVENT COLLISIONS 328
FIGURE 488 - TOOLPATH CONVERSION USING A GUIDE CURVES 329
FIGURE 489 - CONVERTED TOOLPATH ALONG A SPECIFIED ANGLE FROM VERTICAL 330
FIGURE 490 - TOOL PATH CONVERSION THROUGH A POINT ON THE TOOL SIDE 331
FIGURE 491 - THROUGH A POINT ON THE OPPOSITE SIDE FROM THE TOOL 331
FIGURE 492 - INITIAL PARALLEL CYCLE 332
FIGURE 493 - TOOL PATH CONVERTED USING A LINE ON THE OPPOSITE SIDE FROM THE TOOL 333
FIGURE 494 - INITIAL HORIZONTAL Z CONTOURS TOOL PATH COLLIDING WITH THE PART 334
FIGURE 495 - CONVERTED TOOL PATH USING A BOUNDARY TO PREVENT COLLISIONS 334
FIGURE 496 - BEFORE CONVERSION. 335
FIGURE 497 - BEFORE CONVERSION SIDE AND END SHOTS 336
FIGURE 498 - CONVERTED TOOL PATH USING TWO GUIDE CURVES 337
FIGURE 499 - CUT SPLINE OR POLYLINE OPTIONS USING ULTIMATE ALPHACAM 338
FIGURE 500 - CUT SPLINE OR POLYLINE OPTION APPLIED TO A FORM TOOL 339
FIGURE 501 - EXAMPLE FILE FOR CUT SPLINE OR POLYLINE 340
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Conventions used in this manual

To enable you to use the information in this guide effectively, you need to understand the conventions used in
the guide to represent differing types of information.
• Buttons on the screen are represented as the button text in square brackets.
For example: Click on [OK].
• Keys on the keyboard are represented as bold lettering in between < > characters.
For example: Press <Enter>.
• Ribbon Tab options are represented as a path with the Ribbon Tab in UPPER case with sub menus
Capitalised and separated with an arrow
For example: Select FILE > Open.
• Field names are represented as bold text. And the value to be entered will be represented by Bold
Text.
For example: Enter the value 50 in the Offset field. Or
When prompted for the X & Y values type 100,50 <Enter>
Denotes a <LClick> or Primary Mouse Button Click.

Denotes a <RClick> or Secondary Mouse Button Click.
 This is a note. It contains useful or additional information.
 This is a reference. It directs you to another part of the user guide.
This is a thought box. It is generally used in exercises and contains a question for you to
consider.
 This is a highlighted note to emphasise information
 This is a warning; it contains information that you must not ignore.
 This is a tip. It is generally used in exercises and offers further advice.
1. This is the first line of a number list item
2. This is the second item of the numbered instructions, which you must
3. Follow in sequence.
• This is a list
• of items, in which
• The order is not important.
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Recommended Operating Systems and Hardware for

Alphacam
Supported Operating Systems

• Operating System
• 64bit operating systems of the following list are supported,
• Windows 7 (Professional, Enterprise or Ultimate) SP1 required,
• Windows 8.1 Professional and Enterprise,
• Windows 10 Professional and Enterprise.
• Alphacam will install and run on the 'Home' editions of the above operating systems. However, this is
not recommended, and we cannot guarantee to fix any Alphacam issues specifically related to these
operating systems.
• Nvidia or ATI Open GL Graphics Card with 1Gb dedicated memory
 We recommend you keep up to date with the with the latest Software Updates for the
supported operating systems and drivers for your hardware base.
 Any Windows Operating system (OS) prior to and including Vista, is not a supported
operating system.
Alphacam Minimum Specifications

The latest minimum specification can be found at
http://www.alphacam.com/systemrequirements
This minimum specification is to run any Alphacam Essential module, you will need to considerably increase
the specification if you are working with solid models and producing the NC code for 3D machining and 3, 4, or
5 axis simultaneous machining strategies.
Your minimum specifications should be the fastest processor with the most memory and the highest
specification video card that your budget will allow.
 If using Autodesk Inventor Files, please check the current Inventor View requirements at
autodesk inventor view
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Hexagon Customer Portal

At Hexagon, we strive to provide you and your business with first class technical support and services. The
Customer Support Portal allows you the tools you need to receive the best from your software. In addition to
generating new and updating existing support cases, the portal allows you:
• Unlimited user logins for your company.
• Access to all your licenses for easy reference.
• Get the latest releases and software update at the touch of a button.
• View what is available on your support and maintenance schedule.
• Reference to the Customer Support Charter at any time.
• View the status of your Technical Support cases.
• View all purchased Professional Services like Training and Consultancy.
Figure 1 - Customer Support Portal
For the Hexagon Customer Portal visit customers.ps.hexagonmi.com
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ALPHACAM esupport
Another location to gain valuable information about using the software or asking other experienced users for
assistance are the esupport forums.
Figure 2 - esupport page
Asking a question of the community, using the knowledge base or other available information links could save
you time if you have a problem that someone else may already have supplied a solution for.
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Introduction
Objective
The purpose of this training course is to enable you to apply machining strategies to either: Solids + Surfaces
or Surfaces, applied as 3, 4 and 5 Axis machining conditions.
The machine tool and software module level capabilities will place restrictions on the position and orientation of
the model and the machining strategies that can be used.
3D Machining Strategies
Alphacam Modules include 3D Solid Machining strategies that create roughing and finishing tool paths to
optimise the productivity of CNC machine tools while, at the same time, ensuring the highest quality machining
of Solid models and Surfaces.
3D Machining Strategies – 3 Axis Type
Along Intersection
Constant Cusp
Drive Curves
Flat Area Offset
Helical Z
Horizontal Z Contours
Machine Surface with Tool Side
Parallel
Parameter Lines
Projected Contours
Radial
Rest Machining
Spiral
Z (Enhanced Undercuts)
Z Contour Roughing
Figure 3 - 3D Machining Strategy Drop Down
3D Machining 1
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3D Machining
Cylindrical Parallel
Cylindrical Profiling
Drive Curves
Flat Area Offset
Parallel
Parallel – Shallow Slopes
Parallel – Steep Slopes
Parameter Lines
Projected Contours
Radial
Rest Machining
Spiral
Figure 4 – 4 Axis 3D Machining cycle list
Drive Curves
Flat Area Offset
Parallel
Parallel – Shallow Slopes
Parallel – Steep Slopes
Parameter Lines
Projected Contours
Radial
Rest Machining
Spiral
Figure 5 - 5 Axis 3D Machining cycle list
3D Machining 2
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3D Machining
Type Selection Dialogue

The type dialogue box and number of options will differ depending on the 3D machining type and the module
level being used.
The Essential module only has one 3D Machining strategy.
The Standard module only has three 3D Machining strategies.
Type Dialogue (Essential)

There are no options to select other than Parallel in Essential then the prompt is for you to select the
containment boundary.
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3D Machining
Z Contour Roughing Theory

The first machining strategy that is normally used is Z Contour Roughing.
The Z Contour Roughing option can only by actioned as a 3-Axis strategy.
However, the 3-Axis tool paths are generated with respect to the currently active work plane when the strategy
is applied. This can then allow for 3+2 five axis machining.
Figure 6 - 3 Axis type Z Contour Roughing
 Multi planer machining can only be created within the limitations of your machine tool.
3D Machining 4
Alphacam 2020
3D Machining
General
Figure 7 – Z Contour Roughing General Tab
3D Machining 5
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3D Machining
Type
Figure 8 - Contour type tool path Figure 9 - Linear type tool path
Figure 10 - Spiral type tool path Figure 11 - Waveform type tool path
 Note that in some circumstances the Spiral setting will be overridden and a concentric tool
path created. This may occur for large step over values where a spiral tool path would leave
pegs of uncut material in corners.
 The Waveform roughing strategy is a high speed machining technique that maintains a
constant tool cutting load by ensuring the tool engagement into the material is consistent.
The tool path moves in a smooth path to avoid sharp changes in direction which maintains
the machine tool’s velocity.
3D Machining 6
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3D Machining
Close Open Pockets (Contour option)

If unchecked, the tool will work from the outer edge inwards. If checked, all open pockets will be treated as
closed pockets and the tool will start in the middle and work outwards.
Figure 12 - Close Open Pockets active Figure 13 - Close Open Pockets inactive
Smoothing Radius (Waveform option)

This controls the radius of tangential arcs between the linear moves that join the tool path when approaching
into a corner.
 By default, the smoothing radius is set to 25% of the chosen tool diameter or equal to the
minimum radius, whichever is greater. If specified, the radius must be at least equal to the
minimum radius and no greater than the tool diameter.
Back Pass Retract (waveform option)
A large axial depth of cut can cause the tool to flex, so when disengaged on the back pass,
the tool end could remove a small amount of material under the pendulum affect. This will
blunt the bottom of the tool and generate unwanted heat in the component.
The Back Pass Retract is used to raise the tool by a small amount in the Z axis to avoid dragging the tool
across the part surface on the back passes.
The tool starts to lift from the cut Z depth at the point where the tool disengages from the material and lifts over
5° of travel, at which point the tool will switch to the high feed rate, if specified. The tool will descend back
towards the Z cut depth 5° before the tool re-engages with the material.
Use Max Feed on Back Pass (Waveform option)

If checked, the maximum allowed feed rate on the back pass will be used where the tool is disengaged from
the material over a large distance.
Max Feed is specified by $753 or PostConfigure.FeedMax in the post processor.
The high feed rate becomes active 5° past the point where the tool disengages from the material. Then, at 5°
before the tool re-engages the tool path switches back to the cutting feed rate.
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3D Machining
Cutting Type
The cutter can move along a profile on the left or right side. This, combined with the spindle direction,
gives the type of cutting to be either Climb or Conventional.
• Climb • Tool cuts on the left of the profile (i.e. material is on the right).
• Conventional • Tool cuts on right of the profile.
• Optimised • Cycle is optimised to reduce link moves.

The tool may cut on the left or right side.
Figure 14 - Cutting Direction
High Speed Cornering

This setting only affects non-final passes; when checked, a radius is introduced into sharp tool path
corners. This is the default.
This will lower machine stresses, reduce tool path length, maintain tool speed and reduced cycle time.
It will, however, generate more NC code. When unchecked, all tool path corners have an angle from
the profile, however sharp.
Figure 15 - High Speed cornering on Figure 16 - High Speed cornering off
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Take Account Previous Machining

When checked, the cycle looks for and avoids any areas of the part which have been previously
machined at the same cutting depths.
The Top and Bottom levels of areas and stock amount must remain constant between matching cycles
or full complete cycles are created for the smaller cutter.
This option is Work Plane dependant, only cycles applied on the same work plane as each other can
be compared against.
Material Selection
The primary setting for initial machining, ticking this option will use
• Current Material
the only material available once selected or a currently active
material from a previous operation.
• Select Material(s) Allows the use of materials from previous operations to be selected
as the new working envelope for the roughing cycle.
Allows for the automatic updating of the current chosen material to

• Auto update material from reflect any machining that has taken place prior to the current
previous operations operation be set up.
This allows for the removal of unwanted air cutting and speeds up
the machining process.
Allows for the use of a closed geometry path which represents the
• Use Geometry as Material
tool path boundary. Upper and lower Z levels are then applied to
this geometry and used as if it were a material.
• Use Boundaries Allows for the addition of extra controlling 2D geometric boundaries
to contain the roughing cycle.
Avoids the unwanted machining of areas where material does not

• Detect Undercut Stock
exist. For example, a solid model used as a stock material that has
a large aperture within it.
 The Auto Update material option is independent of work planes and allows comparison
of machining between differing work plane set ups, should they interact with each other on
the machined part.
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Levels and Cuts
Figure 17 - Z Contour Roughing levels and cuts Figure 18 - Z Contour Roughing with manual Upper
options and Lower cutting limits
Material Top and Bottom

These options automatically take their settings from the primary material value and all work done on
the part is between these values if the  Auto option is ticked.
Un-ticking Auto allows the user to limit the upper and lower Z machining levels by altering the second
set of options that show.
The machining is still limited even when using this option.

A user defined upper or lower Z limit must still fall within the defined material limits.
Max Depth per Cut

Specifies the depth of each successive cut (for Intermediate Slices).
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Intermediate Slices
Intermediate Slices may be used to reduce the size of the step left by the roughing cycle.
Only the step region is machined by these cuts.
Intermediate Slices will always be cut from bottom to top within each cut increment to reduce unnecessary
cutting. This method roughs and semi-roughs the part in one cycle while allowing the tool to cut to its maximum
depth for the main increments.
Percentage Feed
The feedrate for Intermediate Slices is specified as a percentage of the original programmed cutting feedrate.
Include Flat Areas as Additional Z Levels

Check this to ensure that there is a cutting pass at the height of any flat region. This prevents material being
left un-machined at the bottom of pockets or the top if pillars should the level of those areas fall between the
primary depths of cut setting.
Figure 19 - Additional Z passes inserted between the programmed depths of cut
Without this option checked, the last (lowest) pass occurs when there is not sufficient depth remaining for
another full cut (as specified by the Cut Increment).
It is recommended to leave the option unchecked when working with large surface parts with no flat areas to
increase processing speed.
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Approach Type
Offers you the ability to start the cycle from pre-drilled hole(s) and set a preference for Ramp or Helical
approach.
The cycle automatically applies plunging entry method in a location directly

• Automatic achieved from the cycle itself.
This method is used on materials where entry is not an issue and the nature
of the material and tooling will allow such a plunging process to occur.
Specify a pre-defined drill point as the point of entry. The tool will plunge
down the nearest hole to the start point in a region. When no valid point is
available the tool will ramp instead. The tool will rapid down the hole to the
desired depth unless it is within the safe distance of the pre-drill point where
it will feed to depth from the safe distance above the point. If Feed When
• Pre-Drilled Holes
Plunging is checked, the tool will feed down the hole at the Down Feed
value.
 Geometry for Pre-Drilled holes must have Z Top and

Bottom levels as the approach is of an Auto Z method.
• Helix The cycle will always attempt to place a helical approach in pocket areas
before any other approach type.
• Ramp The cycle will always attempt to place a ramp approach in pocket areas
before any other approach type.
Slope Angle
The Slope angle sets the angle of the ramp move into the stock material. The maximum ramp angle is
calculated from the Maximum Plunge Depth and Centre Cut modifiers. This value will automatically
be used if it is found to be less than the specified Ramp Angle. If the modifier is left blank the
calculated ramp angle will be used.
Maximum Plunge Depth

The Maximum plunge depth specifies the maximum distance in the Z-axis that the tool can plunge into
the material. The value will be used to check that the ramp move does not exceed this value.
If Maximum Plunge Depth is set to 0 the tool cannot plunge or ramp. Therefore, the cycle can only
machine external areas or pocket areas that have pre-drilled holes.
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Cutting Order
 By Zone allows an entire area to be worked on to the full depth prior to moving to the next area.
 By Level performs each dedicated Z step down on each area to be machined prior to the next step down in
Z.
This includes the Intermediate Slices option.
By Zone will complete the main cuts to depth, then perform the slices.
By Level will complete one main slice and its applied intermediate slices before commencing the next main
slice.
Prismatic Geometry
This option alters the format of the finalised NC code from a generated X, Y, Z individual point listing to one
where if a single Arc command can be created to replace hundreds of single points, it will.
The benefit of this command is that it greatly reduces the size of the NC which will be sent to the machine tool,
but the drawback is that the calculations are performed as the cycle is created and will take time depending on
the complexity of the part and resulting code.
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Machining Data
Figure 20 - Z Contour Roughing Tooling Machining Data Tab
Chord Tolerance
The Chord Tolerance is used in setting the mesh size to determine what features are seen to be machined. If
the roughing cycle appears to miss sections, it is usually because the chord tolerance is too large.
When creating the paths along curved features the Chord Tolerance limits the creation of those points taken
into consideration to generate the path. Any points within the given arc bounded by the chord are ignored.
Making the tolerance large will give a very rough version of the profile, whereas a smaller figure will produce a
more accurate profile.
Usually a 0.25mm value will be adequate for a roughing profile, with 0.02 or smaller being used to finish a
product.
Figure 21 - Chord Tolerance description
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Adaptive Feed Rates

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

The Minimum Feed rate is the % of the original specified feed rate to be used in a full width cut (where the
effective step over = 100%). At intermediate effective step over’s, the feed rate is adjusted proportionally.
For example, if the increment % is 10 for a specified cut feed of 5500 and the specified step over is 50% of the
tool dia. i.e. 10, then, if the actual step over is 12 i.e. 60% of the tool dia., the feed rate would be reduced by
10% to 4950. If the step over was 16 i.e. 80% of the tool dia., then the feed rate would be reduced by 30% to
3850. If the step over was 20 i.e. 100% of the tool dia., then the feed rate would be reduced by 50% to 2750.
The Maximum Feed rate is the % of the original specified feed rate to be used as the effective step over
reduces towards 0.
For example, if the increment % is 10 for a specified cut feed of 5500 and the specified step over is 50% of the
tool dia. i.e. 10, then, if the actual step over is 8 i.e. 40% of the tool dia., the feed rate would be increased by
20% to 6600. If the step over was 6 i.e. 30% of the tool dia., then the feed rate would be increased by 40% to
7700. If the step over was 1 i.e. 5% of the tool dia., then the feed rate would be increased by 95% to 10725.
The feed rate can only be adjusted to certain values. This Feed rate Increment is the size of the steps between
these values, as a percentage of the original feed rate.
 Specifying low values helps produce tighter control over the feed rate, but with
potentially more CNC code and slower processing. Specifying high values helps reduce the
CNC code and speed processing, but with less accurate control over the feed rate
 The Step over is specified as a width of cut value in the Z contour roughing Dialogue the
system internally uses the width of cut and the tool diameter to calculate the relevant
percentages.
Figure 22 - Adaptive Feed rate graph
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Trochoidal for Full-Width Moves

Full Width Cut Move = Cut move which exceeds the specified Width of Cut.
This potentially overloads the tool, so Alphacam detects when a cut would be full width and offers this
option. Note that in a narrow channel there may not be room for a trochoidal cut, in which case the
channel is excluded from the cycle.
Figure 23 -  Trochoidal active Figure 24 -  Trochoidal inactive
Links
Link Method
There is a retraction applied to the link

• Always
(rapid) move.
Ramp
(The height of the retraction is set by ‘Link
Type’).
The tool stays at the same depth and there

• Stay At
is no retraction. This does not apply to links
Depth
that clear geometry, for these links there is
always a retraction to avoid gouging.
• Optimised The faster of the two methods above is

automatically selected.
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Link Type
When there is to be a retraction for the link, this setting controls the retract height.
This setting only applies to moves within the same machined out volume (as in a
pocket in a boss in a pocket). For links that move between two separate volumes
• Optimised
(two separate pockets for example), the tool always retracts to the Clearance
height. These moves will be at the maximum feed rate specified in the post
processor.
• Clearance
For the link, the tool always retracts to the Clearance height.
XY Standoff
This allows you to specify the extra clearance distance between the stock and the tool when
approaching from vertical faces.
Feed When Plunging

When checked, the tool will use the assigned feedrate in the cycle when moving down in the Z axis
during the cycle. This is a safe option when the amount of stock material is unknown. When
unchecked, the tool will rapid to the safe distance above the area to be machined then feed into
position.
Avoid Rollover
Check this to eliminate the tool roll-round on the outer corners of open pocket geometry where
damage may occur to delicate materials. This is mainly for use with wireframe and prismatic type solid
geometry.
Figure 25 -  Avoid Rollover inactive Figure 26 -  Avoid Rollover Active
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#1 Z Contour Roughing Example

In this tutor led example, processes that will allow you to rough a part to very close accuracy to the finished
part shape will be discussed.
The need in manufacturing to reduce time and costs is always paramount, so a method of removing unwanted
cutting where a previous operation has already machined the part will be explained.
Open the “#1 Twisted Handrail drawing” from the

“….\ALP TRG 116 3D Machining 2020\Examples\Drawings” folder.
This is to be machined with Ø25 diameter flat tool with cutting length of 125mm.
The component is machined from the Top and 2 sides using residual material to eliminate air cuts.
Using 3D > Auto Set Material with a top at Z+10mm, a bottom Z value of -200mm and a Material
XY Stock of 10mm.
Figure 27 - Auto Set Materials dialogue options
The reason for a Z-200 figure is to represent an oversize piece of material which allows the part to be lifted
above the table or holding fixture.
Ensure the option  Associate for auto-update is active.
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Auto Set Material dialogue options
Upper limit of the define material which cannot be exceeded during

Material Top
the toolpath creation process.
Lower limit of the defined material which cannot be exceeded during

Material bottom
the toolpath creation process.
An oversize value applied to the complete solid part to represent

Material XY Stock excess material when machining is applied. This value is added to
each X and Y side of the material.
If active the Material XY Stock is applied to the part only.

If inactive then the largest diameter tool which is already applied to
the part is taken into consideration and the Material XY Stock is
applied to this which will vastly increase the actual size of the
represented material applied to the part.
 Ignore Tool Paths
 It should also be noted that the Upper and
Lower Z values will be altered in line with the Safe
Rapid Level and the lowest machining level
currently applied.
Deletes any applied material on the part and replaces with the active
 Delete Existing
settings. This removes the need to use EDIT > Delete.
If inactive, a bounding cuboid is applied to the visible Solid Model.

 Manually Select If active, this option allows the user to select a specific 2D geometry
item to bound around.
Creates a new version of the material in the background which is then

 Associate for auto-update used for subsequent operations to reduce machining of areas already
worked on in previous operations.
Allows you to apply a BMP, JPG or PNG file to the simulation process
to visualise the actual material being cut.
Select Texture
Note that this may slow down simulations on very complex parts as
the image is mapped to the resultant shape.
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Figure 28 - Handrail prior to adding material stock
Figure 29 - Handrail with stock material applied
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First stage Roughing

Select tool
Select MACHINE > Select Tool
Figure 30 - Z Contour Roughing Tool selection
Select the Flat-25mm with holder
Select MACHINE > 3D Machining
Select the Z Contour Rouging option from the first on screen dialogue option.
Figure 31 - Selecting Z Contour Roughing
<LClick> [OK] to continue.
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General
Figure 32 - Z Contour Roughing General Tab
Select a suitable strategy to machine this part, Contour or Waveform are the best two.
As this is the first machining operation, the only option for material at the bottom of the dialogue box will be 
Current Material.
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Levels and Cuts
Figure 33 - Z Contour Roughing Levels and Cuts tab
On the Levels and Cuts tab, enter a suitable Safe Rapid Level.
Untick the  Auto option and make the values for the Lower Z Limit to -120.
Set the value in the Intermediate Slices section for Max Depth per Cut to 1.
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Machining Data
Figure 34 - Z Contour Roughing Machining Data tab
In the Machining Data tab, set the allowance for XY Stock and Z stock both to 2.
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Tool Data
Figure 35 - Z Contour Roughing Tool Data tab
The Tool Data tab deals with the specific tool settings you require for this operation.
<LClick> [OK].
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When requested, <LClick> on the actual Handrail solid model as the part to machine.
Figure 36 - Handrail model selected for Z Contour Roughing
<RClick> to finish.
Figure 37 - Applied toolpath
 Refer to the previous descriptions if you are unsure of which options to alter or set.
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Prismatic Geometry note first stage

Activating  Prismatic Geometry using the previous settings will take approximately 1½ minutes to calculate
the tool path using systems similar in specification to the training departments kit.
Second Stage Roughing

For this next section to show the flexibility of 3D Roughing we will apply a tool path to the front face of the
Handrail model and restrict the machining so that there are no unwanted “Air Cuts” which will waste time on
the actual machined part.
Make your drawing clearer

To make the drawing clearer to work on, from the Layers page of the Project Manager,
un-tick  Toolpaths and in the User Layers section,  Materials.
Figure 38 - Turn off Toolpaths and Material
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Create the Side Work Plane
Select WORK PLANES > Slice Through Work Volume

When prompted, <LClick> on the dotted line of the Work volume running along the X axis to create the new
Work Plane.
Figure 39 - Correct line for the creation of the front side Work Plane
Create the second roughing tool path

Select the Z Contour Rouging option from the first on screen dialogue option.
As we are working on a different plane than Flat Land, this warning will appear.
Figure 40 - Warning dialogue shown when not working on Flat-Land
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General
Figure 41 - Z Contour Roughing Auto-update material option active
Change the option on the General tab to  Auto Update material from previous operations.
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Levels and Cuts
Figure 42 - Alter the Lower Z Limit for the second face
On the Levels and Cuts tab, adjust the Lower Z Limit to -75.
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All the remaining tabs are unaltered so <LClick> [OK] to complete, then <LClick> on the Handrail Solid Model
as the item to machine to create the tool paths.
Once the tool path has been generated, run the Solid Simulation to observe how the tool path has
disregarded the previously machined area and only worked on the sections that remain.
Figure 43 - Simulated side machining highlighting only the areas machined
This method can be applied many times over on the same part depending on the nature of the Roughing that
is required.
More Work Planes would need to be created on the reverse face and possibly the ends and across an angle to
fully complete the rough machining of this part.
Prismatic Geometry note second stage

Activating the  Prismatic Geometry option using the previous settings will take approximately 1 minute to
calculate the tool path using systems similar in specification to the training departments kit.
 You may need to use Rapid Manager to control how the machine gets the tool to the
relevant machining face.
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3D Finish Machining Theory

There are several different types of finish machining strategies because one strategy does not suit all cutting
conditions.
It is not uncommon to have to use several different machining strategies on one part. These
machining strategies are usually applied using containment boundaries.
The decision as to which of the machining strategies to use for which of the different 3D features is sometimes
not obvious, as several different strategies may give the desired result. Each feature being machined must be
looked at with respect to,
• Access to the feature.
• The nature of the feature.
• The nature of the surface finish to be achieved.
• The nature of the tool marks you or your customer would be satisfied with.
Multi-Processing of 3D Machining Operations

In the HOME > Configure > General dialogue box is the ability to turn on  Use Background Processing
for 3D Machining when working with 3D machining cycles. This functionality permits the use of unused
processor capacity in your pc to be applied to the complex calculations required when creating and editing 3D
machining cycles.
Figure 44 - Where to set the Background processing option
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During the calculation period, the operation that is being worked on will display the “Processing” tag to
indicate that it is being worked on.
Figure 45 - Tool paths showing the Processing marker
More than one item can be processed at a time and you can also Abort the calculations by <RClick> on the
operation and choosing the only option from the pop up menu, if you feel that you have made an error or
wish to adjust any settings.
Figure 46 - <RClick> menu for a Processing tool path
Allowing Background Processing frees up the waiting time that you would have had to leave Alphacam
alone, so that you can continue to add further operations or geometry items.
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Finish Machining Strategy Options
Figure 47 – 3-Axis Strategy selection dialogue
Figure 48 – 4-Axis Strategy selection dialogue
The finish machining strategies Dialogue options will differ depending upon the level of software module and
current active post processor.
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3D Solid Machining Accuracy

The following section of the manual give you an overview of the main options which control the precision of
how the finish toolpath will be applied to the solid or surfaces you have selected.
Many of the cycles include the ability to alter all of the options but depending on the chosen finishing method,
some may not be available on certain cycles.
Width of Cut
This is normally used for roughing and is the step over distance between the centre lines of each pass of the
cutter.
Cusp Height
This is normally used for finish machining with a ball end tool.
Alphacam will calculate the position of each cut to produce the cusp height set.
If you ask for a very small cusp height, in an attempt to produce a mirror finish, the NC program will be very
long and the calculation will be slow, and machining will take a long time.
A sensible practical value for metric work is between 0.1 and 0.02.
Figure 49 - Step over calculated using Width of Figure 50 - Step over calculated using Cusp Height
Cut
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Cusp Height table
TOOL DIA
 2.0 4.0 6.0 8.0 10.0 12.0 20.0
Step
Over 
0.2 0.00501 0.0025 0.00167 0.00125 0.001 0.00083 0.0005
0.4 0.0202 0.01003 0.00667 0.005 0.004 0.00333 0.002
0.6 0.04606 0.02263 0.01504 0.01127 0.00901 0.0075 0.0045
0.8 0.08348 0.04041 0.02679 0.02005 0.01603 0.01335 0.008
1.0 0.13397 0.06351 0.04196 0.03137 0.02506 0.02087 0.01251
1.2 0.2 0.09212 0.06061 0.04526 0.03613 0.03008 0.01802
1.4 0.28586 0.1265 0.08281 0.06173 0.04924 0.04097 0.02453
1.6 0.4 0.16697 0.10863 0.08082 0.06441 0.05257 0.03205
1.8 0.56411 0.21394 0.13818 0.10256 0.08167 0.06788 0.04058
2.0 1.0 0.26795 0.17157 0.12702 0.10102 0.08392 0.05013
The table above give some examples of how the diameter of the tool and the chosen Width of Cut (Step Over)
will affect the Cusp Height and therefore the resulting finish on the part.
Values in mm.
Chord Tolerance Along Cut

All 3D machining is output as straight line moves in X Y &/or Z, and the Chord Tolerance determines how
many straight lines are output to represent a curved cutting move.
A very small chord tolerance will produce very large NC programs, without much effect on the surface
accuracy. A sensible practical value for metric work is between 0.1mm and 0.02mm.
Figure 51 - Explanation of Chord Tolerance
Facet Tolerance
This is a function of the Chord Tolerance and should not be changed from 0.25 unless producing mirrored
surfaces.
 Altering either of these two options will have a serious effect on the length of the
generated NC code.
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Lead In/Out Links

The Lead-In/Out and Links between cuts can be configured controlling the path extension length, the ramping
angle and length and the radius size between the path extension and ramp.
Bi-directional paths can also be joined with arc type moves to give paths for high speed machining.
The Lead-In/Out and Links check box Specify Moves between Paths switches on the lead in and out options.
1. Extension Length: the amount of overrun from the edge of the surface.
2. Ramp Length: the length of the extension ramp.
3. Arc Radius: the arc radius between the Extension and the Ramp.
4. Ramp Angle: the angle between the Extension and the Ramp.
5.  Join Paths with Arc: if not checked a straight line is used.
Figure 52 - Lead In/Out Links explanation
 Many of the finish machining examples supplied may have these moves included but
exaggerated to demonstrate the processes.
 The actual values of these Lead In/Out options need only be enough to break contact of
the tool and surface being machined.
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Contact Angles
The Contact angles on several cycles provide controls of which surfaces/faces are cut for each operation.
In these follow images, you can see how altering the Minimum and Maximum angle value adjusts where on the
tooling the contact will occur.
Figure 53 - Reference 30° angle value
Figure 55 - Reference both angle values
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As you can see in the images above, altering the angle values corresponds to where the machining will or will
not take place.
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Corners
The tool normally rolls around any external corner and maintains contact in some cases this can cause the
corner to be eroded. To avoid this, use one of the corner control methods.
Tool radius rollover that maintains tool contact with the

Round: corner (Default).
Replaces the rollover with a sharp corner. The tool

Sharp: path extends past the corner until it intersects with the
next section.
Loop: Replaces the round with an external loop move.
Loop Radius: Specifies the radius of the loop move.

path extends past the corner until it intersects with the
High Speed: next section, where it is then blended with a radius of
75% of the tool radius to maintain tool path tangency
and will help the machine tool maintain its velocity.
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Machining Styles
If the application of a cycle is across many and varied sections, it would be more suitable to apply the
machining using Machining Styles.
The purpose of a Machining Style in Alphacam is to remove the need of repetitively using the menu options
for choosing a tool, selecting a machining operation and then applying it to the required geometry within the
drawing file.
A style is created using the <RClick> option on an existing cycle and using the Save as New Style option.
Figure 56 - Creating a Machining Style from a Solid Machining operation
Once a cycle has been saved in this manner it can then be applied to any future models that exhibit the same
requirements for machining.
All information regarding tool used, feeds, speed and allowances are saved, allowing for faster application of
machining cycles.
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Figure 57 - <RClick> menu on a Machining Style to apply
These can then be applied from the Machining Styles page of the Project Manager using the <RClick>
menu options.
 Depending on the cycle contained within the Machining Style, you will then be asked to
select the relevant items needed for the cycle to be calculated.
 Attention needs to be paid to the prompt section at the bottom of the drawing window so
that you select the items in the correct order.
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Example Files
#2 Along Intersection (Surface Machining cycle only)
Open the example file “…. ALP TRG 116 3D Machining 2020\Examples\Drawings\#2 Along Intersection”
Figure 58 - Along Intersection Machining Example
Along Intersection allows for the generation of a single toolpath that is created along a boundary of a pair of
surfaces which physically intersect each other, this type of tool path will not function over a theoretical
intersection.
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Figure 59 - Along Intersection Tool Selection

Set the options as shown below.
Figure 60 - Along Intersection Strategy
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General
Figure 61 - Along Intersection General Tab
This strategy, along with most the solid machining options, can be used as a semi-finishing cycle by using the
Stock to be Left option to allow the tool to stand off the finished part if a value is entered, or to finish to size if
a value of 0 is applied.
The Safe Rapid Level should take into consideration the actual Z datum position in use.
 On first activation of the cycle this dialogue will be set to a zero value.
The Thickness Above Surface to Rapid Down to is a similar value to the options used in 2D machining as a
prepositioning value prior to machining.
This value should never be set to zero to prevent any accidental gouging or damage to the tool if a rouging
allowance has been set and this is the finishing pass.
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Tool Data
Figure 62 - Along Intersection Tool Data Tab
The Tool Data tab deals with the specific tool settings you require for this operation.
<LClick> [OK].
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Selecting the items to machine

Once you have set up the tooling, you will be asked to select the two intersecting surfaces around which you
wish to machine.
Figure 63 - Along Intersection first surface selection
<LClick> the flat surface as the first item, then the dome surface as the second.
Figure 64 - Along Intersection second surface selection
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Step Length
After you have selected both surfaces to work the Intersection from, you are then prompted for a Step Length.
Figure 65 - Along Intersection step length
This value creates the precision along the intersection for how the toolpath is created.
All 3D Machining cycles us X,Y,Z point locations to generate their respective toolpaths and depending on the
values set in either a Chord Tolerance option or a Step Length option, this then dictates how precise the
generated toolpath will follow the chosen guide options.
A large Step Length will create a jagged and poor quality toolpath, but short NC coding.
Whereas a small step length will follow the Intersection more precisely but result in a longer NC code file.
Accept the default values for this example and then <LClick> [OK].
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Now you are requested for two last pieces of information.

A location on one surface to denote the starting point for the toolpath.
This can be a <LClick> selection or a direct value input depending on your part.
Figure 66 - Along Intersection Start Point
After the Start Point, you will then be requested for a point that denotes the direction into the actual
intersection.
In some instances, this will dictate on which side of an intersection between the two surfaces the actual
toolpath will be created.
Figure 67 - Along Intersection selecting the direction INTO the intersection
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Figure 68 - Along Intersection completed toolpath
 Please note that if you have selected a continuous intersection as depicted in the
example above, then the toolpath will never complete its creation process without user
intervention using the <Esc> key, as the intersection is a complete circle for the purposes of
this cycle it is infinite in length.
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#3 Parameter Line Machining (Surface Machining cycle only)

Open the example file “…. ALP TRG 116 3D Machining 2020\Examples\Drawings\#3 Parameter Lines”
Figure 69 - Parameter Line machining example file
The sections to be machined on this part could be created using one of the strategies discussed later but
would create some issues with the finish. Using the Parameter Lines method will give a better quality toolpath.
As this method can only be used on surfaces, we need to extract these from the supplied solid model.
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Using SOLID MODEL EXTRACT > Surfaces from Faces select the two half pipe sections of the
model as shown below.
Figure 70 - Faces selected for Surface Extraction
Figure 71 - Newly extracted surfaces
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Choose the 6mm Ball Nose with holder.
Figure 72 - Parameter Line Tool selection

Figure 73 – Parameter Lines Strategy
This machining strategy is unique to Surface Machining as solids do not have parameter lines.
The parameter lines are the lines drawn when the surface is not shaded; the density of these lines determines
the accuracy of the surface and is defined by the edge tolerance when the surface was created.
Gouge Checking requires prodigious calculations, and you should not ask for gouge checking if it is not
necessary.
Check for Gouging on Current Surface: Check this box only if the surface being machined has undulations
or folds which create valleys into which the tool will not fit. This check is only applicable for the Parameter Line
method.
You have the option for Boundaries, to define the areas to be machined. These will be treated as Hard or Soft
Boundaries and the tool will be kept inside or outside or allowed to move until the tool centre line is on the
boundary depending on how you have set the Tool Directions.
<LClick> [OK].
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General
Make the options as shown below.
Figure 74 - Parameter Lines General tab
This strategy, along with most the solid machining options, can be used as a semi-finishing cycle by using the
Stock to be Left option to allow the tool to stand off the finished part if a value is entered, or to finish to size if
a value of 0 is applied.
The Safe Rapid Level should take into consideration the actual Z datum position in use.
 On first activation of the cycle this dialogue will be set to a zero value.
The Thickness Above Surface to Rapid Down to is a similar value to the options used in 2D machining as a
prepositioning value prior to machining.
This value should never be set to zero to prevent any accidental gouging or damage to the tool if a rouging
allowance has been set and this is the finishing pass.
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Machining Data
Figure 75 - Parameter Lines Machining Data tab
The surface finish achieved is dependent upon the machining step over in the strategy.
Whether this is via Width of Cut or Cusp Height is down to personal choice as to which suits your needs
within the manufacturing area you work in.
 Bi-Directional allows the tool to cut the surface(s) backwards and forwards to speed up the machining
process, should the material benefit from being machined in this fashion.
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Tool Data
Figure 76 - Parameter Lines Tool Data tab
The Tool Data tab allows you to make alterations to suit the current requirements of the tool in relation to the
job to be cut.
<LClick> [OK]
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Figure 77 - Surface selection point during the cycle creation
You are asked to choose the surfaces to be machined; this can be a single surface or multiple options.
 If choosing multiple surfaces to machine within a single operation it is best to identify the
direction of the parameter lines so that the toolpath generated is using a similar direction of
motion.
<LClick> on only the surface indicated above.
<RClick> to continue.
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Figure 78 - Start location for the machining
You are asked to select close to the Start Point for machining.
Once you have selected an appropriate starting location, you will then be asked for a second point on the
same surface to set the direction of travel for the toolpath.
Figure 79 - Second point to fix the direction of cut
<LClick> approximately where the mouse pointer shows on the image to generate a toolpath that follows the
form of the semi-circle cross section of the pipe.
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Figure 80 - Parameter Lines tool path following the U curve
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To compare the two different direction options, create another Parameter Line Machining cycle on the second
extracted surface.
Figure 81 - Start the machining of the second surface from
This time for the direction option, <LClick> as shown below to force the tool to travel along the flow of the pipe.
Figure 82 - Selecting the second point to fix the direction of cut
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Figure 83 - Parameter Lines tool path following the sweep of the curve
It is possible to select both surfaces and machine them within the same cycle.
However, in some circumstances, the toolpath that is generated may give odd results.
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Hints and Tips

When using Parameter Lines, the toolpath starts and finishes exactly on the chosen surfaces.
In some circumstances this may produce a toolpath that could leave unwanted transition lines between the
toolpaths.
As detailed earlier, many cycles have the ability to use Lead In/Out Links to force the tool form the part to
change direction, unfortunately Parameter Lines does not have this ability.
To achieve a run off for the toolpath you will need to use either of the following options depending on the
results that you gain.
Extended Surfaces
Using 3D > Edit Surfaces you have an option from the menu to Extend Surfaces.
Figure 84 - Extend Surface option
This will allow you to create run off areas for the cycle.
Figure 85 - Extend Surface options
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Depending on the requirements, select a value for how far you wish to extend and the option for edge choice.
Usually the amount will be small as you only wish to lose tangent contact with the actually working surface.
Also, single edges are the usual option due to the complex nature of surface creation.
The resulting extended surface may also not be what you require as this image shows.
Figure 86 - Incorrect Surface extensions
This example has used the theoretical untrimmed surface to create four extensions, one on each top edge and
one at each end.
The end to the right of the image will be a usable extension, however the one to the front is not as there is a
complete semi-circle and not just the extension of the side we wish to machine.
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Create New Surfaces

In instances such the previous section, Feature Extraction needs to be employed and a 3D Edge Extraction
used to generate the actual hard geometry edge required.
These can then be copied, and a more accurate surface created in-between the 3D Polylines.
Figure 87 - Polylines for surface creation
Using GEOMETRY > 3D Surfaces you can then generate a surface between your chosen geometries
using which ever of the creation tools is most appropriate.
Figure 88 - Surface creation dialogue
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In this example, a Ruled Surface would give the best results.
Figure 89 - Better quality toolpath
Working with multiple surface

Using Parameter Lines can give extremely flexible toolpaths where other strategies may not work.
Using multiple surfaces requires that when you select the Start Point for the toolpath, the Second Point for
Direction MUST be on the same surface as the start point, the toolpath will be spread across all of you chosen
items.
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#4 Machine Surface with Tool Side

(Surface Machining cycle only)
This particular cycle places itself in a specialised area that predominantly it would be applied on a multi-axis
capable machine, 4-Axis or 5-Axis. This is not to say that it isn’t suitable for 3-Axis work where only a surface
style part has been supplied to you for machining.
Open the example file “…. ALP TRG 116 3D Machining 2020\Examples\Drawings\#4 Machine Surface
with Tool Side”
Figure 90 - Machine Surface with Tool Side example file
This file already has the required surfaces created to allow application of this tool path.
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Figure 91 - Parameter Line Tool selection

Figure 92 – Machine Surface with Tool Side Strategy
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General
Figure 93 – Machine Surface with Tool Side General Tab
The General tab for Machine Surface with Tool Side deals with allowances in XY and Z as well as the
clearance options for the Safe Rapid Level and how far above the part to position the tool for starting the cycle
using the Thickness Above Surface to Rapid Down to setting.
On a first activation of this cycle, the Safe Rapid and Thickness values will be set to zero.
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3D Lead-In/Out
Figure 94 - Machine Surface with Tool Side 3D Lead-In/Out
The 3D Lead-In/Out tab allows the user to add any lead in or out moves to the toolpath as in the same manner
as you would add a Lead-In/Out to a 2D Rough and Finish tool path.
The main difference between a 2D and 3D Lead-in/out is that the values for the Lines and Arcs are actual
millimetres and not multipliers of the tool radius.
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Machining Data
Figure 95 – Machine Surface with Tool Side Machining Data tab
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Tool Axis
The tool Axis section controls how the tool will track along the surface with the side of the tool.
Figure 96 - Tool Axis control options
Depending on the nature of the part the three options can give very similar or dramatically different results, it
will be your own judgement as to which suits your manufacturing methods and machine type best.
 Perpendicular to Picked Edge Will set the tool control angle in relationship to the closest edge picked
when creating the tool path.
 Perpendicular to Other Edge Will set the tool control angle in relationship to the opposite edge to
the one which is picked to create the tool path.
 Parallel to Parameter Lines Will follow the mesh of the actual surface structure in much the same
manner as the Parameter Lines strategy detailed earlier.
Chord Tolerance
Figure 97 - Chord Tolerance options
This controls the precision along which the tool path is created as it follows the chosen surface.
Check Fouling at Picked Edge
Figure 98 - Check Fouling options
Activating this option will prevent any fouling along the chosen edge if the surface form creates a tool path that
would allow the bottom edge of the cutter to pass inbound of the chosen edge, damaging the part.
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Tool Data
Figure 99 - Machine Surface with Tool Side Tool Data
Allows for any adjustments to the pre-set values of the chosen tool.
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Figure 100 - Machine Surface with Tool Side Applied toolpath
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#5 Horizontal Z Contours
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#5 Horizontal Z
Contours”
This example already has the tool path applied.
Figure 101 - Horizontal Z Contours example file
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Figure 102 - Horizontal Z Contours Tool Selection
To apply this toolpath, use Select MACHINE > 3D Machining
Figure 103 – Horizontal Z Contours strategy
Select the Horizontal Z Contours option, <LClick> [OK].
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General
Figure 104 - Horizontal Z Contours General Tab
The General tab for Horizontal Z Contours deals with allowances in XY and Z as well as the clearance options
for the Safe Rapid Level and how far above the part to position the tool for starting the cycle using the
Thickness Above Surface to Rapid Down to setting.
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Lead-In/Out Links
Figure 105 - Horizontal Z Contours Lead-In/Out Links tab
The Lead-In/Out Links tab allows the user to add any lead in or link moves to the toolpath.
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Machining Data
Figure 107 - Horizontal Z Contours Machining Data tab
Horizontal Z Contours creates paths that are at a constant step down in Z.

This distance is controlled by either  Width of Cut or  Cusp Height in the Z axis direction.
Figure 108 - Horizontal Z Contours Cut Spacing
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Mill Type
Figure 109 - Cutting type options
Figure 110 - Climb and Conventional milling explanation diagrams
The Conventional and Climb options can be used if consistent (single) direction cuts are desired.
The Optimised option results in an optimised, bidirectional tool path.
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Finish Precision
Figure 111 - Chord and Facet tolerance settings
Using the options for the Chord Tolerance and Facet Tolerance can produce finishes ranging from those
needing large amounts of hand finishing to mirrored surfaces depending on the values set.
Chord Tolerance
All 3D machining is output as straight line moves in X Y &/or Z, and the Chord Tolerance determines how
many straight lines are output to represent a curved cutting move. A very small chord tolerance will produce
very large NC programs, without much effect on the surface accuracy. A sensible practical value for metric
work is between 0.1 and 0.02.
Figure 112 - Chord Tolerance explanation diagram
Facet Tolerance
surfaces.
 It cannot be stressed enough that altering either of these two values will have a serious
impact on the length of the actual generated NC code.
 You must be aware of the capacity of your machine control to ensure that you can
successfully use the created program.
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Connect Aircut Length
Figure 113 - Connect Aircut settings
The minimum distance allowed for rapid moves between cuts within the cycle.
Rapid moves with lengths less than this distance will be converted to feed moves, keeping the tool at the cut
depth.
 The default value for the Aircut Length will always be the diameter of the chosen tool.
Additional options
Helical – This option applies to closed contours only. Instead of the

depth increasing in a step after each Z level pass, the depth
increases continuously throughout the pass. For each complete
pass, the depth increases by the cut increment. There is a final
pass at the finish depth with no Z movement.
Bottom to Top – If checked, the machining will start at the lowest

level first and work upwards, rather than starting at the top and work
downwards.
Tool can under-cut – This option allows undercuts to be applied.

This is only available if an undercutting tool is selected (e.g.,
Lollipop). Note that this option should be left unchecked unless it is
known that undercuts will be applied as this will help minimize
processing time. Also, note that with this option checked, the Rest
Finish settings are unavailable.
Figure 114 - Horizontal Z contours

Include Flat Areas as additional Z Levels –This option allows you
cycle specific options
to specify that an additional cutting pass is created at the height of
any “flat” region. This ensures that material is not left un-machined
at the bottom of pockets, for example.
Prismatic Geometry –This option detects areas of prismatic

geometry, such as cylindrical islands, cones, and rectangular
pockets. This geometry is then used to produce arcs and line
moves. On some parts, this can drastically reduce the size of the
NC code output but will increase processing time.
Prismatic Geometry Processing times on sample file

For reference, on this sample file, the NC code produced using the Alphacam Standard 5 Axis post processor
has 179000 lines of code.
With  Prismatic Geometry active for both Z Contour Roughing and Horizontal Z Contours, there is just
over 3 minutes of processing time for both cycles combined (1min 40sec for processing the roughing and 1min
20sec for processing the finishing), the length of the program is reduced to 142803 lines of code.
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Cut Between Z Levels

The Upper and Lower Z Level can also be set to limit the machining to within the reach of the tool.
Having the option set to  Auto will machine the entire part.
Figure 115 - Automatic depth option selected
Unticking the option allows for specific Z values to be entered to contain the Upper and Lower machining limits.
Figure 116 - User defined depth limits with Auto not active
Cutting Order
Figure 117 - Cutting Order options
These options allow you to specify how the cutting order will be created.
The  by Zone option will force the cycle to machine the profiles in regions.
All levels, within a region, will be machined before the cycle moves to the next region.
The  by Level option will force the cycle to machine profile based on the height.
All areas that exist on the same level will be machined before the cycle moves to the next level.
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Advanced
Figure 118 - Horizontal Z Contours Advanced tab
The Advanced tab options are dependent on the style and needs of the machining cycle.
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Contact Angle Limits
Figure 119 - Contact Angle options
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not take place.
You can specify angles between 0 and 90, except for Minimum Contact Angle which can only be up to 85. The
defaults are 0 (min) and 90 (max).
Only the regions where the contact angle is within the Minimum and Maximum values are machined and these
values cannot be the same.
If these settings break the tool path into separate regions, the normal rules for leads, links and ordering are
applied to each region and the move between the regions.
To avoid the tool path fragmenting into small sections, additional Z level passes may be included outside the
contact angle range.
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Finish Shallow Areas
Figure 123 - Horizontal Z Contours Shallow Area finishing options
This option allows extra passes to be inserted to correct for the Z level passes being too far apart to give a
uniform finish (due to the surface being near-horizontal).
The options are;
• None. Take no special measures to finish shallow areas.
• Constant Cusp. The extra passes are created by projecting the Z level passes, with an offset
calculated to give a constant cusp height. The extra passes are stopped when they meet a Z level
pass.
• Projected. The extra passes are created by projecting the Z level passes across the surface with a
constant XY offset (as seen looking from the top), which is defined by the XY Step-over value. The
extra passes are stopped when they meet a Z level pass.
Note that for the extra passes, the 3D tool path spacing (as seen looking at right angles onto the
surface) gets smaller as the surface gets flatter. This is the opposite of the Z-level areas, where the
3D spacing gets larger as the surface gets flatter.
• Lace. This will insert extra passes using a Parallel strategy. This is generally used on flat faces of
prismatic type parts.
XY Step Over
This value is used for each of the strategies above, specifying the distance between each tool pass as a
percentage of the tool diameter.
Clip to Depth
If checked, the tool path in the shallow regions will be clipped at the Depth value. If unchecked, the cycle
behaves as if the shallow region surface extended into a flat region at the Depth height.
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Mill Type
Figure 124 - Secondary Advanced cutting type
See Mill Type options in the General tab settings.
Corners
Figure 125 - Advanced corner techniques
This option controls how external corners are handled. External sharp corners can be controlled by replacing
them with loops or arcs to improve part quality, beneficial in high speed machining.
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Rest Finish
Figure 126 - Horizontal Z Contours Rest Finish tab
Setting  Take Account of Previous Machining allows a process the same as using a 2D cycle to compare
a smaller tool against a larger previous tool and only machine the areas where the larger cutter could not gain
access.
 Auto works with the immediately preceding tool;  Auto allows for the selection via the Alphacam Tool
Selection dialogue by <LClick> on [Find Tool].
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Tool Data
Figure 127 - Horizontal Z Contours Tool Data tab
The Tool Data takes care of all the tooling information.

Once all options have been set according to your specific tooling, machine and material requirements,
<LClick> [OK] to apply the toolpath.
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Select the items

You are then requested to select the items to machine.
Figure 128 - Horizontal Z Contours selecting the items to machine
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Start Location
You will be requested for an approximate starting location.
Figure 129 - Horizontal Z Contours setting the cycle start location
 It is a good idea to look at the part you wish to machine from the XY view perspective so
that you place the starting point over the part.
 Whilst you can apply the start point in the ISO view, you may not actually be over the
part itself.
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Figure 130 - Horizontal Z Contours toolpath
Figure 131 - Horizontal Z Contours simulated processing
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#6 Parallel
The Parallel 3D machining strategy is an excellent general purpose method for semi roughing or finishing.
This is the only finish machining option available in Standard.
The tool paths are generated in straight lines in any direction over any amount of surfaces/faces. Any number
of boundaries can be used to limit the machined areas. These will be treated as Hard or Soft Boundaries and
the tool will be kept inside or outside or allowed to move until the tool centre line is on the boundary depending
on how the tool direction options have been set.
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#6 Parallel”
Figure 132 - Parallel machining example file
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Figure 133 - Parallel Tool Selection
Figure 134 – Parallel Strategy
Select the Parallel option, <LClick> [OK].
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General
Figure 135 - Parallel General tab
The General tab for Parallel deals with, allowances in XY and Z as well as the clearance options for the Safe
Rapid Level, and how far above the part to position the tool for starting the cycle using the Thickness Above
Surface to Rapid Down to setting.
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Lead-In/Out Links
Figure 136 – Parallel Lead-In/Out Links tab
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Machining Data
Figure 138 - Parallel Machining Data tab
Parallel creates paths that are at a constant step over in X and/or Y.

This distance is controlled by either  Width of Cut or  Cusp Height in the chosen axis direction.
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Cut Spacing Uses

Parallel creates paths that are at a constant step across in either X or Y, or a combination of both depending
on the option settings.
This distance is controlled by either Width of Cut or Cusp Height.
Figure 139 - Cut Spacing options
Mill Type
Figure 140 - Direction of machining options
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Finish Precision
Figure 141 - Chord and Facet precision options
All 3D machining is output as straight line moves in X Y & Z, and the Chord Tolerance determines how many
straight lines are output to represent a curved cutting move. A very small chord tolerance will produce very
large NC programs, without much effect on the surface accuracy. A sensible practical value for metric work is
between 0.1 and 0.02
Figure 142 - Chord tolerance description
Facet Tolerance
surfaces.
 It cannot be stressed enough that altering either of these two values will have a serious
impact on the length of the actual generated NC code.
 You must be aware of the capacity of your machine control to ensure that you can
successfully use the created program.
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Cut Direction
Figure 143 - Cut direction option
The value entered into this dialogue option dictates whether the tool machines in;
• The X Direction. Using the value of 0°.
• The Y Direction. Using the value of 90°.
• Any other direction. Using any differing value.
 Using a negative 90 value or a positive 270 value would also give a Y direction of travel
in the same manner that a value of 180 would apply an X direction.
Connect Aircut Length

The minimum distance allowed for rapid moves between cuts within the cycle.
Figure 144 - Connect Aircut setting
depth.
 Note that the default setting for Connect Aircut is always the diameter of the chosen
tool.
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Step Direction
This option allows the user to dictate at which end of a part the toolpath will commence.
Figure 145 - Parallel step direction drop down options
For example, if you chose to machine along the X axis (0° direction of cut) on a rectangle based on
X0 Y0 and 200x150 in size.
The tool path would commence at 0,0 and travel towards the X200 distance.
Then when viewed from behind the tool in the direction of cutting, the very first step over would be
to the tools Left.
If the options were set to the Right, the tool path would commence its run at the X200 end and
travel towards X0, then step to the right, when viewed from behind the tool in the direction of
cutting.
Figure 146 - Parallel machining depth control options
Clip to Depth
If checked, the tool path in the shallow regions will be clipped at the Depth value. If unchecked, the cycle
behaves as if the shallow region surface extended into a flat region at the Depth height.
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Advanced
The Advanced tab is only available in Advanced and Ultimate module levels.
Figure 147 - Parallel Advanced tab
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Exclude Flat Areas and Ignore External Edges
Figure 148 - Flat Area and Edges options
 Exclude Flat Areas when checked will NOT machine the flat areas with the parallel strategy.
 Ignore External Edges will clip the tool path to the edges of the surface/faces.
No options selected
Figure 149 - No Advanced Options selected
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 Exclude Flat Areas
Figure 150 - Exclude Flat Areas active
 Ignore External Edges
Figure 151 - Ignore External Edges Active
Any additional tool paths that are generated because of the controlling criteria that are not required can be
deleted.
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Corners
Figure 152 - Vertical corner transfer options
The tool normally rolls around any external corner and maintains contact in some cases this can cause the
corner to be eroded. To avoid this, use one of the corner control methods.
Tool radius rollover that maintains tool contact with the

Round: corner (Default).

Sharp: path extends past the corner until it intersects with the
next section.
Loop: Replaces the round with an external loop move.
Loop Radius: Specifies the radius of the loop move.

path extends past the corner until it intersects with the
High Speed: next section, where it is then blended with a radius of
75% of the tool radius to maintain tool path tangency
and will help the machine tool maintain its velocity.
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Perpendicular Lace
The Perpendicular Lace option will add additional tool paths that are perpendicular to the main tool path to
ensure an even surface finish on the different surfaces/faces.
There are three options for perpendicular lace,  None,  Primary Bounded and  Primary Unbounded.
Figure 153 - Perpendicular Lace options
If the Primary Bounded option is selected the original tool paths are removed where the perpendicular paths
are created (each area is only machined once).
If the Primary Unbounded option is used where perpendicular tool paths are created these areas are cut in
both directions.
Figure 154 - Perpendicular Lace Primary Bounded
Figure 155- Perpendicular Lace Primary Unbounded
The contact angle option restricts how far up or down an area the perpendicular paths are applied.
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Up Down Mill
Figure 156 - Up or down Mill options
This restricts how the surface/faces are cut.

The Down Mill options cause the tool to always cut in a downward direction and the Up Mill option cause the
tool to always cut in an upward direction.
Figure 157 - Parallel cycle set to down Mill
Figure 158 - Parallel cycle set to Up Mill
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Contact Angles
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not take place.
This is the angle between the point of contact between the tool and face being machined and the tool axis.
You can specify angles between 0 and 90, except for Minimum Contact Angle which can only be up to 85.
The defaults are 0 (min) and 90 (max).
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Tool Data
Figure 162 - Parallel Tool Data tab
Tool Data takes care of all the tooling information.

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Select the items

Figure 163 - Selecting the items to Parallel machine
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Figure 164 - Parallel applied toolpath
Figure 165 - Parallel simulated processing
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#7 Projected Contours
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#7 Projected
Contours”
Figure 166 - Projected Contours example file
This method requires one or more boundaries to control how the tool paths are calculated.
The ghost tool sets whether it is to be used as Hard or Soft Boundary.
The method constantly offsets the closed boundaries to create projected paths onto any number of faces. The
step over is controlled by Width of Cut or Cusp Height.
Cut in a clockwise or anti-clockwise direction. Cut from inside to outside, or outside to inside. Two variations of
path can be achieved. One method offsets the outer boundary inwards and trim it to the inner boundary. The
other offsets the inner boundary outwards and trim it to the outer boundary.
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Figure 167 - Projected Contours Tool Selection
Figure 168 - Projected Contours strategy
Select the Projected Contours option, <LClick> [OK].
 Note that the Boundaries is set to From Drawing.
 You must have these created prior to activating the cycle.
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Boundary Rules
With the use of boundaries in this style of machining and other cycle types, the tool side dictates which areas
will be machined. Using a single boundary, the tool side dictates either contained within or excluded from the
bounded area.
If two boundaries are selected;
• Boundaries with Tool side set on

Centre will machine between and
include the bounding geometries.
Figure 169 - Boundaries set to Centre

opposite sides to each other will not
machine between or on to the
bounding geometries.
Figure 170 - Boundaries set to the opposite of each other
• Boundaries with Tool side set on the

same side as each other machine
within but not including the geometries.
Figure 171 - Boundaries set to the same side as each other
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Boundary Selection for Block Engraving
Figure 172 - Projected Contours boundary selection for engraving
<LClick> the curved Alphacam logo as the boundary items for machining.
<LClick> [Finish (ESC)] to continue.
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General
Figure 173 - Projected Contours General tab
The General tab for Projected Contours deals with allowances in XY and Z as well as the clearance options for
the Safe Rapid Level and how far above the part to position the tool for starting the cycle using the Thickness
Above Surface to Rapid Down to setting.
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Lead-In/Out Links
Figure 174 - Projected Contours Lead-In/Out Links tab
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Machining Data
Figure 176 - Projected Contours Machining Data tab
Cut Spacing Uses

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Tolerances
Figure 178 - Finish tolerance options
Machining Options
Activating this option will force the toolpath to be created from the middle
 Start Cutting at Inside
of a single boundary to the outside, or from an inner boundary to the
outer boundary.
This option allows for the direction of the generated toolpath to be altered
 CW
to Clockwise or Counter Clockwise depending on it being active or not.
With this option inactive, the toolpath uses the outer boundary as the
 Offset Islands driving shape to create the toolpath, setting the option active will use the
inner boundary shape as the master driving form.
This option only becomes available when using a 5 Axis set up and
Angle between Tool and
allows for a tilt angle to be applied to the toolpath for better cutting
Surface Normal
conditions.
Depending on the selection and the shapes of the boundaries, this can have greatly differing effects on the
completed toolpath.
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Tool Data
Figure 179 - Projected Contours Tool Data tab

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Select the items

Figure 180 - Projected Contours selected items to machine
As the silver STL capping item is not within the area to be engraved, it does not need to be included in the
selection.
Figure 181 - Projected Contours used for block engraving in ISO view
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Boundary Selection for Face Machining

On the current open file, use Hide All on the Operations Page of the Project Manager to deselect all the
current applied toolpaths.
Select CAD > Hide Parts , and select the geometries representing the Alphacam writing.
Figure 182 - Projected Contours worked example
Extracting the Boundary Geometries

To generate the two required boundaries around the outside of the actual part and the base of the dome
section, use SOLID MODEL EXTRACT > Projected Face Outlines to Work Plane
<LClick> on the blue face indicated below.
Figure 183 - Extraction of required boundaries
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Figure 184 - Extracted boundary geometries
<RClick> to extract the items.

<RClick> again to finish the command.
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Tool Directions
Due to the nature in which manual extraction works, in this example the ghost tools are on the wrong sides of
the geometries to machine correctly.
Figure 185 - Ghost Tools as extracted
Using MACHINE > Tool Directions use the  Centre option to set the ghost tools correctly.
Figure 186 - Ghost Tools set to Centre as required
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From the Operations Project Manager Page, <RClick> on the 6mm Ball tool and use the option Use This Tool
to make this the active tool to use on the cycle.
Figure 187 - Tool selection from an existing cycle using <RClick> option
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Figure 189 - Projected Contours boundary selection for area machining
<LClick> the square and circle extracted geometries to continue.
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Machining options
Figure 190 - Projected Contours machining options
As we have previously applied a Projected Contours cycle and the options we are using will remain unaltered,
<LClick> [OK] to proceed.
This does not preclude you from altering any values if you wish to see different options applied.
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Select the items

Figure 191 - Projected Contours items to machine
 As the area to be machined is dictated by the square and circle boundaries, the silver
solid section is outside of the area to be machined, therefore we do no need to select it.
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These two images demonstrate the difference between having the Offset Islands option active or not.
Figure 192 - Projected Contours Inactive Offset Islands
In the upper image with the option not active, the Square boundary is the driving force for the toolpath creation.
With this option active in the lower image, the Circle boundary takes precedence.
Figure 193 - Projected Contours Active Offset Islands
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#8 Radial Fan
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#8 Radial Fan”
Figure 194 - Radial Decorative Sample File
Radial requirements
Radial requires one or more closed boundaries to contain the cycle within.
As with all boundary machining, the Tool Side is important to set whether an area is to be machined or not.
Radial also requires the you to select the location of the centre of the radius from which all the radial cuts
theoretically pass, note that the centre point does not have to lie within the boundary.
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Decorative application
Figure 195 – Radial Tool Selection
Select the Radial option, <LClick> [OK].
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Boundary Rules
bounded area.



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Boundary Selection for Radial Machining
Figure 200 - Radial Boundary Selection
<LClick> the curved geometry as shown as the boundary for machining.
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General
Figure 201 - Radial General Tab
The General tab for Radial deals with allowances in XY and Z as well as the clearance options for the Safe
Rapid Level and how far above the part to position the tool for starting the cycle using the Thickness Above
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Lead-In/Out Links
Figure 202 - Radial Lead-In/Out Links tab
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Machining Data
Figure 204 - Radial Machining Data tab
Options
Figure 205 - Radial machining options
The Options section sets the step over for the cuts using a Width of Cut that is measured in Degrees of Arc.
A cusp height cannot be used as the tool paths generated will be progressively further apart from each other
the further away from the centre of the radius the cutter travels.
Using the  Start Cutting at Inside option will drive the toolpath from the centre of the radius and using the 
Bi-Directional option will allow for a toolpath created in a single direction or allow the cutter to work to and
from the centre of the radius.
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Angles
Figure 206 - Radial Angle options
Using the Angle controls can further enhance or limit the creation of the toolpath depending on the
requirements of the machining.
A 5 Axis tool path will allow access to the Tool Normal angle, greyed out in the image.
Tolerances
Figure 207 - Finish tolerance options
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Tool Data
Figure 208 - Radial Tool Data tab

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Select the items

Figure 209 - Radial items to machine

Once you have selected the items to machine, you are the requested for a point from which the Radial toolpath
will be created.
Figure 210 - Radial centre point location
In the image above, we are using the centre of the large end arc as the location.
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Figure 211 - Radial generated decorative toolpath
 Note that the angle values we placed in the set up dialogues have permitted the entire
form to be machined.
 If you alter the Start Angle and End Angle values, this will limit the extent of the
machining even though it is contained within the boundary geometry.
 Altering the Start Point for the Radial creation will also have an impact on the area being
machined as shown in the following images.
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Same Values, Different Centre Points

All of the toolpaths in the following images have exactly the same options and boundaries used, only the Start
Point location differs.
Start Point set to the Intersection of the two

straight lines of the boundary
Start Point set to the Mid Point of the smaller of

the two arcs of the boundary.
Start Point set to the Centre Of the larger arc,
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#9 Radial Curved Pocket

Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#9 Radial Pocket
Finishing”
Figure 212 - Radial Pocket Finishing example file
In this example, we look at finishing four small areas between curved walls and corner sections where a
conventional flat tool cannot complete the process.
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Blend Machining Application

Figure 213 – Radial Tool Selection
Select the Radial option, <LClick> [OK].
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Boundary Rules
bounded area.



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Boundary Selection for Radial Machining
Figure 218 - Radial Boundary Selection
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Machining options
Figure 219 - Radial Machining Options
As we have previously applied a Radial cycle and most of the options we are using will remain unaltered, the
only tab we need to be concerned with is the Machining Data section.
Adjust the Width of Cut to read 0.2.
Once we apply the cycle using this value, we can directly compare the difference between the four original
individually applied toolpaths against a single toolpath using the four triangle geometries.
<LClick> [OK] to proceed.
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Select the items

Figure 220 - Radial items selected for machining
Figure 221 - Radial centre location set
Once you have selected the items to machine, you are the requested for a point from which the Radial toolpath
will be created.
In the image above, we are using the centre of the pocket (Global Origin) as the location.
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Figure 222 - Radial applied toolpaths
Though this looks like a good toolpath, on closer inspection and comparing with the original single set
toolpaths, you can see a marked difference between the step overs of the two cycles.
Figure 223 - Radial cycle when applied to individual Figure 224 - Radial cycle when applied to all four
boundaries boundaries at once
Using the exact same settings for step over but placing the centre of the radius further away leads to much
greater step overs on the paths.
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#10 Spiral
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#10 Spiral”
Figure 225 - Spiral example file
With the Spiral style of 3D Machining you can machine several faces of a 3D model without the specific needs
for boundary containment.
Theoretical boundaries are used by specifying an inner and an outer radius for the spiral to be contained
within.
Whether the machining is to be from the inside to the outside or vice versa, and whether the spiral is to be
clockwise or counter-clockwise.
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The spiral tool paths are projected onto the surfaces and ‘trimmed’ to keep the tool contact point to be at the
edge of the outer surfaces. Note that this means that a ball end or bull nose tool will drop off the edge of a
surface if the outer radius is outside the surface edge.
Where the toolpath is trimmed, a rapid move is placed between the end of one trim and the start of the next.
Figure 226 - Tool Path Rapids turned on
In practical applications, this may lead to considerable up and down moves in the Z axis so care should be
taken as to whether this is a suitable method for machining your part.
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Worked Example
It can be seen from the supplied example that whilst the toolpath is very good for the central area of this part,
the amount of lifting between the separate step overs around the edge of the form does not lead to a very
productive toolpath.
Delete the existing Spiral toolpath so that we can reapply the machining in a more suitable machine friendly
method.
Firstly, we need to limit the actual travel of the Spiral option and then combine this with the Projected Contours
cycle to make a much more effective toolpath.
Use SOLID MODEL UTILITIES > Face/ Edge/ Point Details to find the size of the lower circle at
the bottom of the blending radius.
Figure 227 - Evaluating the size of the area to machine
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Figure 228 - Solid Machining Finishing selection dialogue
 Note that the Boundaries option is not available, it is the two radius values used in the
cycle which limit the machining.
<LClick> [OK].
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General
Figure 229 - Spiral General tab
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Lead-In/Out Links
Figure 230 - Spiral Lead-In/Out links tab
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Machining Data
Figure 232 - Spiral Machining Data tab
Cut Spacing Uses

Spiral creates paths that progressively step across in either X or Y, or a combination of both depending on the
option settings.
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Spiral Options
Figure 234 - Spiral options
The Spiral Options section sets up the theoretical boundaries inside which the spiral toolpath will be created.
In this example, we make the Inner Radius to 0 to cut from the very centre, and the outer Radius to 32 so that
there is an overlap onto the flatter section of the form.
The Start Angle option allows you to control where the spiral commences if this were for a decorative form
where the actual positioning of the spiral was critical.
Tolerances
Figure 235 - Chord and Facet finishing options
Options
Figure 236 - Spiral direction options
The only options available to select are whether to produce the toolpath from the Inside or to cut Clockwise or
not.
Once you <LClick> [OK] to continue, you are requested for the solid(s) to machine and then a specific
location for the centre of the spiral.
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Figure 237 - Selecting the Solid to machine
Select the [All] option as both the gold solid and silver cap are needed in this cycle.
 If you forgot to select the silver item, this would allow the cycle to pass through it and
machine where we do not want.
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Figure 238 - Setting the start point for the Spiral cycle
Set the centre location for the spiral to be X0 Y0 Z0, then <LClick> [OK].
Figure 239 - Spiral cycle applied
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Now we have a more suitable Spiral toolpath that does not involve the original lifting and lowering to work
around the outer edges, we need to apply a more suitable toolpath to finish the remaining area.
Projected Contours is perfect for this.
To generate the two required boundaries around the outside of the actual part and the base of the dome
section, use SOLID MODEL EXTRACT > Projected Face outlines to Work Plane
<LClick> on the face indicated below.
Figure 240 - Selecting the face for Boundary Extraction
<RClick> to extract the items,
Figure 241 - Extracted Boundaries
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Tool Directions
Using MACHINE > Tool Directions use the  Centre option to the correct tool side.
Figure 243 - Ghost Tools set to Centre as required
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Figure 245 - Projected Contours boundaries to blend with the Spiral
<LClick> the square and circle extracted geometries to continue.
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Machining options
Figure 246 - Projected Contours Machining Data options
The tab we are concerned with is the Machining Data options, here we set the Cut Spacing to match the Spiral
options for a good quality toolpath, <LClick> [OK] to proceed.
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Select the items

Figure 247 - Projected Contours items to machine
 As the area to be machined is dictated by the square and circle boundaries, the silver
solid section is outside of the area to be machined, therefore we do no need to select it.
Figure 248 - Spiral and Projected Contours working together.
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#11 Rest Machining

Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#11 Rest Machining”
Figure 249 - Rest Machining example file
Rest Machining has two options within the cycle to allow a similar function to the Take Account of Previous
Machining found in standard 2D cycles.
This first example deals specifically with the  Previous Tool option.
As this is a complete machined example, we will look in detailed at the applied toolpaths and the options
available for use when using Rest Machining.
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 Previous Tool
Figure 250 - Rest Machining Strategy
The image above shows the choices to make when applying this cycle as a brand new item on your operations
list.
For the purpose of this exercise we will be Editing the applied cycle.
Figure 251 - Editing the existing Rest Machining cycle
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General
Figure 252 - Rest Machining General tab
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Lead-In/Out Links
Figure 253 - Rest Machining Lead-In/Out and Links tab
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Machining Data
Figure 255 - Rest Machining Data tab
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Type
Figure 256 - Rest Machining Type options
 Previous tool Using the Previous Tool option sets the Rest Machining cycle
to operate in the same manner as using the Take Account of
Previous Machining options available on 2D Pocketing and
Rough and Finish cycles.
The process allows for the comparison between the two tools
in a pair of methods.
Making this option active and then <LClick> on

the [Find Tool] button will compare the cycle
 Auto being added directly to the immediate preceding
tool. Care needs to be taken to ensure that the
correct tool is being checked against.
Figure 257 - Previous Tool Auto active
With this option inactive the [Find Tool] button

now becomes a [Select Tool] option.
<LClick> on [Select Tool] opens the standard
Alphacam tool selection dialogue where you are
 Auto
then able to compare against a tool selected from
your library.
Care needs to be taken to ensure the correct tool
Figure 258 - Previous Tool Auto not active
in the library is selected to compare against.
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Steep/Shallow
Figure 259 - Steep/Shallow active
Activating the  Steep/Shallow option gives you the flexibility to alter the style of how the Rest Machining
cycle is applied.
With the option not active, the Rest Machining cycle is applied in a similar style as a Parallel cycle where the
Width of Cut value is applied in the XY plane of the part.
If the option is active, then the Width of Cut is calculated as a Horizontal Z Contours style of cycle where the
step over is applied in the Z axis.
Control over what is Shallow and what is Steep is set via the Contact Angle value where any area where the
Surface Normal and Vertical is greater than this will be machined using the Horizontal style of step value.
Options
Figure 260 - Rest Machining Width of Cut option.
The Width of Cut when using Rest Machining is a single value which is applied to the cycle for however the
cycle will be created.
Figure 261 - Rest Machining Cut Between Z Levels
With  Auto off, you control the Z values of the part to be considered for machining.
Make the option active,  Auto, the entire part is considered for machining.
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Tolerances
Figure 262 - Chord and Facet finishing options
Mill Type
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Tool Data
Figure 264 - Rest Machining Tool Data tab

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#12  Pencil Tracing

Using the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#12 Pencil Tracing”
Rest Machining has two options within the cycle to allow a similar function to the Take Account of Previous
Machining found in standard 2D cycles.
This second example deals specifically with the  Pencil Tracing option.
Figure 265 - Pencil Tracing sample file
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Figure 266 - Rest Machining Strategy
The image above shows the choices to make when applying this cycle as a brand new item on your operations
list.
For the purpose of this exercise we will be Editing the applied cycle.
Figure 267 - Editing the existing Rest Machining cycle
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General
Figure 268 - Rest Machining General tab
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Lead-In/Out Links
Figure 269 - Rest Machining Lead-In/Out and Links tab
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Machining Data
Figure 271 - Rest Machining Data tab
 Pencil Tracing allows for the machining of blend radii between walls and floors of parts and, in some
instances, between near vertical blend radii and floors.
Figure 272 - Extra options for Pencil Tracing settings
The Number of Extra Passes option is used to set the cuts used to generate the actual radius.
If this value is set to 0 then a single cut is used to form the radius which runs along the actual centre line of the
radius to be cut.
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More than 0 and the cycle generates a toolpath like a Contour Pocket or Projected Contour cycle to work
further out from the absolute centre of the radius, this can be useful to blend into other areas created by
differing cycles.
This option will add the stated number of extra passes to each side of the initial central cut.
For example, if you were to set this value to 3, then there would be seven toolpaths created, the initial centre
pass plus three extra to the left and also three extra to the right.
Adding extra passes will also activate the Width of Cut option for the actual distance between the cuts.
Figure 273 - Step over value for extra passes
Figure 274 - Extra passes set to 0 Figure 275 - Extra passes set to 3
 Down Mill allows the user to dictate if vertical or near vertical blends are machined first or last.
Ticked cuts the vertical items first.
The Down Mill Angle, default setting is 30°, allows you to set the minimum angle for which Down milling
should be considered. This can benefit the cycle by not having the tool break up the toolpath where a
continuation would be preferable where the angle of the wall alters slightly.
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#13 Drive Curves

Drive curves can be either Geometry or Tool paths the type of drive curve is set in the machining Dialogue
box. The geometry/polyline or tool path can be in any work plane and any orientation to generate a drive curve
over any number of surfaces/faces. The tool will track along the drive curve being projected onto the part.
Using Geometries
As an example, these drive curves have been created using the Waves add-in macro.
Waves add-in used to create the initial geometries for

use as the Drive Curves.
Figure 276 - Waves Add-in used to generate Drive

Curves
Geometries selected and toolpaths projected to

the actual model.
Figure 277 - Waves geometries projected to the solid

model
Resulting final part.
Figure 278 - Simulated toolpath
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Using Toolpaths
In certain manufacturing circumstances, it may prove more effective to generate the desired tool path using
conventional 2D cycles and then projecting those to the solid model.
In this example, a conventional 2D pocket cycle is used as the Drive Curve, created on Flat-Land and selected
for projection.
Using this type of Drive Curve, there is no requirement to add any Z depths to the cycle as it will be wrapped to
the model for completion.
Figure 279 - 2D toolpath used as a Drive Curve
 When creating a toolpath using this method, the originating 2D cycle is altered to create
the 3D path. This projected path cannot be edited in the usual <RClick> method.
 Making a copy of the original 2D path and using that as the guide will leave the original
available to edit, copy and use as a drive curve in case the first options prove inaccurate.
 You MUST ensure that any geometry or tool path to be used in Drive Curves is ABOVE
the surfaces or faces to be machined.
Projection is always in the Negative Z direction.
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Worked Example using Geometries

Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#13 Drive Curves”
Figure 280 - Drive Curves example file
This example file already has several geometries assigned to it.
• An extracted profile for the pocket detail to be used for the toolpaths section of this cycle.
• Written script for engraving purposes to be used for the geometries section of this cycle.
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Choose the 3mm Ball cutter from the 3D Machining folder.
Figure 281 – Drive Curves selecting a 3mm Ball cutter for the worked example
Figure 282 – Drive Curves strategy
Select the Drive Curves option, <LClick> [OK].
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General
Figure 283 – Drive Curves General tab
The General tab for Drive Curves deals with allowances in XY and Z as well as the clearance options for the
Safe Rapid Level and how far above the part to position the tool for starting the cycle using the Thickness
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Figure 284 - Drive Curves specific requirements
Note the options of the main cycle selection dialogue.
You need to choose which method of application you wish to use; the default option on first use will always be
 Geometries.
<LClick> [Pick Drive Curves] to allow access to the main part where you will then select the required
geometries for the cycle to work with.
Other than the finish precision of the toolpath, there are zero options to work with when using the Drive
Curves finish machining method.
All the attributes for toolpath creation are taken from the geometries selected and the model they are applied
to.
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Figure 285 - Select the required items
Figure 286 - Green tick indicates correct options
Only when this section has a green tick mark will you be allowed to proceed.
As this is the method we will use to start with, <LClick> [OK].
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Lead-In/Out Links
Figure 287 – Drive Curves Lead-In/Out and Links tab
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Tool Data
Figure 289 – Drive Curves Tool Data tab

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<LClick> the large dome shape as the solid.
Figure 290 - Select the solid to machine
<RClick> to finish.
Figure 291 - Drive Curves using Geometries applied toolpath
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Worked Example using Toolpaths

Still using the same example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#13 Drive
Curves” we will look at the implications for using existing toolpaths to generate the cycle.
This method can be very useful should none of the dedicated cycle creation methods suit the area to be
machined.
In the first instance, we need to generate a usable toolpath on the part.
As the geometry already exists, we will create a normal 2D pocket cycle to drive the 3D toolpath.
Note that as this is a pocket, care must be taken on the original geometry that the tool side is set correctly.
Figure 292 - Ensure the tool direction is correct for a pocket cycle
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Figure 293 – Drive Curves selecting a 3mm Ball cutter for the worked example
To create the guide toolpath, use MACHINE > Pocketing
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Types
Figure 294 - 2D Pocket cycle creation process
Make the options  Vertical and  Selected.
General
Figure 295 - 2D Pocketing style options
Set the pocketing options as required, in this instance as the shape is a non-uniform one,  Contour is the
most suitable option.
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Levels and Cuts
Figure 296 - 2D Levels and Cuts options
Because this pocket cycle is never going to be actually machined direct from this cycle, the values for the top
four boxes can all be set to any value.
If your Z origin is the top of the part, then all these values could be set to zero.
For safety though, setting them well above the part is a better and safer option as will be explained later.
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Machining Data
Figure 297 - Machining Data Width of Cut options to suit the finished 3D machining
The Machining Data tab is the one that would normally be set to a default step over of 50%.
However, this is where we will control the distance between each step on the final 3D toolpath.
This is in a similar manner to the Width of Cut and Cusp Height options.
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Tool Data
Figure 298 - Tool Data options
Finally, any alterations to the tooling information.
<LClick> [OK] to complete.
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When prompted, <LClick> the pocket side profile extracted from the model.
Figure 299 - Selecting the profile to apply the pocket to
Figure 300 - Applied initial 2D Pocket cycle
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Figure 301 – Drive Curves strategy
Select the Drive Curves option, <LClick> [OK].
Figure 302 - Ensure the Tool Paths option is set
Ensure that Tool Paths are set as the option, then using the [Pick Drive Curves] options, select the previously
created 2D tool path when prompted.
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When prompted, <LClick> the previously created 2D pocket cycle.
Figure 303 - Select the previous 2D pocket as the Drive Curve
<LClick> [Finish (ESC)].
Figure 304 – Drive Curves using Tool Paths
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Other than the finish precision of the toolpath, there are zero options to work with when using the Drive Curves
finish machining method.
All the attributes for toolpath creation are taken from the 2D toolpath selected and the model they are applied
to.
Figure 305 - Drive Curves General options
<LClick> [OK].
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Figure 306 – Drive Curves initial converted tool path
As we can see from the image, there appears to be some odd movements around the sides of the pocket that
need attention.
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 It must be noted at this point that this is the only cycle that you cannot use the <RClick>
and Edit option in the Solid Machining cycle set.
Figure 307 - Drive Curves using Toolpaths are not editable
 When creating a toolpath using this method, the originating 2D cycle is altered to create
the 3D path. This path is subsequently non-editable.
 Making a copy of the original 2D path and using that as the guide will leave the original
available to edit copy and use as a drive curve in case the first options prove inaccurate.
Using the EDIT > Undo option, step back an operation so that you have the original 2D cycle.
Figure 308 - Using Undo to step back
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From the Operations page of the Project Manager, Edit the original cycle.
In this example, altering the Stock on the Machining Data page to 0.01 creates a more beneficial tool path.
Figure 309 - Original 2D Pocket cycle edited to suit
<LClick> [OK] to apply the changes.
Use the <RClick> menu and select the Copy Operation option.
Figure 310 - Use the <RClick> menu to Copy the operation
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Once all alterations have been made, it is this COPY that will be projected so that you have that actual working
toolpath, plus an original 2D cycle to go back to and make any adjustments during testing.
On final NC output, the original 2D guide cycle will be deselected and not sent to the machine.
Figure 311 - Projected copy cycle with original hidden
Figure 312 - Edited 2D tool path copied and applied to the solid
 You must ensure that to produce NC code in this manner, your post processor MUST
have the ability to produce code when toolpaths are hidden.
 If you have an error when attempting this, contact the Alphacam support team for a
modification to your post processor.
 This is why also, the driving pocket toolpath in this example is placed high above the
actual part to machine, just in case the code is accidently output to the machine.
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#14 Flat Area Offset

Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#14 Flat Area Offset”
Figure 313 - Flat Area Offset example file
This method is ideal for the machining of flat surfaces with flat or bull nose tools.
In this cycle, Flat Areas are those defined as being at 90° or Normal To the axis of the tool centre line.
Alphacam will automatically identify the flat areas and their boundaries are automatically created and the area
pocketed by the tool.
You can set the cutting parameters in the third Dialogue as shown below on two separate tabs in the dialogue.
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Figure 314 – Flat Area Offset strategy
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General
Figure 315 - Flat Area Offset General Tab
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Lead-In/Out Links
Figure 316 – Flat Area Offset Lead-In/Out and Links tab
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Machining Data
Figure 318 - Flat Area Offset Machining Data tab
This distance should only be controlled by Width of Cut because you should be using a tool that has a flat
bottom and you need to machine with maximum efficiency for this cycle.
Cusps on toolpaths should not exist when using Flat Area Offset.
Cut Spacing Uses
Figure 319 – Use Width of Cut for spacing options
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Mill Type
Figure 320 - Machining method
Tolerances
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Strategy
Figure 322 - Pocket style options to machine Flat Areas
The Strategy section controls how the tool will move around the Flat Area.
•  Contour Creates an area clearance toolpath that is the same style of machining
available in a 2D Contour Pocket cycle option.
Figure 323 – Flat Area Contour style machining
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•  Linear Creates an area clearance toolpath in the same manner as the 2D Linear
Pocket cycle.
Figure 324 – Flat Area Linear style machining
Linear also allows for the direction of the toolpath using the Cut Direction dialogue in the
same manner as used in the Parallel strategy.
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 Close Open Pockets allows the user to

force a pocket style of machining working
from the centre of the area outwards or to
allow individual toolpaths which follow the
finished profile.
 Close Open Pockets
Figure 325 - Close Open Pockets active
 Close Open Pockets
Figure 326 - Close Open Pockets inactive
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•  Finish Pass Generates a single toolpath that follows the profile of the blend between the Flat
Area and the non-flat section. In the same manner as a 2D Rough and Finish
cycle but without the requirement to create extracted 2D geometry.
Figure 327 – Flat Area Finish style machining
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If the  Auto option is selected then the entire model from top to bottom is analysed, if the option is not ticked,
then the Upper and Lower Z limits become available for user input to restrict the distance in the current Z axis
direction to be analysed.
Options
When the distance between isolated areas at the same Z level, are less than the value set in Connect Aircut
Length, the tool path will be kept at the cutting height and feed rate across the gap, thus reducing short rapid
motions.
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Rest Finish
Figure 328 - Rest Finish tab
Setting  Take Account of Previous Machining allows a process the same as using a 2D cycle to compare
a smaller tool against a larger previous tool and only machine the areas where the larger cutter could not gain
access.
 Auto works with the immediately preceding tool;  Auto allows for the selection via the Alphacam Tool
Selection dialogue by <LClick> on [Find Tool].
 Flat Area can be used in association with any applied work plane with only the Planar
faces Normal to the Z axis of the active work plane having tool paths applied to them.
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Worked Example
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#14 Flat Area Offset”
Figure 329 - Flat Area Offset example file
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Choose the 20mm Flat cutter from the 3D Machining folder.
Figure 330 – Flat area select a suitable flat tool for machining
Figure 331 – Flat Area Offset strategy
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In the tooling details section, options for the speed, feed can be adjusted from the defined options of the
chosen tool.
Figure 332 – Flat Area Offset General options
Note on this particular example part, the Z Origin is placed to the bottom of the part so the Safe Rapid Level
needs to be a high figure to clear the part.
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Figure 333 - Flat Area Offset Machining Data options
Note that as this is a large diameter cutter, the  Width of Cut is the option to control the step over value to
machine flat faces.
This cycle will be applied to the entire part so there are no other alterations to be made to the default settings.
<LClick> [OK].
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Figure 334 - Selecting the solid to machine
<LClick> [Finish (ESC)] to complete the cycle.
Figure 335 - Flat Area Offset toolpath applied
You can edit the cycle at this point to see the differences between the Parallel option and the Finish Pass
option.
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Single Face Machining

To allow for the machining of a single or only a few faces, use the  Select Faces option on the first dialogue.
Figure 336 - Using Select Faces and Collision Detection in Flat Area Offset
You may also need to activate the  Avoid Fouling Non-Machined Surfaces/Solids to give a better result if
there are surrounding sections that do not need to be cut.
It is quite possible that not using this Avoid option will allow the tool to pass into areas that it should not.
Adding an Offset value will stop the tool short of the chosen exempt areas for safer machining.
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The following images detail the inactive and active generated toolpath when using the  Avoid Fouling Non-
Machined Surfaces/Solids option.
Figure 337 - Flat Area Offset Avoid option inactive
Figure 338 - Flat Area Offset Avoid option active
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#15 Helical Z
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#15 Helical Z”
Figure 339 - Helical Z example file
The Helical Z cycle is an enhancement to the option available when using the Horizontal Z Contours cycle.
Helical Z tool paths are always closed tool paths and cannot be created as open tool paths.
The tool paths are produced either around the inside or the outside of the shape. It cannot be used to cut along
a shape.
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Figure 340 – Helical Z strategy
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General
Figure 341 – Helical Z General Tab
The General tab for Helical Z deals with allowances in XY and Z as well as the clearance options for the Safe
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Lead-In/Out Links
Figure 342 – Helical Z Lead-In/Out and Links tab
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Machining Data
Figure 344 – Helical Z Machining Data tab
Cut Spacing uses
Figure 345 - Helical Z Cut Spacing options
This distance is controlled by either Pitch or Cusp Height.
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Tolerances
Figure 346 - Chord and Facet options
Figure 347 - Helical Z cut between options
then the Upper and Lower Z limits become available for user input to restrict the distance in the current Z axis
direction to be analysed.
Direction
Figure 348 - Cutting Directions
Allows for the choice of direction that the tool will travel around the profile.
Note that Bi-Directional cannot be selected as this cycle is only for use on complete closed toolpaths.
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Cutting Order
Figure 349 - Cutting Order
Options
Figure 350 - Helical Z Options for machining
• Bottom to Top – If checked, the machining will start at the lowest level first and work upwards, rather
than starting at the top and work downwards.
• Tool can under-cut – This option allows undercuts to be applied. This is only available if an
undercutting tool is selected (e.g., Lollipop). Note that this option should be left unchecked unless it is
known that undercuts will actually be applied as this will help minimize processing time.
• Cut Inner Surfaces – Allows the user to create the toolpath on outside of a part if the option is not
ticked, and on the inside of the part should the option be ticked.
Not ticked is the default setting for this cycle.
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Worked Example
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#15 Helical Z”
Figure 351 - Helical Z example file
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Figure 352 - Helical Z select a suitable tool for machining
Figure 353 – Helical Z strategy
Make the options as shown, ensuring that  Select Faces is ticked.
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General
Figure 354 – Helical Z General Tab
Lead-In/Out Links
Figure 355 – Helical Z Lead-In/Out and Links tab
The Lead-In/Out Links tab allows the user to add any lead in or link moves to the toolpath as detailed earlier in
this manual.
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Machining Data
Figure 356 – Helical Z Machining Data tab
Make the options as shown, <LClick> [OK] to continue.
Figure 357 - Selection prompt for machining
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When prompted, <LClick> one of the yellow faces.
Figure 358 - Select one yellow face then use the Face Selector option
When the Face Selector dialogue opens, use the [Same Colour Faces] options to pick the remaining faces to
machine.
Figure 359 - Helical Z Using the Face Selector
Then <LClick> [Finish (ESC)] to apply the toolpath.
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You will be asked for a starting location for the cycle, so long as the start point is within the area to be
machined, you only need to <LClick> should a specific location be needed, then the X, Y and Z dialogue
boxes can be used.
Figure 360 – Helical Z selecting the start location
It may appear that no toolpath has been generated if you are viewing in Shading
Mode.
Use VIEW > Shading to toggle between solid and wireframe to see the resulting toolpath.
Figure 361 - Shaded view shows no toolpath
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Figure 362 - Unshaded shows the toolpath inside the solid model
 Important Note
 This cycle has been added in this manner to graphically demonstrate that if you forget
to set the option  Cut Inner Surfaces the toolpath will be generated about the outer areas
of any chosen section of a model, even if this means that the toolpath would drive through
the actual finished part.
To solve this, <RClick> on the cycle and choose Edit.

Change the Cut Inner Surfaces option from  unticked to  ticked to see the correct result.
Figure 363 – Cut Inner Surfaces option switched on
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#16 Cylindrical Parallel

This strategy creates a 4-Axis method of machining where the part is machined along the axis of rotation then
either the head is rotated by a set step in degrees of arc, or the part is rotated in the same manner depending
on the type of machine being used to generate the part.
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#16 Cylindrical Parallel
Finial and Newel Post”
Figure 364 - Cylindrical Parallel sample file
This allows cylindrical parts to be cut with a ball ended tool using a 4 axis cutting method.
This sample part already has a created toolpath and the following instruction set and images relate to that
particular toolpath due to the time taken to generate.
 This toolpath with the associated options takes around 15 minutes to generate.
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Figure 365 – Cylindrical Parallel strategy
To gain access to the Cylindrical Parallel strategy in Ultimate, you must select one of the 4-Axis options from
the Type drop down menu, this then displays the available strategy on the lower drop down menu.
Figure 366 - Selecting the correct Axis type
 The axis selection options are specific to the actual machine set up. You must select the
correct option based on your own machine tool in use.
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Axis of Revolution
Once the Cylindrical Parallel strategy has been chosen, you are then asked for the location of the rotational
axis physically on the part.
Figure 367 - Cylindrical Parallel axis of rotation
In this particular sample file, the toolpath has been created around the global Z (blue polyline) axis.
Depending on the location of a part, you may have to draw this line prior to commencing the cycle should your
part not sit on the global origin.
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Faces to Machine
As we only wish to machine the top section of this part, using the face selector to choose like coloured faces is
the quickest option.
Figure 368 - Selecting the faces to machine
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General
Figure 369 – Cylindrical Parallel General Tab
The General tab for Cylindrical Parallel deals with allowances in XY and Z as well as the clearance options for
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Lead-In/Out Links
Figure 370 – Cylindrical Parallel Lead-In/Out and Links tab
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Machining Data
Figure 372 - Cylindrical Parallel Machining Data tab
Cut Spacing uses
The step over value in this cycle is defined as Degrees of Arc instead of XY values.
The Cusp Height, if selected instead, is still calculated in mm but the step over would then be back calculated
inside the cycle to degrees of arc.
Selecting the Browse option at the end of the Width of Cut option allows for more fine tuning of the
option.
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Figure 373 - Cylindrical Parallel Secondary Width of cut options
Using this allows for the calculation of a linear width of cut that can then be applied at a dedicated diameter
value by direct input or using the Browse option a second time, to physically select on the actual model should
a direct value not be available.
Cutting limits.
Figure 374 - Cylindrical Parallel angle limit options
These options allow for restricting the rotational aspect of the part of head depending on the machine type or
access restrictions due to set up or machine capabilities.
Finish Precision
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Bi-Directional
With the option  Bi-Directional selected, the toolpath is generated so that the tool maintains contact with the
job and at the end of each pass across the length of the part, the part is then rotated by the amount set in the
cut Spacing option.
If the option is not ticked, at the completion of each pass along the part, the tool lifts to clearance, moves back
to the starting end of the job to begin the next cut.
Max to Min
The Max to Min option sets the point at which the toolpath will commence from.
Figure 376 - Max to Min active start point location
Figure 377 - Max to Min not active start point location
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Direction of Rotation
Setting this option will allow a clockwise or counter clockwise rotation around the item being machined.
Cut Between Values.
Figure 378 - Cylindrical Parallel machining limit settings
This option sets the area in which the machining will take place.
The values are attributed to the axis around which the part is rotating.
Figure 379 - Graphic representation of the working limit
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Tool Offset from Centre Line

This option helps prevent the tool from always cutting on its centre.
Figure 380 - Tool Offset from Centre set to Zero Figure 381 - Tool Offset from Centre with an applied
value
This will lead to a better cutting action on from the tool on the part and possibly prevent any unwanted rubbing
or burning depending on the material being cut.
The offset amount can be either a positive or negative value depending on which side of centre you wish to
machine the part.
For those using the Ultimate level of Alphacam, this could also be linked with the Angle Between Tool and
Surface Normal to give even more flexibility within the movement options of the machine being used.
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Figure 382 - Cylindrical Parallel shown in simulation
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#17 Cylindrical Profiling

Whereas Cylindrical Parallel cuts along the part and then rotates by a set amount for the next pass, a
complimentary cycle is Cylindrical Profiling. This method of machining places the cut around the solid model
and then at the end of each pass, steps along the axis of rotation by a set amount for the next pass.
It can be likened to wrapping the Parallel strategy around a rotating part.
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#17 Cylindrical
Profiling Finial”
Figure 383 - Cylindrical Profiling sample file
This allows cylindrical parts to be cut with a ball ended tool using a 4 axis cutting method.
This sample part already has a created toolpath and the following instruction set and images relate to that
particular toolpath due to the time taken to generate.
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Figure 384 – Cylindrical Parallel strategy
To gain access to the Cylindrical Profiling strategy in Ultimate, you must select one of the 4-Axis options from
the Type drop down menu, this then displays the available strategy on the lower drop down menu.
Figure 385 - Selecting the correct Axis type
 The axis selection options are specific to the actual machine set up. You must select the
correct option based on your own machine tool in use.
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General
Figure 386 – Cylindrical Profiling General Tab
The General tab for Cylindrical Profiling deals with allowances in XY and Z as well as the clearance options for
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Tool Control
Figure 387 - Cylindrical Profiling Tool Axis control options
The Tool Control drop down options allows you to further enhance this particular cycle if your machine has the
capabilities to use them.
The default option is Through Axis, where the central axis of the tool is always pointing directly through the
axis of rotation of the part.
The four Normal options will keep the tool pointing at right angles to the chosen option for differing tool path
creation options.
Figure 388 - Tool Control Tool Tip
You must keep in mind that the Normal to options are limited by the functionality of the machine in use.
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Lead-In/Out Links
Figure 389 – Cylindrical Profiling Lead-In/Out and Links tab
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Machining Data
Figure 391 - Cylindrical Profiling Machining Data tab
Cut Spacing uses
Figure 392 - Cylindrical Profiling Cut Spacing options
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Options
Figure 393 – Cylindrical Profiling Options for machining
 Bottom to Top – If checked, the machining will start at the lowest value level along the axis of
rotation first and work towards the highest, rather than starting at the highest value and work
towards the lowest.
 Include Flat Areas as additional Z levels - This option will insert extra cutting passes along
the axis of rotation where any flat sections occur and would be missed out due to the value set in
the Cut Spacing option.
Finish Tolerances
Cut Between Values
Figure 395 – Cylindrical Profiling cut between options
If the  Auto option is selected then the entire model from analysed along the axis of rotation, if the option is
not ticked, then the Upper and Lower axis limits become available for user input to restrict the distance in the
current rotation axis direction to be analysed.
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Direction
Figure 396 - Cutting Directions
This option directly affects the rotation of the cycle around the part.
Depending on which end of a part you commence the cycle from, this option will then set either a CW or CCW
motion around the part to be machined.
Cutting Order
Figure 397 - Cutting Order
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Tool Data
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Axis Location
Figure 399 - Cylindrical Profiling axis location choice
You are now asked for a specific location point around which the rotation will take place.
In the example file, these values are set to Y0 and Z0.
Depending on the values entered, this could have an impact on the generated tool path
Part Selection
Figure 400 - Cylindrical Profiling part selection
<LClick> the main model as the item to machine.

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Figure 401 - Cylindrical Profiling Start Point setting
Finally set the Starting location for the tool path.

For this example file, X0, Y0 & Z50 are chosen.
<LClick> [OK] to generate the tool path.
Figure 402 - Toolpath shown in simulation
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#18 Constant Cusp

Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#18 Constant Cusp”
Figure 403 - Constant Cusp sample file
Constant Cusp brings together the application of the parallel strategy and applies the step over in an even
wrapping over the entire area to be machined.
This removes the requirement for the parallel lace option that was looked at earlier in the Parallel strategy.
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Constant Cusp step over

To compare the methods of step over, the following diagrams indicate the differences between the Parallel
strategy applied to the part and the Constant Cusp strategy applied.
Figure 404 – Constant Cusp step over
Parallel step over
Figure 405 - Parallel step over
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Figure 406 - Constant Cusp step over overlaid on the Parallel step over
Overlaying one style on the other shows how dramatic the difference is towards the lower end of the radius.
The step overs for the Constant Cusp strategy are generated by Normal To method against the part being
machined, these vectors are then transferred to a dedicated variable XY step over to produce the correct
toolpath.
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Comparison of tool paths for the same cusp height.
Figure 407 - Projected Contours toolpath
Figure 408 - Constant Cusp toolpath
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Figure 409 - Constant Cusp Strategy
Select the Constant Cusp option, <LClick> [OK].
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General
Figure 410 – Constant Cusp General Tab
The General tab for Constant Cusp deals with allowances in XY and Z as well as the clearance options for the
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Lead-In/Out Links
Figure 411 – Constant Cusp Lead-In/Out and Links tab
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Machining Data
Figure 413 - Constant Cusp Machining Data tab
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Cut Spacing Uses

Mill Type
Tolerances
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Figure 417 - Parallel machining depth control options
If  Clip to Depth is checked, the tool path in the shallow regions will be clipped at the Depth value. If
unchecked, the cycle behaves as if the shallow region surface extended into a flat region at the Depth height.
Options
Figure 418 - Constant Cusp extra options
Number of Offset Passes allows for additional side stepped passes when the  Use Guide Curve option is
selected on the strategy selection page.
Connect Aircut Length is the minimum distance allowed for rapid moves between cuts within the cycle.
depth.
 Note that the default setting for Connect Aircut is always the diameter of the chosen
tool.
 Start Cutting at Inside will allow you to cut from inside out or from outside in depending on the option being
set active or not.
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Contact Angles
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not take place.
This is the angle between the point of contact between the tool and face being machined and the tool axis. You
can specify angles between 0 and 90, except for Minimum Contact Angle which can only be up to 85.
The defaults are 0 (min) and 90 (max).
Unlike the Parallel strategy, Constant Cusp does not have the option to ignore flat areas, so this could be a
practical use of the Contact Angles to set the lower limit to slightly more than 0 to prevent the machining of
large flat sections of a part.
 It should be noted though, that should a curved feature be so shallow in its radius that it
too falls below this angle, then it too will not be machined.
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Tool Data
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Worked Example
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#18 Constant Cusp”
Figure 423 - Constant Cusp example file

Figure 424 – Constant Cusp selecting a suitable tool
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Figure 425 - Constant Cusp Strategy
Select the Constant Cusp option, <LClick> [OK].
chosen tool.
Figure 426 - Constant Cusp tooling information dialogue options
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Figure 427 – Constant Cusp Lead-In/Out and Links tab
Figure 428 - Constant Cusp Machining Data options
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Figure 429 - Selection prompt for [All] solids
When prompted, <LClick> [All] to include the main solid and the STL cap.
<LClick> [Finish (ESC)] to apply the toolpath.
Figure 430 - Constant Cusp applied toolpath
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Boundary creation
Whilst this has given us a much superior toolpath for this part in comparison to the Parallel strategy we looked
at earlier, there are areas that need to be looked at.
Unlike Parallel, Constant Cusp does not have the option to Ignore External Edges, so we need to adjust the
machining options so that only the top faces are machined and not allow the tool to drop over the sides of the
part.
To do this we need to apply a boundary to the existing toolpath.
To generate the required boundary around the outside of the actual part and the base of the dome section, use
SOLID MODEL EXTRACT > Projected Face outlines to Workplane
<LClick> on the face indicated below.
Figure 431 - Constant Cusp face selection for boundaries
<RClick> to continue.
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Figure 432 - Constant Cusp generated boundaries
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Tool Directions
Using MACHINE > Tool Directions use the  Centre option to the correct option.
Figure 434 - Ghost Tools as required
Though this has generated both boundaries we will only be using the outer square.
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Add Boundary
To add the boundary to the existing cycle, in the Operations page of the Project Manager, expand the
Constant Cusp cycle as shown below.
Figure 435 - Constant Cusp cycle expanded to show more details
<RClick> on the Boundaries option.
Figure 436 - <RClick> options to Add Boundaries to the existing cycle
In this particular example, use the option Add Boundaries.
 The Re-select Boundaries option can be used once there are existing items to either
change incorrect items or to change the entire area to be machined should the cycle have
been copied for ease of programming.
Figure 437 - Select only the square in this example
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Update the tool path
<LClick> only the outer boundary when prompted. <LClick> [Finish (ESC)] to apply the alteration.
Figure 438 - After adding the new Boundary, you need to Update the toolpath
The cycle does not automatically update itself but is highlighted in blue to inform you that something affecting
the cycle has altered.
<LClick> the Update Tool Paths button on the prompt bar or <RClick> on the cycle itself and select the
Update option.
Figure 439 - <RClick> menu Update option
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Figure 440 – Constant Cusp modified toolpath using boundaries
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Constant Cusp Tips

Due to the manner in which the toolpath has been applied using the boundary, there could be a case where
you would need to drive the tool from the actual faces being machined to give a better finish.
If this were the case then use of the SOLID MODEL EXTRACT > Surfaces from Faces
command would be used to create the large curved surface to machine.
Figure 441 - Extracted surface
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Then using the 3D > Edit Surfaces command and the option to Extend Surfaces to then create a
larger area to machine which includes a small section off the actual part.
Figure 442 - Extend Surfaces options
The amount of extension required would be enough to drive the tool to loose contact with the actual part being
machined.
Figure 443 - Extended toolpath with new boundary
The boundary would also need to be increased to contain the toolpath within the extended surfaces.
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#19 Z (Enhanced Undercuts)

This cycle is specifically designed to be used in more complex multi axis machining and take advantage of the
Tool Axis Conversion options available from the <RClick> menu options when using the Ultimate module of
Alphacam.
In the process of creating this toolpath, the actual generated cycle will give more toolpaths than are required as
the cycle does not know which side of the part you are working on. This is because the creation of this cycle
allows the tool to physically pass through the solid model unlike all the previous cycles that worked with the
solid model in mind as the images below demonstrate.
Tool paths generated with Horizontal Z
Figure 444 - Example of Horizontal Z
When creating the toolpath using the Horizontal Z strategy, the tool maintains contact up to the point where it
cannot follow the actual form any longer, then producing a simple vertical drop toolpath.
With the use of a lollipop cutter, the tool can gain a little more contact into the undercut section, but still fails on
the generation of a good usable path as the shank of the tool now fouls the part.
Figure 445 - Generated toolpath
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Tool Paths Generated with Z (Enhanced Undercuts)
Figure 446 – Z (Enhanced Undercuts) initial toolpath seen in XZ view
When applying the original setup for the Z Enhanced Undercuts cycle, the tool is permitted to completely foul
the part so that the contact area of the tool can generate a usable toolpath.
Figure 447 - Z (Enhanced Undercuts) initial tool path in ISO view
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Figure 448 – Z (Enhanced Undercuts) Strategy
Select the Z (Enhanced Undercuts) option, <LClick> [OK].
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General
Figure 449 – Z (Enhanced Undercuts) General Tab
The General tab for Z (Enhanced Undercuts) deals with allowances in XY and Z as well as the clearance
options for the Safe Rapid Level and how far above the part to position the tool for starting the cycle using the
Thickness Above Surface to Rapid Down to setting.
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Lead-In/Out Links
Figure 450 – Z (Enhanced Undercuts) Lead-In/Out and Links tab
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Machining Data
Figure 452 - Z (Enhanced Undercuts) Machining Data tab
Cut Spacing Uses
Figure 453 - Z (Enhanced Undercuts) cut spacing options
This distance is controlled by either Width of Cut or Cusp Height using mm step.
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Options
Figure 454 - Z (Enhanced Undercuts) options for the cycle
 Bottom to Top – If checked, the machining will start at the lowest level first and work upwards, rather
than starting at the top and work downwards.
 Tool can under-cut – This option allows undercuts to be applied. This is only available if an
undercutting tool is selected (e.g., Lollipop). Note that this option should be left unchecked unless it is
known that undercuts will be applied as this will help minimize processing time.
 Cut Inner Surfaces – Allows the user to create the toolpath on outside of a part if the option is not
ticked, and on the inside of the part should the option be ticked.
Not ticked is the default setting for this cycle.
 Include Flat Areas as additional Z levels. - Allows for the option to insert extra cuts in the Z axis to
cater for those sections that fall between the specified step options in the Cut Spacing section.
Figure 455 - Z (Enhanced Undercuts) Z limiting options
then the Upper and Lower Z limits become available for you to input to restrict the distance in the current Z
axis direction to be analysed.
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Tolerances
Cutting Order
Figure 457 - Z (Enhanced Undercuts) area ordering options
Direction
Figure 458 - Z (Enhanced Undercuts) direction of cut options
Allows for the choice of direction that the tool will travel around the profile.
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Tool Data
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Worked Example
Open the example file “…. ALP TRG 116 3D Machining 2020 \Examples\Drawings\#19 Z Enhanced
Undercuts”
Figure 460 - Z (Enhanced Undercuts) example file
This example working file has pre-created items included.
• A 2D geometry to use as a specific controlling boundary.
• A single surface used to alter the tool angle for machining.
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Choose the 16mm lollipop cutter from the 3D Machining folder.
Figure 461 - Z (Enhanced Undercuts) selecting a suitable tool for manufacture
Figure 462 – Z (Enhanced Undercuts) Strategy
Note the use of From Drawing option in the Boundaries section.

Select the Z (Enhanced Undercuts) option, <LClick> [OK].
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Select the 2D boundary, then <LClick> [Finish (ESC)].
Figure 463 - Z (Enhanced Undercuts) Boundary selection prompt
chosen tool.
Figure 464 - Z (Enhanced Undercuts) tooling information dialogue options
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Figure 465 - Z (Enhanced Undercuts) Lead-In/Out Links
Make the options as shown below for Machining Data.
Figure 466 - Z (Enhanced Undercuts) Machining Data options
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When prompted, <LClick> the main solid model.
Figure 467 - Z (Enhanced Undercuts) selection options
Then <LClick> [Finish (ESC)] to continue.
Figure 468 - Z (Enhanced Undercuts) Setting the Start Point for machining
You are finally asked to choose a Start point, in this example, zero for all three values will work.
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Figure 469 - Z (Enhanced Undercuts) applied initial tool path that will need editing
There may be more toolpaths generated than the actual finished part needs, even when using a boundary.
Use EDIT > Delete to remove all the toolpaths on the top of the solid model.
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Figure 470 - Z (Enhanced Undercuts) toolpaths marked for deletion
Figure 471 - Z (Enhanced Undercuts) final required toolpaths
These remaining toolpaths will be converted to the finished toolpath.
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Figure 472 - Using the <RClick> menu to use Tool Axis Conversion
On the Operations page of the Project Manager, <RClick> on the previously created toolpath and select
Tool Axis Conversion from the pop up menu options.
 Note that this option is ONLY available in Ultimate Alphacam
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Tool Axis conversion

Make the options as shown below.
Figure 473 - Tool Axis Conversion options dialogue
Tool Axis Conversion allows a simple 2D or 3D toolpath to be easily transformed into a multi-axis one.
The option needs to be turned on by ticking the  Apply Tool Axis Conversion option at the top of the form.
In this example, we use the option  5-Axis and  Normal to Surface so that the tool axis is set to 90° to the
controlling chosen surface.
 A more detailed listing of the options used in Tool Axis Conversion can be found in the
next section of this manual.
Once the options are made, <LClick> [OK] to continue.
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When prompted, <LClick> the surface, then <LClick>

to complete.
Figure 474 - Surface option selected to adjust the current 3 Axis tool path
Figure 475 - Z (Enhanced Undercuts) toolpath using Tool Axis Conversion
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Figure 476 - Z (Enhanced Undercuts) finished converted tool path
 Note that further editing of the required toolpaths may be needed depending on the
angle of the tool and the limitations of the machine in use.
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3D Finish Machining tutorial example.

Example file “…. ALP TRG 116 3D Machining 2020 \Examples\Models\Alphacam Designer\Finish
Machining Example.vdf”
This example part has been designed so that several different strategies can be used to complete the part.
On the following page is a suggested outline for machining this part, it is not rigid and you may use as many or
as few options as you wish to complete the process.
Figure 477 - Example file for practice
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Finish Machining Outline

1. Z Contour Roughing
a. Create Material with 3mm XY Stock and 2 mm on top Z.
b. Z Contour Rough to 20mm from bottom face.
2. Parallel
a. Draw rectangle boundaries snapping to model edges.
b. Extract Surfaces from Faces 2.
c. Un-trim the surfaces.
d. Extend the Surfaces.
e. Offset the geometries to be able to machine past the solid edges.
3. Constant Cusp, Projected Contours, Helical Z, Horizontal Z.
a. Extract the geometry from the Top edge of the pocket to use as the boundary.
4. Projected Contours or Constant Cusp.
a. Extract the edge around area 4.
b. Offset the curved section bigger, by 0.5 less than tool radius.
to allow the tool to get down the side.
5. Horizontal Z
a. Project Face outlines to Work plane and edit the geometry to give boundary for the horizontal Z,
Offset the curved section bigger, by 0.5 bigger than tool radius.
6. Flat Area.
7. Pencil Trace.
8. The outside profile and the hole detail are more suitable for Feature Extraction and then using 2D
Rough or Finish to machine the outer profile and a 2D Drill cycle for the hole.
 Note that these are suggestions on the many differing methods that are available in
Solid Machining. Use the information you have gained to apply various tool paths to the
sample part.
 What works for one part, may be totally unsuitable for another.
 Remember that the correct choice of cycles will be developed by active practice to find
which work best in your own manufacturing environment.
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Tool Axis Conversion

Further control of 2D and 3D tool paths can be achieved with tool axis conversion.
 Tool Axis Conversion is only available using the Ultimate level of Alphacam
Tool axis conversion is only possible on tool paths using Ball cutters.
Tool Paths created by Alphacam are already either 2 or 3 Axis so you may wonder why we want 2 and 3 Axis
Conversion. Sometimes it is easier to get the type of cutting strategy required by creating the Paths in an
angled work Plane.
Figure 478 - Explanation of Tool Axis Conversion dialogue
The actions available will depend upon the type to which you are converting.
 It is useful to mention at this point the checkbox “Tool can Under-cut” on the Dialogue in
the Z Level type strategies, if a lollipop tool is selected then this will be on by default,
however If the tool is normal it will be off by default, but the user can activate it, and this
will let the tool undercut in preparation for the conversion.
Tool Axis conversion is better applied to specific tool path operations via the project
manager local popup menu command.
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#20 Convert 3D work plane tool path to Vertical

In this example the Spiral Path on an Angled Plane is converted to 3axis vertical which would yield a very good
surface coverage.
When the 3 Axis Type is selected, all the Action Selections are greyed out. The selected tool path should be
converted into Flat Land or if a work plane is active, the user is prompted to confirm the transformation to the
current plane.
Figure 479 - Spiral cycle created in a work plane
Figure 480 - Spiral cycle converted to a 3 axis toolpath not on a work plane
 Note that any toolpath that has had Tool Axis Conversion applied to it will be marked
with a Gold Star.
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#21 Convert 2 Axis tool path in work plane to Vertical

In this example, there are 2 operations each multi cut at a single depth, the depth being increased for the
second cut.
The first image shows the tool orientation as created.
The second shows the tool path after conversion.
The simulation shows the ball ended cutter however this could be changed to a flat ended end cutter on the
machine.
Figure 481 - 2D Pocket Cycle applied on a Work Plane
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Figure 482 - 2D pocket cycle converted from a work plane to Vertical
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4 Axis XZ or YZ Rotation
#22 Through Axis
With this option the user will be asked to select a point on the Axis. The conversion will then make the tool
paths Rotate about the selected axis.
Parallel tool paths
Figure 483 - Parallel Strategy as applied
Figure 484 - Tool Axis Conversion at the centre of the circle
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#23 Helical Z tool paths in work plane

Used with Z (enhanced undercuts)
Before Conversion.
After Conversion through axis at centre of circle on end, along the global X.
Figure 485 - Z Enhanced Undercuts converted to Vertical through an axis
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5 Axis
#24 XZ Rotation Confined with Boundary
This will work with the same principles as the 5 axis option with the limitation of the Axis control dependent
upon the Axis configuration selected. YZ or XZ
Before Conversion machining with lollipop tool Horizontal Z using lower boundary and selected faces, setting
the option for tool can undercut.
Figure 486 - Initial Horizontal Z toolpath
After Conversion tool confined to upper boundary, this will allow tool paths to be created with a lollipop tool but
a straight ball tool can be used on the machine.
Figure 487 - Toolpath altered using a boundary to

prevent collisions
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#25 Normal to Curve or Curves

Before Conversion machining tool paths created using Constant Cusp.
After Conversion using guide curve on plane causes tool to cut on the side of the ball for better machining.
Figure 488 - Toolpath conversion using a guide curves
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#26 XY Rotation Tool at Fixed Tilt Angle

With this option the user will be asked to select an XY point in the flat Plane. The conversion will then be made
similar to the 5 Axis option, but the tool will stay at the fixed tilt angle and the XY Vector around the Z axis will
point towards the selected point.
Before Conversion Projected Contours.
After Conversion to a tilt angle of 45° and the point selected at centre of the recess.
Figure 489 - Converted toolpath along a specified angle from vertical
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#27 Project through Point

The tool axis vector will be transformed so that the tool axis will always pass through or point towards a user
defined point. There is a prompt asking the user if the picked point is on the tool side of the part. If the point is
on the tool side of the part, then the tool axis will pass through that point. If the point is not on the tool side of
the part, then the tool will point towards the user defined point, but not pass through it.
Before Conversion Projected contours as #26 XY Rotation Tool at Fixed Tilt Angle previous.
After Conversion with point at centre of dish and at Z 100 on tool side.
Figure 490 - Tool path conversion through a point on the tool side
After Conversion with point at centre of dish and at Z -200 not on tool side.
Figure 491 - Through a point on the opposite side from the tool
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#28 Project through Axis

With this transformation, the tool axis will always be normal to the selected Line Axis. The user will be
prompted to select Line of Axis of Revolution.
 Using the points that describe this axis and the point at the centre of the ball tool we will
calculate the vector perpendicular to the axis in the plane created by the three points.
Before Conversion Parallel cuts.
Figure 492 - Initial Parallel cycle
After Conversion tool adjusted to point at polyline axis.
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Figure 493 - Tool path converted using a line on the opposite

side from the tool
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#29 Confine with Boundary

This method requires the user to select a boundary. The boundary must be a closed geometry and the tool
direction Inside\Outside will determine as to whether the tool axis remains inside or outside the boundary.
When the tool exceeds the boundary, it can no longer remain vertical so the tool axis needs to be tilted
keeping the tool normal to the boundary.
Before Conversion tool path cut using Horizontal Z Contours allowing the tool to undercut and cut from bottom
to top.
Figure 494 - Initial Horizontal Z Contours tool path colliding with the part
After 5 axis conversion with boundary.
Figure 495 - Converted tool path using a boundary to prevent collisions
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#30 Project through Guide Curves

The tool axis control can be set with either one or two curves. If there is only one curve selected, then the
plane that the geometry is within controls the angle of the tool axis, which is then rotated within that plane to be
normal to the profile at the nearest point. If there are two guide curves, then they must be in planes that are
perpendicular to each other.
Figure 496 - Before Conversion.
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Figure 497 - Before Conversion side and end shots
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After Conversion.
Figure 498 - Converted tool path using two guide curves
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#31 Cut Spline or Polyline
This command will drive any tool along any spline or polyline. If a spline is being machined, the Chord
Tolerance is asked for, which determines the accuracy with which the straight line XYZ tool moves match
curves in the spline. For a polyline, the tool is simply moved along the straight line segments.
In Standard, and Advanced modules, the tool is assumed to be vertical, with the tool tip centrally on the
spline or polyline, and you are not given any options about tool angle.
If the module is Ultimate and you have selected a 4 or 5 axis post processor, you are able to set the tool to be
 Left,  Centre or  Right of the spline or polyline.
The check box  Show Ghost Tools will immediately show the direction of the spline or polyline so that you
can determine which side is left and which is right.
You can set the Tool Angle to be Normal to nearest Surface/Solid, Parallel to nearest Surface/Solid or at
angles relative to the line or as absolute angles. For angles relative to the line, the angle is measured from the
vertical, and the sign is set by looking along the direction of the spline or polyline. That is, looking at the ‘back
of the tool as it moves away from you along the line. If the tool is leaning to the left, the angle is counter-
clockwise and is therefore positive. If the tool is leaning to the right, the angle is clockwise and the sign is
negative.
Figure 499 - Cut Spline or Polyline options using

Ultimate Alphacam
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Figure 500 - Cut Spline or Polyline

option applied to a form tool
 If the selected post processor has been configured to take account of the ability of the
controller to apply Tool Radius Compensation (G41/42) (this is indicated in the post by setting
$148 to 1 and the tool has been set to be right or left of the spline or polyline, then a check
box –  Machine Compensation – is enabled. Select this to produce the necessary code.
 Please note that the post has to have the correct code in $40. Post variable TCF = 1 if G41/42
is selected when Alphacam is used, TCX, TCY, TCZ gives the tool displacement unit vector,
that is the direction from the contact point to the tool tip. CPX, CPY, CPZ gives the contact
point on the polyline.
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5 Axis Cut With side of tool
Figure 501 - Example file for Cut Spline or Polyline
The angle can be cut using either:

Cut spline or Polyline parallel to model faces
or
Cut between 2 Geometries
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Model Examples
Bracket
Curved Block
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Curved Recess
Helical Z
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Male Form 1
Mould Insert
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Mould 1
Mould 2
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Mould 3
Mould 4
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Panel + Shape
Part Machined with lollipop cutter
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Pipe
Pocketed Plate
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Version amendments
V Amendment Description A Software Version Amended Date

13 Template altered to Hexagon branding 0 2020.0 15/03/2019
Alphacam 2020
3D Machining
Alphacam
Floor Two Tel.+44 (0) 1189 226677
No. One, Waterside Drive Email.info@alphacam.com
Arlington Business Park Web.www.alphacam.com
Theale
Reading Support.support@alphacam.com
Berkshire Portal.customers.ps.hexagonmi.com
RG7 4SA
United Kingdom

ALPHACAM 3D Machining 2020

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ALPHACAM 2020

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Conventions used in this manual........................................................................................... xxii

Recommended Operating Systems and Hardware for Alphacam ..................................... xxiii

Hexagon Customer Portal ...................................................................................................... xxiv

ALPHACAM esupport .............................................................................................................. xxv

3D Machining Strategies ............................................................................................................. 1

Z Contour Roughing Theory ....................................................................................................... 4

Include Flat Areas as Additional Z Levels ............................................................................. 11

#1 Z Contour Roughing Example ............................................................................................. 18

3D Finish Machining Theory ..................................................................................................... 32

Machining Styles ........................................................................................................................ 41

Example Files ............................................................................................................................. 43

#2 Along Intersection (Surface Machining cycle only) .......................................................... 43

#3 Parameter Line Machining (Surface Machining cycle only) ............................................. 51

Tool Axis ............................................................................................................................... 71

#5 Horizontal Z Contours .......................................................................................................... 74

Finish Precision ................................................................................................................... 101

#7 Projected Contours............................................................................................................. 115

#8 Radial Fan ............................................................................................................................ 134

#9 Radial Curved Pocket ......................................................................................................... 147

#10 Spiral .................................................................................................................................. 154

Select the items ...................................................................................................................... 170

#11 Rest Machining ................................................................................................................. 171

#12  Pencil Tracing ............................................................................................................... 181

#13 Drive Curves ...................................................................................................................... 188

#14 Flat Area Offset ................................................................................................................. 213

Lead-In/Out Links ................................................................................................................... 216

#15 Helical Z ............................................................................................................................. 233

#16 Cylindrical Parallel ............................................................................................................ 248

Direction of Rotation ........................................................................................................... 258

#17 Cylindrical Profiling .......................................................................................................... 261

#18 Constant Cusp .................................................................................................................. 273

Tool Directions .................................................................................................................... 293

#19 Z (Enhanced Undercuts) .................................................................................................. 299

3D Finish Machining tutorial example. .................................................................................. 320

Tool Axis Conversion .............................................................................................................. 322

#26 XY Rotation Tool at Fixed Tilt Angle ............................................................................ 330

#31 Cut Spline or Polyline ....................................................................................................... 338

5 Axis Cut With side of tool .................................................................................................... 340

Model Examples ....................................................................................................................... 341

FIGURE 52 - LEAD IN/OUT LINKS EXPLANATION 37

FIGURE 105 - HORIZONTAL Z CONTOURS LEAD-IN/OUT LINKS TAB 77

FIGURE 158 - PARALLEL CYCLE SET TO UP MILL 109

FIGURE 211 - RADIAL GENERATED DECORATIVE TOOLPATH 145

FIGURE 264 - REST MACHINING TOOL DATA TAB 180

FIGURE 317 - LEAD IN/OUT LINKS EXPLANATION 217

FIGURE 370 – CYLINDRICAL PARALLEL LEAD-IN/OUT AND LINKS TAB 253

FIGURE 423 - CONSTANT CUSP EXAMPLE FILE 287

FIGURE 476 - Z (ENHANCED UNDERCUTS) FINISHED CONVERTED TOOL PATH 319

Conventions used in this manual

Denotes a <LClick> or Primary Mouse Button Click.

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

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

 This is a highlighted note to emphasise information

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

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

1. This is the first line of a number list item

• The order is not important.

Recommended Operating Systems and Hardware for

Supported Operating Systems

• 64bit operating systems of the following list are supported,

• Windows 7 (Professional, Enterprise or Ultimate) SP1 required,

• Windows 8.1 Professional and Enterprise,