EWC 2008 Conference Proceedings

Conference Proceedings
Welcome to ESPRIT® World Conference 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ESPRIT For All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ESPRIT Mold For All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Milling and MillTurn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SolidMill® Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SolidMill and SolidMillTurn FreeForm 5-Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SolidMillTurn for Mori Seiki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
SolidMillTurn for Mazak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Post Processor FreeForm 5-Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Post Processor SolidMillTurn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Wire EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
SolidWire® Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
SolidWire Advanced Draft Feature Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
SolidWire for Agie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
SolidWire for Charmilles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
SolidWire for Sodick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Post Processor SolidWire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
ESPRIT Mold™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
ESPRIT Mold 3-Axis Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
ESPRIT Mold 3+2 Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
ESPRIT Mold 5-Axis Composite Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
ESPRIT Mold 5-Axis Impeller, Port Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
ESPRIT Mold Post Processor and Machine Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
ESPRIT KnowledgeBase™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
KnowledgeBase Launchpad, Part 1: The Art of Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
KnowledgeBase Launchpad, Part 2: Automation in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Cutting Tool Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Welcome to
ESPRIT® World Conference
2008
Welcome to the largest annual meeting of the ESPRIT CAM community and your one-stop shop for top-notch technical
training.
ESPRIT World Conference 2008 is tailored for the launch of the latest versions of ESPRIT® and ESPRIT Mold™. The
program is jam-packed with the latest technology and the best technical training to ensure that you walk away knowing
how to make the most of ESPRIT 2009 and ESPRIT Mold v10.
Offered for the very first time at ESPRIT World Conference 2008 and designed for new users, ESPRIT Boot Camp
— a three-and-a-half-day course equivalent to standard ESPRIT introductory training — provides a comprehensive
introduction to milling and turning programming in ESPRIT.
The vibrant city streets and surrounding rugged beauty of Denver, Colorado, make this an ideal site for ESPRIT World
Conference 2008. With its spacious facilities and elegantly modern atmosphere, the Grand Hyatt Denver is a lively city
venue at which to work and play in style.
ESPRIT World Conference 2008 1

ESPRIT For All
Jump into the newest release of ESPRIT with this fun and informative session. Discover how the newest enhancements
can make you job easier and faster. This discussion covers all the general enhancements to ESPRIT 2009—from improved
graphics to interface enhancements to time-saving tips.
— You Will Learn —

9 9 Faster ways to rotate and zoom using a combination of mouse and keyboard actions
9 9 How to automatically create backup files of your work using the new Auto Save Options
9 9 How to check the status of imported CAD models and assemblies
9 9 How to update associated features when an imported CAD model has changed
9 9 How easy it is to use the redesigned Tool Manager
9 9 How easy it is to use the redesigned Milling Tools interface that now includes new definitions for the tool
shank
9 9 How to quickly enable the selection of sub-elements from the new SUB-ELEMENTS mode in the Status area
9 9 How to position an imported CAD model using the new Orient Part functions
9 9 About improved simulation

Panning, Zooming, and Rotating the View
The ability to pan, zoom, and rotate the view has been improved in ESPRIT
2009 to align more closely with the viewing functionality in CAD applications. Pan, Zoom, and Rotate At-A-
Now the mouse and the keyboard provide a faster way for you zoom in, Glance
rotate, zoom out, and shift the position of parts on the screen without having • Interact faster and more
to click commands on the View tool bar. Plus, the user can customize the dynamically with work models
actions of the mouse and keyboard using new “Mouse and Keyboard” options • Use the mouse and keyboard to
in the Options dialog. spin and zoom for a better view
• Use Smart Zoom to zoom based
on the model, not the cursor
location
• Use dynamic free rotation to spin
the model to any angle
• Incrementally pan, zoom, and
rotate using the arrow keys
• Customize the interaction of
mouse and keyboard
Use Shift + scroll wheel for Smart Zoom Use Ctrl + scroll wheel for Free Rotation
When you place your scroll wheel (or middle To easily rotate the view can rotate the view about
cursor on the screen mouse button) and then without clicking the Rotate that axis or element.
and spin the scroll wheel move the mouse forward command, simply hold
forward or backward, the or backward, the view is down the Ctrl key plus the
view is zoomed from the zoomed from the center scroll wheel (or middle
location of the mouse. of the model regardless mouse button) and then
This can sometimes cause of where your mouse is move the mouse to rotate
the view to “fly out” of located. the view.
the window. That way, the model is If you first hover the
Now, if you hold down always in view. cursor over an axis line
the Shift key plus the or geometry element, you
4 ESPRIT For All

Use the arrow keys to pan up, down. left, or right Use Shift + up or down arrows to zoom in or out
If you want more precise and left arrow keys to pan You can also use the up
control when you pan horizontally. and down arrow keys to
the view, you can now You can also hold down incrementally zoom the
use the arrow keys to an arrow key to pan more view.
incrementally pan the view quickly. Shift + the up arrow key
horizontally or vertically. lets you zoom in from the
Use the up and down center of the screen.
arrow keys to pan Shift + the down arrow
vertically. Use the right will zoom out.
Use CTRL + arrow keys to incrementally rotate the view Customize the mouse and keyboard actions
When you hold down the New Mouse and Keyboard Customize the direction of
CTRL key and press any of options have been added the zoom when you scroll
the arrow keys, the model to the Workspace tab in forward and backward
will rotate incrementally the Options dialog that let Customize the incremental
by 15 degrees. you: angle when the arrow keys
The incremental angle can Select the View command are used to rotate the
be changed in the Options (Pan, Zoom, Rotate) to view
dialog. activate when the middle
mouse button and Shift,
CTRL, or Alt are pressed

Auto Save Options
Everyone knows they’re supposed to save their work often. But then along
comes a power outage and you realize you just lost hours of work because Auto Save At-A-Glance
you forgot to save. It’s easy to get so involved in your work that you forget to • Back up ESPRIT files automatically
hit that pesky Save button.
• Choose where to store backups
Now ESPRIT will save your work for you at whatever interval you want so
you always have a backup when the unexpected happens. • Limit the number of backup files
by total number and age
• Control the interval between
backups by time or by activity
• Easily enable or disable Auto
Save without losing user-defined
preferences
Opening the Auto Save Options dialog Choose a folder for your backup files
Open the Auto Save soon as you check “Enable There are two settings ESPRIT Files location
Options dialog from the Auto Save”, ESPRIT will that let you control where designated in the Options
Tools menu. The very first use the options you’ve your backup files are dialog.
option lets you enable chosen to automatically saved. To store your backup files
or disable the Auto Save create backup files. When the option “Save in a different location,
function. Backup to Document uncheck “Save Backup to
You can set the options in File Folder” is checked, Document File Folder”
the dialog even if “Enable all backup files are and click the Browse
Auto Save” is unchecked. automatically saved to the button to choose another
When Auto Save is same folder where your folder location.
disabled, ESPRIT simply ESPRIT files are stored.
ignores the options. As This is the same as the
6 ESPRIT For All

Choose how often backup files are created Control the number of backup files
Backups can be created at the level of work being The number of backups system, up to a maximum
timed intervals or by the performed, so if you leave created for any one of 10 versions.
number of commands that your desk the system ESPRIT file is controlled The option “Before Save
have been clicked. won’t create backups while in two ways: by the total Delete all Backup Files
The option “Backup by you’re away. number of backups and by Older Than (days)” lets
Number of Commands” The option “Backup by the age of a backup file. you decide whether to
lets you choose how many Elapsed Time (minutes)” The option “Number automatically delete
clicks it takes to create lets you select a constant of Versions to Save” backups based on how old
a new backup file. The time interval from 1 controls the total number they are, to a maximum of
range is from 1 to 500. minute to 100 minutes of backups saved by the 100 days.
This option is based on between backups.
Open a backup file in ESPRIT Convert a backup file to a standard ESPRIT file
Backup files are saved with be helpful to look at the If you know which version backup file before deciding
a .esp_bak file extension. time stamp rather than of a backup file you want to convert it to an ESPRIT
These files can be opened the version number. to convert to an ESPRIT file.
directly in ESPRIT so that Saving a backup as a file, you can simply remove
you can view the file and standard ESPRIT file is the “_bak” extension from
decide whether to replace quite simple. On the File the file name.
the current ESPRIT file. menu, click Save As, make However, this method is
Click Open and set Files sure “Save as type” is set not recommended. It is
of Type to All Files (*.*). to ESPRIT Files (*.esp), and better to use the method
You can then open any click Save. shown in Step 5 because
ESPRIT backup file. It may you can preview the

Check Reference Files Status
Change is the one certainty in engineering and manufacturing. Since parts
often go through a revision process that may include minor as well as major Reference Files Status At-A-
changes, it makes sense for ESPRIT to recognize that a CAD file has changed Glance
when you open the associated ESPRIT document.
• Check the status of imported
Now you can check the status of files that have been imported from a CAD CAD parts to see if they have
system to see if the file has been updated or if the original file is missing. You been modified or moved
also have the option to replace one imported CAD file with another. • Check the status of CAD
You can also check the status of assemblies imported from SolidWorks assemblies and their components
or Solid Edge. The status of the assembly and all its component parts are imported from SolidWorks or
Solid Edge
displayed.
• Update the ESPRIT model when
If a file has been changed, you can choose whether or not to update the changes are made to an external
model in ESPRIT. If ESPRIT can’t find a CAD file because it’s been renamed or file
moved, you can search for the missing file on your computer and update the
link inside ESPRIT. • Re-link to files that are renamed
or moved
You also have the option to delete links to CAD files. If a part model is
• Delete referenced files
deleted in the work area, ESPRIT still retains the link. But, if you delete the
link to the CAD file, the link and the model are deleted from ESPRIT.
Opening the Reference Files Status dialog File Status

The new “Check file, the status (Current, Current – The CAD originally imported file
Reference Files Status” Modified, Missing), the File has the same name, and it has a different time
command has been added date of the most recent is located in the same stamp.
to the File menu. file update, and the absolute path (the exact Missing – The CAD File
This command is only location where the file is file path address) as the cannot be located by its
enabled when the ESPRIT stored. originally imported file and name and/or its absolute
document contains an it has the same exact time path.
imported part file or stamp.
assembly file. Modified – The CAD
The dialog displays the File has the same name,
name of every imported is located in the same
absolute path as the
8 ESPRIT For All

Modified Status Missing Status
The CAD files that have the reference file the The CAD files that reference and timestamp
the same absolute path timestamp of the updated can no longer be found will be recorded when
and a different timestamp reference file is recorded through the absolute it completes the load
are displayed as Modified. in the ESPRIT file and the path are displayed as process. The solid body
With a Modified status solid body in the ESPRIT Missing. With a Missing in the ESPRIT file is then
the user has the option file is then replaced with Status the user has the replaced with the new
to update the reference the updated reference file. option to reload the referenced file.
file in ESPRIT by selecting reference file by selecting
the Update button. If the the Restore Link button.
user chooses to update The new file’s absolute
Updating a modified file Re-linking to a file that has a newer revision

ESPRIT does not you a visual cue that the Quite often, designers You can then navigate to
automatically update the file has changed. and engineers will save the file you want to load.
part geometry when an You can choose whether revisions of the same part After linking to the new
external file has been or not to update the part with a different file name. file, the status changes to
modified. geometry in ESPRIT. If you need to replace an “Modified”.
When a referenced file has To update the ESPRIT imported part file with a Click Update and the part
been changed outside of part to match the updated newer revision, just select geometry is updated in
ESPRIT, the status changes CAD file, select the file the file in the list that ESPRIT.
to “Modified”. The dialog in the list that has been needs to be replaced and
also displays an updated modified and click Update. then click Restore Link.
icon next to the file to give

Restoring a missing file Deleting a referenced file
Sometimes a referenced of the missing file, you can You can also delete You cannot undo the
CAD file is moved to restore the link to the file. referenced part files. deletion of a referenced
another folder or simply Select the line that shows When a file is selected file.
renamed. In that case, the missing part file and in the list, the item is If you delete a file by
ESPRIT cannot find the then click Restore Link. highlighted in the work mistake, you can add
file and lists its status as Navigate to the file that area so you can verify your it back with the Open
“Missing”. The dialog also will replace the missing selection. command. Be sure to
displays an updated icon file, select it and click OK. When you click Delete, click Merge in the Open
next to the missing file to the link and the part dialog to add the CAD
give you a visual cue. geometry are immediately file back into your current
If you know the new deleted from the current document.
location or the new name document.
Restoring the components of an assembly

If one or more
components of an
assembly file have been
deleted from the file list,
you can restore all the
components at once by
selecting the assembly file
and then clicking Update.
The assembly is restored
to its original condition.
10 ESPRIT For All

Associativity
Now that ESPRIT retains the link between an imported CAD file and the
ESPRIT document, features created on those imported models can be Associativity At-A-Glance
updated when the CAD model is updated. • Provides a way to update
ESPRIT retains the link to the CAD file as well as to the faces selected when associated features when an
imported CAD model has
a feature is created on an imported CAD solid in ESPRIT. If the CAD model
changed
changes, ESPRIT recognizes when faces have been changed, added, or deleted
and will update the associated ESPRIT feature when the user clicks Update in • Maintains association between
the Reference Files Status dialog. the CAD model features and the
finished tool path
In ESPRIT 2009, associativity is only intended to address the subset of • This is particularly useful when an
problems best described as engineering changes. Engineering changes are engineering change has been made
changes where a face(s) in the absolute reference changes, but the collection to the original CAD model
of faces does not change. An example of a typical engineering change is a
radius is enlarged/reduced or a hole is repositioned or even a pocket is moved
or increased/decreased
Limitations:
• Associativity is limited to features created with Draft Feature Recognition
and the new FreeForm features for 5-axis milling operations
• Limited to features created from solid bodies and faces and the selected
absolute reference collection
• The collection of CAD faces must never change, and can only be modified
(Note: When the ESPRIT FX Add-In can be utilized, the user will have
fewer restrictions.)
Associativity and ESPRIT FX™

The preferred way to use associativity in ESPRIT 2009 is through ESPRIT FX because there is more control, flexibility
and reliability. When using the ESPRIT FX CAD Feature Tree, the user is still limited to solid bodies and faces, and the
absolute reference collection; however the absolute reference collection is now mapped to a specific CAD feature.
This means that the absolute collection associated to the appropriate CAD Feature can change and associativity will be
maintained through the CAD Feature.
Also, the Check Reference Files Status can be viewed and accessed through the CAD Feature manager. The icon
preceding the imported Solid model shows the current status.
Current- A check mark is placed on the specific solid modeler icon used. (In this example it is SolidWorks)
Modified
Missing
By right-clicking on the imported solid model name in the CAD Feature manager the Update, Restore and Delete can be
accessed.

Example of associativity in ESPRIT
A solid model is loaded into ESPRIT and draft features and toolpath are added to the part. (Note: in this example only
features are displayed for clarity and less clutter).
The the original CAD model is modified with the following changes:
a) The dimensions and location of the Die are changed
b) The Hole sizes and locations are changed
When the Check Reference File Status dialog is opened, the status of the CAD file has changed to Modified.
When the Update button is clicked, the Die and Hole features get updated. Note that the absolute references do not
change between the two models (the face ID numbers are the same).
12 ESPRIT For All

Example of associativity using ESPRIT FX and the CAD Feature Manager
Load the Solid Model into ESPRIT
Place the Draft Feature and Toolpath onto the part model.
Modify the original CAD model.

a) The Cut Opening dimensions are changed.
b) Filleted corners are ADDED to the 4 inside corners.
Click on the solid model name and select Update Cad File.
The feature gets updated. (Note: the absolute reference changes between the two models. The face id numbers are
different). However, associativity is maintained because the CAD Feature that is used to create the Draft Feature is the
same,

Redesigned Tool Manager
In ESPRIT 2008, the display of the Operation Manager was redesigned to
provide a more friendly interface to the user. Tool Manager At-A-Glance
ESPRIT 2009 takes that redesign one step further with the new Tool Manager. • Simplified interface that is
Now the Tool Manager presents the same look for both milling and turning consistent for both milling and
tools, with tools grouped by the milling head or lathe turret they belong to. turning tools
Tools can be dragged and dropped from one tool station to another or even • Improved interaction with the
dragged off of a head/turret to unmount the tool. Cutting Tool Manager in the
KnowledgeBase
The new Tool Manager also has better integration with the Cutting Tool
Manager in the KnowledgeBase. Icons show which tools have been added • New menus make it easy to find
from the KnowledgeBase and tools created in the ESPRIT document can be commands for file management,
easily added to the KnowledgeBase so others can use them. machining, the KnowledgeBase,
and tool creation
The Tool Manager also has the same Advanced Options and Field Chooser
• Drag and drop tools to mount or
as the Operation Manager to let users customize the display of tools in the unmount them from a milling head
manager. or lathe turret
Consistent interface design for milling and turning tools Controlling the display of the tool grid
The new interface is the In SolidTurn mode, every Users can customize the To customize the display,
same regardless of which turret defined in Machine colors of items that display right-click inside the Tool
machining mode is active Setup is displayed, which in the tool grid, such as Manager and then select
(SolidMill or SolidTurn). can include a milling head the background color, text Advanced > Options.
Tools are grouped by for mill/turn machines. color (foreground color), You can always reset
where they are mounted Tools can be added to a or border color. the display of the Tool
on the machine. In station or dragged and You can also set the Tool Manager to the installation
SolidMill mode, tools are dropped between stations Manager to automatically defaults by clicking the
grouped on the milling in the new interface. change the tool number to Reset button.
head. match the station number.
14 ESPRIT For All

Controlling the display of data in the tool grid See which tools are loaded from the KnowledgeBase
The display of data in the To control the types of In the Database Status KnowledgeBase and which
tool grid is controlled by data displayed, click Field column, a new icon makes tools belong only to the
right-clicking on a column Chooser. Place a check it easy to see which tools ESPRIT document.
heading and choosing a next to the tool data belong to the Cutting
command. you want to display and Tools Manager in the
You can sort the data, fit uncheck the data you want KnowledgeBase.
the width of the columns to hide. When a tool is imported
to the data within them, To reset all columns back from the KnowledgeBase,
delete a column, or use to the installation defaults, an icon displays next to
the Zoom command to set click Reset Columns. the tool ID so you can see
the size of the display. which tools belong to the
New Machining menu New KnowledgeBase menu

New menus have been the display of associated The new KnowledgeBase tool association so the
added along the top of the operations by suppressing menu has commands that tool becomes part of the
Tool Manager that make or hiding them, and group let you open the Cutting ESPRIT document, or
commands much easier to operations in the work Tool Manager directly delete the tool itself from
find and use. area by tool. from the Tool Manager. the KnowledgeBase.
When one or more tools When you select one You can also select tools
are selected, you have or more tools that have created in the ESPRIT
access to commands on been loaded from the document and add them
the Machining menu that KnowledgeBase, you to the Cutting Tools
let you simulate by tool, can refresh the tool Manager.
generate NC code, control information, delete the

Creating new tools Loading tools from the KnowledgeBase
You can create new automatically inserted on You can load tools from to the Tool Manager at
turning tools or milling the tool page. the Cutting Tools Manager the turret number and
tools directly from the by selecting the tool and station number defined in
Tool Manager. then dragging it into the the KnowledgeBase tool
If you first select a tool Tool Manager or you definition.
station and then click a can select one or more The pre-existing tools in
type of tool on the Milling tools in the Cutting Tools the KnowledgeBase are
Tools or Turning Tools Manager and click Add always defined on Turret
menu, the turret name Selected Tools to ESPRIT. Number1, Station Number
(or milling head) and It is important to note 1.
the station number are that the tools are added
Moving, copying, and unmounting tools Dragging and dropping tools between stations
When you right-click on Tools can be easily Then, click on the
a tool, two new menu dragged and dropped highlighted tool(s) and
options are available: Copy from one tool station to hold down the left mouse
To and Move To. another or even to a tool button as you drag the
These commands let you station on another turret. tool to another station.
move or copy tools to First, click on a tool so it
another station on any of is highlighted in the tool
the existing turrets or you grid. You can use the Ctrl
can select “Unassigned” to or Shift key to select more
unmount a tool. than one tool.
16 ESPRIT For All

Redesigned Milling Tools Interface
The tool pages for Milling Tools have been redesigned to simplify the interface
and to support the definition of the tool shank. Milling Tools At-A-Glance
The new tool pages display a more accurate image of the tool you are defining • Simplified tool definition
with interactive dimensions to help you define the tool geometry more easily. • Accurate images of each tool type
Information about the tool is grouped logically on separate tabs to make it • Interactive tool dimensions
easier to define the tool holder, tool shank, cutting edge, and position of the let you see exactly what tool
tool in the machine. geometry you are definind
• New shank definition to
separately define the shank from
the cutting edge of the tool
• Simulate the shank using a
different color
New graphical tabs Setting the General tool parameters

When you click a Each button represents General information about In previous versions of
command on the Milling the different the tool, such as the Tool ESPRIT, these parameters
Tools toolbar or menu, characteristics of the tool ID and tool number, are were combined with other
you will immediately you can define: General, grouped on the first page parameters that let you
notice that the dialog has a Machine, Holder, Shank, of the dialog. define the tool position
new look. and Tool. If you’ve selected a and movement on the
Instead of tabs across the Speed Feed Standard for machine.
top of the tool page, there the current document, Now the parameters are
are graphical buttons you can also select a separated to make them
for each group of tool Tool Material from the easier to define
characteristics. KnowledgeBase.

Defining the position of the tool in the machine Holder parameters
The Machine parameters specify that the tool is Previously, the dimensions which dimension you are
are the same as previous mounted on the milling for the holder and the tool defining. This dynamic
versions of ESPRIT, but are head. were defined on one page. display of dimensions
now located on their own It is recommended that Now the holder reduces the clutter on
page. you always specify where dimensions are grouped the screen so you can
For milling tools used on a the tool is mounted since on their own page. quickly see the dimensions
mill/turn machine, you can you can’t machine a part that apply to the tool
As you click on each geometry.
mount the tool on a turret with an unmounted tool. geometry setting,
or on the milling head. You can also mount and dimension arrows display
For milling tools used on unmount tools in the on the image of the tool
a standard mill, you can redesigned Tool Manager. to let you know exactly
New Tool Shank page Tool Shank definitions

These parameters are The tool shank type can When saving the shank
completely new. Now be set to Cylindrical, geometry, P0 (the origin
you can properly define Conical or, in some cases,point) represents the
the shape, diameter, and Reverse Conical depending bottom of the shank and
length of the shank. on the type of tool. not the tip of the tool.
The new shank definition Users can also define The same shank geometry
provides a more realistic a custom shank using can be used with different
simulation with collision imported profile geometry cutting lengths.
detection between the from an external *.ect
shank and the part. (Tool Geometry) file.
18 ESPRIT For All

Separate parameters for the cutting edge Automatic validation of tool geometry
The Tool parameters let If a valid revolved tool a simulation solid can
you define the cutting profile cannot be created be created from the
edge of the tool. from the tool geometry dimensions entered on the
defined on the tool pages, tool pages.
an error message will The validation lets you
display after you click OK. know immediately that
During simulation, ESPRIT an invalid tool cannot be
uses solid models to simulated. You can then
represent tools. After correct the tool definition
a new tool is created, so the simulation does not
ESPRIT validates that fail later.
Choose the simulation color of the tool shank Simulating the tool shank
Now that the tool shank also choose to make When “Tool Visibility” is
can be defined seaparely, it transparent during active on the Simulation
you can also define the simulation. toolbar, the tool and shank
color that displays for the simulate together with
shank during simulation. collision detection on
“Tool Shank” has been both.
added to the Colors list in
Simulation Parameters.
You can set the simulation
color of the shank and

Sub-element Selection
The selection of sub-elements is extremely useful for selecting the individual
faces on a solid model that you want to machine. The Grouping Properties Sub-element Mode At-A-
command relies on the selection of sub-elements to automatically group Glance
faces for several types of features: Holes, Draft Feature Recognition, Turning
• The ability to enable or disable
Profiles, and the new FreeForm feature for 5-axis milling. sub-element selection is now
In ESPRIT 2008, you could only enable or disable the selection of sub- conveniently located in the Status
elements in the Options dialog. This method is inconvenient because it takes area of the screen for faster
the user away from the task at hand. creation of features
In ESPRIT 2009, the addition of SUB-ELEMENTS mode to the Status area • Set the default status in the
Options dialog
makes the selection of sub-elements much more convenient. Just like HI mode
and SNAP mode, you can now enable and disable sub-element selection with
a single click of the mouse.
The option to enable the grouping of sub-elements is still available on the
Input tab of the Options dialog so you can save it as your current user
defaults.
New SUB-ELEMENTS mode in the Status area Enable SUB-ELEMENTS mode

A new SUB-ELEMENTS by opening the Options When SUB-ELEMENTS When SUB-ELEMENTS
mode has been added to dialog. mode is enabled, you can mode is enabled, you
the Status area. select the sub-elements can also select the sub-
You only need to click the of solid models or EDM elements of draft conic
mode to enable or disable features in the work area. features.
it. For example, you can When SUB-ELEMENTS
Previously, you could select the faces, faces mode is disabled, you are
only enable or disable the loops, or edges of a solid restricted to selecting only
selection of sub-elements model. the solid model or the
EDM feature.
20 ESPRIT For All

Orient Part
When a solid model is imported into ESPRIT, it is rarely in the correct
orientation for machining. The commands on the new Orient Part menu Orient Part At-A-Glance
provide an easy way to move a solid model into the position it will be
• Quickly move a part into the
mounted on the machine.
proper position for machining
In ESPRIT 2008, the Part Orientation Add-In let users change the orientation
of a solid model by selecting a planar or cylindrical face and aligning the face • Align a single planar face with the
along the X, Y, or Z axis. X, Y, or Z axis
This functionality is now built into ESPRIT 2009 with the additional • Align two parallel planar faces
improvement that geometry can also be aligned along an axis. with the X, Y, or Z axis
• Align a cylindrical face along the
X, Y, or Z axis
New toolbar and commands Aligning a planar solid face along an axis
The new Orient Part Each of these commands Planar faces are aligned In this example, the
menu is located on the aligns the selected solid perpendicular to the top face is selected for
Edit menu. The menu and face or geometry along the alignment axis. alignment with the Z axis.
toolbar have the following respective global axis. By default, the solid is You can see that the part
commands: aligned so that the positive is moved up so that the
• Align X direction of the alignment selected face is positioned
• Align Y axis is pointing outside the perpendicular to the Z
• Align Z solid body. axis in the same plane as
P0.

Reversing the direction of alignment Aligning two parallel planar faces along an axis
If you want to reverse the to the Z axis but the part When two parallel planar In this example, the middle
alignment direction so the has been flipped over so faces are aligned with an of the front and back faces
axis is pointing inside the the axis points inside the axis, the part is moved are aligned with the X
solid body, hold down the solid model. so that the two faces axis.
Shift key when you click an are perpendicular to the To move the part so the
aligment command. alignment axis. axis points inside the solid
In this example, the The positive direction of body, hold down the Shift
top face selected in the the axis points outside the key while you select the
previous example is also solid body. alignment command.
positioned perpendicular
Aligning a cylindrical solid face along an axis Aligning planar wire frame geometry along an axis
Cylindrical faces are The selected geometry
aligned so that the cylinder must define a plane, such
axis is co-linear with the as a circle, arc, ellipse, or
alignment axis. two line segments.
The direction of the axis When the selected
is arbitrary. If you need to element is aligned along an
reverse the direction of axis, all geometry in the
the part, hold down the work element is moved,
Shift key and align the part not just the selected
with the same axis again. element.
22 ESPRIT For All

ESPRIT Mold For All
Discover all the general enhancements to ESPRIT Mold V10.

9 9 How to create an extruded stock model
9 9 How to rename an operation
9 9 How to rename the output file for all machining operations
9 9 How to check for tool holder collisions on all operations
9 9 How to use an existing project to machine a similar model

Lesson 1: A Complete Session with EM V10
This lesson provides a good overview of how to use ESPRIT Mold V10 to
create roughing and finishing toolpaths on an imported model. Lesson Summary
This lesson will also introduce you to some of the enhancements in EM V10: In this lesson, you will:
• More types of CAD files can be imported • Import a model
• Create stock by extruding a curve • Create stock
• Position the tool on a selected point in the toolpath during simulation • Import an existing tool library
• Create basic toolpaths for
roughing and finishing
• View a realistic simulation
• Run the post processor and get
the g-code
1 Create the model

The model is the base on which ESPRIT Mold can build Click the “Create model” icon.
the toolpaths. You can import the model file from one of Browse for the file model1.igs.
the standard/native file types: IGES, VDA, 3DM, Parasolid,
ACIS, UG, CATIA V4, CATIA V5, PRO/E, Inventor. New! Click OK.
ESPRIT Mold stores all the surfaces and also creates a
triangulated model in tolerance with the surfaces.
The model database (surfaces and triangles) is disjointed
from the geometry database, which stores the geometry
created inside the ESPRIT Mold environment or imported
through the icon Import geometry.
24 ESPRIT Mold For All

2 View the model
Use the “Shading” icon to view the part as shaded or Scroll the mouse wheel to ZOOM.
wireframe. Hold down the mouse wheel to PAN.
Right-click to ROTATE.
3 Extract curves from the model to create the stock

We will now use a new capability of EM V10 to create the Select the 4 surfaces around the perimeter of the upper
stock by extruding a curve. Let’s suppose that the part to plug.
be machined is just the shape of the upper plug. Right-click to confirm the end of the selection.
We extract the curve using the “Curve from contour Press OK in the left bottom corner, leaving the default
(automatic)” function. tolerance of 0.05 for the extraction.

4 Delete the upper curve
Two curves are extracted, CURV1 and CURV2, as you can To delete the curve just select it (to be sure to abandon
see by picking them (when you pick a geometric entity, any previous selection, press F5 to redraw) and press the
you select it and its color change to green). Delete key.
The upper curve (CURV2) can be deleted as we only need We will use CURV1 to create a stock by extruding it.
the bottom one.
5 Start the stock definition

On the Snap toolbar select the “Snap on model” icon, so Select “Define start rough” in the pop-up menu.
that we can refer to the model point later when we will
define the extrusion values for ZMIN and ZMAX.
In the workspace, right-click on the “Rough undefined”
icon.

6 Create the stock as an extrusion
When the “Stock definition” window opens, select the Pick the curve, CURV1, to be extruded (if needed you
“Extrusion” tab. New! could extrude more then one curve).
Define ZMIN and ZMAX by picking on points of the
model.
7 View the stock

Select the “Show stock” icon in the “OpenGL Graphic”
toolbar.
If you click “Show stock” again, the stock is hidden.

8 Open the Tools manager
On the Technology toolbar select the “Tools Managing” In the “Tools manager” window, click “Import” and then
icon. browse to the tools_model1 file.
9 Import all the tools from a file

In the “Import table” window, check “Overwrite current
tool table” and then select the button “All” to import all
the tools.

10 Select a tool
Now you can select the C10 tool, end-mill diameter 10 The tool displays on the screen.
mm, from the list by just double-clicking on it.
11 Create the first roughing on the part

On the Technology toolbar, click “New 3 axis machining”. Select ROUGHING, the first machining cycle in the list.
Click Next.

12 Calculate the roughing toolpath
Just select the “Finish” button.
The toolpath is soon calculated.
13 View the CPU processing time

If your Task Manager is open during this calculation you This technique is applied to most 3 and 5 axis machining
can see that, if you have a PC with multiple CPUs like a cycles.
Centrino Dual Core, the system works on all the CPUs
available. New!

14 Simulate the toolpath
To simulate the toolpath just drag and drop the machining To exit the simulation, press the STOP icon in the
from the workspace to the graphic area and select the “Standard” toolbar:
“Play” button as shown.
You can position the tool on any interpolated point of the
toolpath by just right-clicking on the point. New!
15 Show the stock during simulation

Press the “Show/hide stock” icon again to see the result in
terms of stock.

16 Create a roughing re-machining operation
Select “New 3 axis machining” again. This time select the tool S6, ball diameter 6 mm. This
Select again the ROUGHING operation. tool is smaller than the tool used in the first roughing
operation.
Click Next.
17 Calculate the re-machining toolpath

Click Finish to calculate the toolpath.

18 Show the stock
And again, to see the result in terms of stock, just select
the “Show/hide stock” icon.
19 Create a finishing operation

We will finish the shape using the Z-level strategy ZMILL , Select the Contour Finishing ZMILL strategy.
maintaining a constant scallop on the surface. Select the tool S4, ball diameter 4 mm.
Select “New 3 axis machining”. Go to the Next page.

20 Define the scallop height
Check the “Automatic cuts distance”.
Select Next until you reach the 4th page.
21 Define the machining mode

Check the “Climb mode” option. Click Next until you reach the 9th page.
Set “Minimum slope of zones to machinings” to 0. The
machining will be performed on all zones of the model
where the slope is greater than 0 degrees.

22 Add the surface to be machined
Click “Add/Remove”. Select the shaped surface as shown. The finishing toolpath
will touch only the selected surfaces. Any contact with
unselected surfaces is avoided.
23 Calculate the finishing toolpath

Click Finish to calculate the toolpath.

24 Start a realistic simulation
To get a realistic simulation, click on the “Start realistic EM enters the realistic simulation environment.
simulation” icon in the “Realistic Simulation” toolbar. In the workspace, right-click on “Toolpaths” and in the
pop-up menu select “Animation”.
Start the simulation by clicking on the Play button.
25 End the simulation and return to the graphic environment

The simulation runs through every operation in sequential To return to the graphic environment, click on the
order. “STOP” icon and then on the “Design” tab at the bottom
of the graphic screen.

26 Run the Post Processor and get the NC code
On the “Technology” toolbar, click on the “Start Post- In the Post-processor window, select the post library
processor” icon: (when EM has just been installed, only the DefaultLibrary
is available).
Click Start.
27 View the NC code

The output file is opened in a Notepad window.

Lesson 2: New in EM V10 Architecture
Lesson Summary
In this lesson, you will:
• Rename the machining name
New!
• Rename the output file for all
machining operations New!
• Check for tool holder collisions
for all machining operations New!
• Use an existing project to machine
a similar model New!
1 Rename operations directly in the workspace

Import the project created in the previous lesson: Repeat the same steps for the second and third
lesson1.atc operations, giving them the names “RE-ROUGH_S6” and
In the workspace, right-click on the first operation and “Z_FINISHING_S4”:
select “Rename” in the pop-up menu.
In the Rename window, type “ROUGH_C10” as the new
name.
Generally, it is useful to enter a name that can help
to identify the operation later, or to use important
parameters in the name so you can identify those
parameters at a glance.

2 Rename the output file for all machining operations
At the moment the output file name for all the machinings Open the tree of any of the selected operations by
is C:\ppfile. Let’s suppose we want to change it in C:\ clicking the + icon.
toolpaths\model1.nc (of course we have the folder C:\ Right-click on the output file name and, in the pop-up
toolpaths prepared on our disk). window, select “Modify output file”.
In EM V10 it is now possible to select a set of machinings Type a new name in the dialog.
in the workspace using the Windows technique:
As soon as you click OK, the output file name is changed
Select the first operation in the list. for all the operations.
Hold down the Shift key and select the last operation in To abandon the selection process, just left click on
the list. “Toolpaths” at the top of the tree.
All the operations in between are selected.

3 Check for tool holder collisions for all machining operations
Again, select all 3 operations like before. Browse for a report file name. For example C:\My ESPRIT
Right-click on one of them. Mold Projects\EWC-2008\test_toolholder_model1.txt.
In the pop-up menu, you have a list of all the commands Click OK
available for all the selected operations. You can open the file C:\My ESPRIT Mold Projects\
In our case, select “Test toolholder”. EWC-2008\test_toolholder_model1.txt in Notepad.
In the “Test toolholder” dialog, enter 2 mm as “Minimal These messages also appear in the Control Panel area at
Distance Piece-Holder [DSIC]. the bottom of the screen.
Save this session as lesson1_2.atc

4 Use an existing project as a template to machine a similar model
We want to apply the same technology, tools, strategies, On the Technology toolbar, click “Recorder ON/OFF” to
and parameters of an existing atc file to a similar model. ON
Restart EM V10
Create a new model from model2.igs
This model is similar but not equivalent to model1 in
Lesson 1.
To better understand the test, open the “Tools Manager” Reduce the size of the EM window.
and delete all the tools.
5 Drag and drop an existing project into the current EM session

Drag and drop the file lesson1_2.atc into the graphic
area of the new EM session as shown.

6 Operations and tools are automatically loaded
The operations contained inside lesson1_2.atc are Also, if you open the “Tools Manager” you will see that
inserted inside the workspace of the new session with an the tools contained in lesson1_2.atc have been loaded into
“*” symbol to the right of the operation name, indicating the table.
that they need to be regenerated on the new model.
7 Create stock on the new model

On the Technology toolbar, click “Recorder ON/OFF” to
switch it OFF.
Create the stock using the same steps from Lesson 1,
extruding the curve extracted at the bottom of the plug.

8 Regenerate the two roughing operations
We can regenerate the first 2 operations without verifying
their parameters because they only refer to the stock.
Select the first 2 operations (use the Shift key) , right click
and then select “Regenerate”.
9 Modify and recalculate the finishing operation

The third machining, Z_FINISHING_S4, refers to the Click the Add/Remove button and select the 2 surfaces
surface internal to the slot, so we need to enter its that form the internal shape.
parameters and select the related surfaces again. Click “Finish”
Enter into the parameters of the finishing operation and Answer “Yes” to recalculate the toolpath immediately.
go to the 9th page.
Click the “Remove all” button. Notice that the counter
goes to 0.

10 View the final stock
The toolpath is completely recalculated on the new
model, and this is the result in terms of stock.

Milling and MillTurn
SolidMill® Essentials
Get the most from SolidMill Traditional and SolidMill Production with practical hands-on examples of the latest
functionality and product enhancements. Attend the SolidMill Essentials class first and then round out your conference
experience by attending the other SolidMill classes available throughout the conference.

9 9 New Facing Tool
9 9 Improved Adaptive Facing
9 9 How to use the Feature Utilities Add-in
9 9 How to benefit from the Open Pocket Toolpath
9 9 How to create a Side Slot Mill Toolpath
9 9 How to mill a chamfer
9 9 How to use the Partial Depth setting
9 9 New Threading Tool
9 9 An easier way to define the Lead-In/Out of the Threading Point
9 9 New Undercut technology in the 3D Milling - Z Level Finishing cycle
9 9 New open pocketing capability in the 3D Milling - Variable Z Roughing cycle
9 9 How to simulate a machine with colinear axes
9 9 New ESPRIT FX™ CAD Models
9 9 Enhanced ESPRIT FX™ Tree

Facing
Facing operations have been enhanced in ESPRIT 2009 by introducing a new facing tool as well as an improved version of
the adaptive facing toolpath introduced in ESPRIT 2008.
Enhanced Facing Tool Definition

The Facing tool has been enhanced in ESPRIT 2009 to an indexable tool
with 8 types of insert. With new settings such as Bottom Clearance and Facing Tool At-A-Glance
Orientation Angle, the facing tool is now more accurate than ever. • New insert definition lets you
The definition of the shank is also more suitable for this type of tool. choose from 8 different types of
insert
Along with the new tool definition, the simulation will now detect any
collision with the shank. • New Bottom Clearance
parameter for better simulation
accuracy
• Shank Collision Detection
Define the facing inserts Define the insert settings

The new facing tool allows • Hexagonal Each type of insert has
the user to choose an • Octagonal its own set of parameters
insert from among eight • Diamond to be defined by the user,
different shapes: such as the insert width,
• Round The user can also define height, and corner radius.
the total number of inserts
• Triangular on the tool. The orientation of the
• Square insert is controlled by the
• Rectangular “Orientation Angle”:
• Pentagonal
46 SolidMill® Essentials
Define the Shank Type Shank Collision Detection (Plunging)
The new Face Mill Tool When the facing tool is
lets you choose from two plunging, the simulation
new predefined shank will now show the collision
types for more realistic between the shank and the
simulation (including stock as soon as the shank
collision detection): hits the stock.
• Cylindrical Note: If the Bottom
• Reverse Conical Clearance is greater than
zero, the tool will be able
to plunge to this value.
Shank Collision Detection (Slotting)

Now that users can tool as close as possible
properly define the shank, to the real tool in order
if the incremental depth to have an accurate
of the facing operation simulation.
is set to a greater value
than the insert height, the
simulation will also show a
collision with the shank.
Therefore it is now very
important to define the

Enhanced Adaptive Facing Toolpath
ESPRIT 2008 introduced a new adaptive facing toolpath for the Facing
operation. Adaptive facing is a single-pass toolpath that is based on the Adaptive Facing At-A-Glance
skeleton of the shape. • More efficient toolpath
In ESPRIT 2008, this technology worked fine on “regular” and “continuous” • Smoother toolpath
shapes. However, when the shape was complex and had several branches, the
toolpath was trying to extract the skeleton of each branch. This resulted in
multiple “single pass” for the shape.
Since the tool needed to be repositioned for each pass, the adaptive facing
was not efficient on some shapes that could have benefited from this
technology.
ESPRIT 2008 Toolpath Improved ESPRIT 2009 Toolpath

In ESPRIT 2008, the In those situations, the In ESPRIT 2009, the new Note: If the tool is not
adaptive facing was not adaptive facing was not adaptive facing algorithm wide enough to cover the
able to detect a single pass efficient when the tool is now able to detect the shape in one pass, it is
along the skeleton of the was able to cut the shape longest path along the not recommended to use
part. Therefore the tool in one pass. skeleton to get only a adaptive facing since it will
was moving and plunging in single pass as expected. leave some material.
areas already cut.
Open Pocketing
The new Open Pocket Toolpath was released in ESPRIT 2008, but are you using all its power?
• The “Feature Utilities” add-in introduced in ESPRIT 2008 Service Pack 1 is now part of the ESPRIT 2009 install. Do you
know how to use it to simplify the creation of open pocket feature or even regular features?
• Have you ever considered using the open pocket toolpath to machine a slot?
• Are you looking for a concentric facing toolpath?
Feature Utilities Add-In

In ESPRIT 2008 SP0, when using the open pocket toolpath, the user had to
define the open/close edges of the feature one by one using the Property Feature Utilities At-A-Glance
Browser. For features with multiple edges, this was a tedious task. • Automatically recognize Open
The Feature Utilities add-in lets you directly pick the edges to open/close Pocket features
from the feature. • Easy open/close edges selection
In addition to an easy way to manage the open/close edges, the Feature • Easy extension of the features
Utilities add-in also contains two commands to extend features from/to a face
• Intuitive feature name
or geometry.
Quickly define Open/Close edges Extending features to a selected face/geometry

The command “Define Note: A feature should When using the Face up to a selected face/
Open Edges” ( ) lets not be selected before Profile command in geometry.
you manually select the executing the command; ESPRIT on the bottom of The command “Define the
sub-element of the feature otherwise it will open/ a pocket, the feature will Feature Depth” ( ) lets
you want to open. close all edges. not be be extended to the you define the depth of
The command “Define highest adjacent wall. the feature.
Close Edges” ( ) lets The command “Define Note: This command will
you manually select the the Feature Position” also work with PTOPs.
sub-element of the feature lets you move the feature
you want to close.

Define multiple Open/Close Edges at once View Open Edges
When most of the feature Without the Feature edges of the feature. That
Edges” ( ), ESPRIT will
is open and only a few of Utilities add-in, you will way you can see easily if
automatically set all the
the edges are closed, it need to go through all the your open pocket feature
edges of the selected
will be easier to make all sub-element of the feature is correctly defined.
feature as open.
the edges of the feature to know whether or not
open first, and then select a sub-element is open or
the remaining close edges. close.
If you select the feature Using the command “View
before running the Open Edges” ( ), ESPRIT
command “Define Open will “highlight” all the open
Feature Naming Convention CAD Feature properties

When using the • Open Pocket if there is In ESPRIT 2009 the
Open Pocket Feature at least one open edge Feature Utilities add-in has
Recognition, you will and one closed edge been enhanced to get the
notice that the name • Facing if all edges are CAD Feature properties
of the features are not open of the selected face
just “xx Chain”, but • Boss attached to the created
have a different naming feature. This way, you
convention. • Close Pocket will be able to use the FX
properties of the feature
with the Knowledgebase.
Open Pocket Feature Recognition
One of the major applications of the Feature Utilities add- automatically extend the feature by looking at the side
in is the Open Pocket Feature Recognition. wall (it uses the highest wall to define the top of the
Instead of using the Face Profile command to create a feature).
feature and then define, one by one, the open/close edges,
the command “Create an open pocket Feature from
the selected Face” ( ) lets you directly create an open
pocket from a face.
The Open Pocket Feature Recognition works on the
bottom face of an open pocket. It will automatically
find the open/close edges based on the solid and will

Open Pocketing and Slot Machining
Before the Open Pocket toolpath, it was not easy to machine slots because
the user had to manually offset the feature when applying a pocket operation Slot Machining At-A-Glance
or a contouring operation. • Easier feature creation
With the Open Pocket feature, the user does not have to manually change the • Choose from three different
feature to have the tool going outside of the material. toolpaths: straight passes,
Since the open pocket technology is available on the Pocketing, Contouring trochoidal passes, or a
combination of the two
and Trochoidal Pocketing operations, the user can choose type of toolpath to
apply on the slot.
Alternate Cut Toolpath Full Trochoidal Toolpath

Using the Alternate The open pocket Combined with the
Cut Direction setting technology also works “engagement angle”
of the Open Pocketing with the trochoidal settings, the user can
technology, the tool will toolpath. optimize the cut of the
machine the slot by going Using the full trochoidal trochoidal.
back and forth. toolpath, the user will be
able to machine the slot
at a high feedrate in “one
pass”.
Partial Trochoidal Toolpath Spring Passes
The main inconvenience of toolpath on the first pass, In order to create the Since the contouring cycle
machining a slot is that the you will be able to reduce spring pass to finish the and the wall finish pass
first pass that will be fully the heat on the tool and walls of the slot, the user supports the open pocket
engage (unless if you are have a better cut. has two choices: feature, you do not have
using the full trochoidal). • Contouring Cycle to create a feature per
By combining the • Wall Finish Pass of the side of the slot, and the
Alternate Cut Direction Pocket Cycle toolpath will automatically
and the trochoidal machine only the closed
edges.
Open Pocketing and Concentric Facing

Using the Open Pocket Toolpath and the Feature Utilities add-in, the user has the possibility to use the pocket toolpath
on a face feature.
With the open pocket toolpath, you can use a concentric toolpath, morphing, or alternate cut direction plus add a
finishing pass for the island with more control than the regular facing operation.
When the face has an irregular shape or has islands, the open pocket toolpath will be more efficient than the regular
facing operation. However, since the open pocket is based on the pocket operation, the technology may be more
complicated than the facing operation. Therefore, on rectangular shapes, the facing operation is more suitable.

Facing Feature Creation (Face Profile) Open Feature Creation (Feature Utilities)
When using the Face Therefore, the created The Feature Utilities Note: The expression
Profile command to feature cannot be used “as will automatically find for the total depth/
create the feature, the is” with the Open Pocket the islands and tag the incremental of the
depth of the feature is Cycle. You will have to open/closed edges of the facing operation may
“going down”. Therefore manually open the edges. selected face for you. be incorrect since by
the depth of the facing Since the Feature default the input for this
operation cannot be Utilities will also extend operation is a feature
automatically set by the the feature to the right positioned at total
KnowledgeBase. position and depth, the depth=0
Note: The Face Profile feature will be ready to be
command does not set the used with the KBM in the
open edges automatically. Pocket Operation.
Regular Facing Operation Open Pocket Toolpath

When the face contains suitable when there is no When the face has the ultimate shape of the
islands, the facing island because the facing islands, the regular facing toolpath (use morphing,
operation will go around technology is easier to use operation may not be trochoidal toolpath,
them but the toolpath will and configure. efficient enough. alternate cut direction,
not be improved based on Using the open pocket etc…)
this kind of shape. toolpath on an open
The regular facing “facing” feature, the user
operation is more has more control over
Contouring
The contouring cycle is probably the most used cycle in ESPRIT because of its flexibility. We will see in this section three
applications of toolpath based on the contouring cycle:
• Side Slot Milling
• Chamfer Milling
• How to use the Partial Depth setting
ESPRIT 2009 has fixed numerous issues from previous versions, and also change some behavior based on the input we’ve
had in the support web. Let’s see two of them.
Enhanced Slot Milling Tool

In ESPRIT 2009, the slot mill tool has been improved to support a new type:
“Side Slot Mill”. The Slot Mill Tool also benefits from the other milling tool Side Slot Tool At-A-Glance
enhancements in ESPRIT 2009, such as the new shank definition and collision • New “Side Slot” type
detection.
• Better shank definition
• Better slot name
Define Shank Type Define the Slot Mill Type

With ESPRIT 2009, the The Slot Mill supports two
Slot Mill Tool has two new types of slot: “Side Slot
predefined shank types for Mill” and “T-Slot Mill”.
more realistic simulation The position of the cutting
(including collision edge relative to the shank
detection): on the “Side Slot” is
• Cylindrical controlled by the setting
• Reverse Conical “Shank Extension”.

Contouring and Side Slot Milling
ESPRIT does not have a specific “Side Slot” operation, but this type of
operation can be performed using the contouring cycle. Side Slot Milling At-A-Glance
• Define the correct feature
• Extend the toolpath
• Minimize the retract/entry
movement
Incorrect Feature Correct Feature
Creating a Side Slot Feature

In the case of a side slot, the feature should represent In addition, the orientation of the feature work plane
only the side wall of the slot. needs to be in the same direction as the tool.
The feature should not include the top or bottom face of
the slot, as shown in the incorrect feature above.
Slot Height (Total Depth)
Incremental Depth + Start Depth = Tool Thickness

Tool Thickness
(Incremental Depth)
Defining the machining depths

Set the Total Depth equal to the height of the slot. You Set the Incremental Depth equal to the Tool Thickness.
can extract this value from the depth property of the You can extract this value from the tool properties.
feature. Note: The Incremental Depth plus the Start Depth must
equal the thickness of the tool.
Extend the toolpath Optimizing the Entry/Exit movements

Since the Slot is “open” “safe” rapid entry/exit Due to the open shape,
on the side, it is highly movement. the tool can plunge in
recommended to extend Set the Start/End Overcut rapid mode directly to/
the toolpath on both to a value greater than from the start/end point
sides in order to have 50%. (with the proper start/end
overcut).

Optimizing the retract movements
The fastest way to move a tool during a retract movement With “Retract for Incremental Depth” set to “Partial
is obviously in rapid mode. Since the slot is open and will Depth”, ESPRIT will retract the tool between the current
finish the current pass outside, the rapid movement can and the next pass to the last Z position + Clearance.
be safely done. Once you set the clearance to zero, you will get all your
retract movement in rapid mode.
Contouring and Chamfer Milling

Chamfer operations are performed in ESPRIT using the SolidMill Contouring
cycle. Defining a contouring technology to perform a chamfer usually requires Chamfer Milling At-A-Glance
that you define the technology specifically for the chamfer. • Three new types of chamfer tools
In ESPRIT 2009, the definition of the chamfer tool is more accurate with • Using the tapered wall angle
support for three new chamfer types. The Chamfer End Mill also benefits method to create a chamfer
from the other enhancements to milling tools in ESPRIT 2009, such as the operation
new shank definition and collision detection.
Image courtesy of FAIRFIELD MANUFACTURING
New chamfer tool types
In ESPRIT 2009 the chamfer tool has been improved to The chamfer Milling Tool also benefits from the other
support three new chamfer types. enhancements to milling tools in ESPRIT 2009, such as the
new shank definition and collision detection.
Define the Chamfer Tool

The easiest way to cut a chamfer is to use the method of When the control diameter is equal to the tip diameter,
the taper wall since the chamfer already exists. ESPRIT will control the offset of the tool at the bottom of
In order to use this method, use the chamfer tool the tool.
“Shape2” with a control diameter equal to the tip
diameter:
=
Define the feature

When the chamfer already exists in the solid, the feature Note: The depth of the feature is irrelevant unless you
must be located at the top of the existing chamfer. want to use expressions to compute the total depth.
Define the Taper Wall Angle

With the taper wall method, the “trick” consists of using Therefore, for Tapered Wall Angle, you need to enter the
the setting “Tapered Wall Angle” of the Contouring cycle complementary angle of the Chamfer Angle value:
to compute the chamfer toolpath based on the chamfer Taper Angle = 90 – Chamfer Angle
angle.
By definition the chamfer angle and the taper angle do not
refer to the same angle:

Define the Total Depth
Since the offset is controlled by the taper angle routine, the total depth controls the position of the tool along the wall.
If you want to machine the chamfer in one pass, the total depth must be greater than the chamfer height.
Contouring and how to use Partial Depth

When you have two continuous operations, in some cases, you do not want to have the tool retract between the two
operations especially when the second operation is on a “level” below the first operation.
Partial Depth - Definition
ESPRIT Help File: “The z-value of the retract move is equal to the Clearance value measured from the current tool
location at the time of retract”.
In the case of two operations on different levels, this setting will prevent the tool from having a “full retract between
the operations”.
Partial Depth – Use the Start Depth to remove extra moves…

When using the Partial Depth setting, the tool will retract at the last position in the operation plus the clearance.
Sometimes, it will be better to avoid this movement to go straight to the next operation. When clearance is set to
zero, you will achieve this behavior but this could cause a crash. Using a negative start depth will force ESPRIT to get a
“clearance” at the beginning of the operation but not at the end.

Changes and improvements to Contouring in ESPRIT 2009
Submitting issues and enhancements is helping R&D improve the software. Here are two examples of changes that have
been made in ESPRIT 2009 based on user’s requests.
Lead-In/Out Collision Detection Spiral Milling Tapered

In ESPRIT 2008, in some If so, ESPRIT will prompt In ESPRIT 2008, when
circumstances, the Lead- you with an error using the Spiral toolpath
In/Out move was gouging message “Wrong lead-out on a tapered wall, the
the part because the lead- parameters were set”. offset of the toolpath was
in type was incorrect. Usually you will have to available only with an end
In ESPRIT 2009, the change the lead-in/out mill tool.
system will check whether movement type or values In ESPRIT 2009, the
the lead-in/lead-out to avoid it. toolpath is now doing
movement will cross the the offset of the ball/bull
feature for any reason. nose mill tool at the touch
point.
Threading
The Threading Operation has been enhanced in ESPRIT 2009 with an enhanced Threading tool and a new lead-in/out
setting to simplify the entry/exit movement in the threading operation.
New Threading Tool

The Threading Tool has been enhanced in ESPRIT 2009 to add new settings
and type of tool: Threading Tool At-A-Glance
• New Thread Type setting • New Thread type
• Thread Angle • Accurate tool geometry
• Number of Flutes • Number of Flutes (for Feeds and
The definition of the shank is also now more suitable for this type of tool. Speed calculation)
Along with the new tool definition, the simulation will now detect any collision
with the shank.
New Single Point thread type Thread Angle

In ESPRIT 2008, in order In ESPRIT 2008, the angle condition to choose a tool
to have a Single Point of the thread was set to a in the KnowledgeBase.
Thread Tool, the user had fixed value (60 degrees).
to set the Pitch to 0. In ESPRIT 2009 the user
In ESPRIT 2009, the type has the ability to define
of tool “Single Point the angle of the thread
Tool” was added as a new to get a more accurate
Thread Type. simulation.
Note: This thread angle
could be used as a

Number of Flutes Define Shank Type
In ESPRIT 2008, the number of flutes was set to a fixed In ESPRIT 2009 the
value (1); therefore the calculation of the Feeds and Thread Mill Tool comes
Speed were not accurate. with two new predefined
In ESPRIT 2009 the user now has the ability to change shank types for more
the number of flutes, and the calculation of the feeds realistic simulation
and speeds will be: (including collision
detection):
XYFeedratePM=RPM x XYFeedratePT x Number of Flutes • Cylindrical
ZFeedratePM=RPM x ZFeedratePT x Number of Flutes • Reverse Conical
New Threading Lead-in/Out

When defining the Threading Lead-In/Out in ESPRIT 2008, starting/ending at
the center of the circle was not easy. Threading Technology At-A-
The Lead In/Out Distance in ESPRIT 2008 was computed after the Lead In/out Glance
movement. Since this movement was not easy to determine, the user had to • Better control of the Lead-in/out
guess what should be the distance value to reach the center of the circle.
In ESPRIT 2009, a new setting was added to the threading operation to
automatically define the center of the circle as lead-in/out without entering
the distance value. This point will remain the same whatever the minor/major
diameter (since the lead-in/out movement depends on those parameters, the
user had to change the distance value according to the minor/major diameter).
Lead-In/Out Point Computation Start/End Center Hole in ESPRIT 2009
The calculation of the lead-in point is a combination In ESPRIT 2009, the
of the Minor Diameter, the Tool Radius and the Edge threading cycle has a new
Clearance. Therefore, when Lead-In/Out Type was set setting “Start/End Center
to Tangential Arc in ESPRIT 2008, to have a lead-in Hole” that will compute
start at the center of the hole, you need to set the lead- the lead-in/out distance
in distance to: automatically to always
MinorDiameter/2 - ToolRadius - EdgeClearance start/end at the center of
the hole.
However, the formula may be different with another
lead-in movement, and the technology will not be able
to recalculate it unless you use an expression.

3D Milling - Z Level Finishing
In ESPRIT 2009, the Z Level Finishing operation has been enhanced to support
Undercut Machining. Along with this new toolpath, a new Undercut tool was Undercut Machining At-A-
added to ESPRIT. Glance
• New undercut toolpath
parameters
• New Undercut milling tool
• Mill undercut areas on a standard
3-axis mill without repositioning
the part
• Machine parts in a single piece
that would have previously
required the assembly of multiple
pieces
• Use any milling tool capable of
undercut machining
Undercut Technology
By design, in ESPRIT 2008 the Z Level Finishing operation would machine only “visible” surfaces, therefore any undercut
surfaces were left unmachined.
In the following example, when machining the yellow surfaces, the undercut is all the volume you cannot see by looking at
the part from the top (red volume in the picture).
Undercut Machining Setting Shank Allowance - Definition
The undercut toolpath For example, in the When machining undercut performing the toolpath
is activated only when picture at right, the tool areas, ESPRIT will perform calculation.
“UnderCut Machining” (on will be able to machine the a collision detection with The “Shank
the Advanced Tab) is set undercut area because the the shank to adapt the Allowance” value must
to “Yes”. Otherwise the Undercut width is smaller toolpath based on the size be greater than the
operation will ignore the than the undercut tool of the shank. Tolerance.
undercut area (same as in “clearance”. The “Shank Allowance”
ESPRIT 2008). setting will add a
The Undercut machining cylindrical “safe envelope”
will cut only what is of the allowance value
machinable with the around the shank before
selected tool.
Supported Tool Styles

The undercut toolpath supports the same tools as Z Level
Finishing, but in order to machine the undercut areas, the
tool needs to have an “undercut” cutting area:
• Undercut Mill
• Bull Nose End Mill
• Slot Mill

Restrictions of the Undercut Toolpath
The undercut toolpath will not support the following The horizontal areas (setting “Cut Horizontal Areas”) will
options in ESPRIT 2009 (the settings will be disabled when be found only if they are not in an undercut area.
undercut is on):
• Stock Automation
• Vary Step by Scallop
New Undercut Tool
Define the Undercut Tool Define the Shank Type

The Undercut tool is Tool Radius: The new Undercut Mill support the conical shape
defined by two main Tool lets you define two as is, it is recommended to
settings: new predefined shank use a cylindrical shank for
Tool Diameter: types for more realistic the undercut toolpath.
simulation (including
collision detection):
• Cylindrical
• Reverse Conical
Note: The Shank Diameter Since the undercut tool
must be smaller than the calculation does not
Tool Diameter.
3D Milling - Variable Z Roughing
In ESPRIT 2008, the Open Pocket Pattern was introduced in the 2D milling
cycles. In ESPRIT 2009, Variable Z Roughing has been enhanced to support Variable Z Roughing At-A-
the Open Pocket Pattern. Glance
Unlike 2D milling, Variable Z Roughing does not require the user to manually • New open pocket pattern
tag the sub-elements of a feature as open or closed.
Open Pocketing parameters

The Open Pocket Pattern Parameters are located in the Advanced tab of the Variable Z Roughing operation.
When “Open Pocket Pattern” is set to “Yes”, ESPRIT will automatically apply the open pocket pattern for each Z level
of the toolpath when available.
If there is no “open area” at a level, ESPRIT will automatically switch to the regular toolpath.

Use Alternate Cut Direction
The Alternate Cut Direction setting is similar to the When set to Yes, open edge cutting passes are created in
Alternate Cut Direction of the 2D Pocketing cycle. a back and forth motion connected by bridge movements.
It applies only when Tool Motion Pattern is set to When set to No, open edge cutting passes are created in
Concentric In or Concentric Out. one direction based on the specified cut strategy.
Lead-In/Out Distance
The Lead-In Distance and Lead-Out Distance are used any
time the tool needs to retract in an open edge section.
These distances are measured from the profile offset.
Colinear Machine Axes in Simulation
In ESPRIT 2008, when your machine had a colinear axis, you had to
use the simulation API in order to have correct simulation.
In ESPRIT 2009, the simulation has been enhanced to support
machines with colinear axes.
Defining the colinear axis freedom

If you have, for example, two colinear Z axes, the
machine cannot use both axes at the same time; you
will usually set one axis to a specific value and then use
the secondary axis for the machining.
When ESPRIT detects a colinear axis, it will show the
name of the two axes in the Property Browser, and it
will be up to the user to set the axis status for each
operation.
Quill — Upper Position Quill — Lower Position

When machining the top of the part, we can use the To machine the bottom of the part, the head cannot
quill in the upper position (Z Quill value =0). reach this position without crashing into the part,
therefore the machine needs to move the quill into the
lower position (Z Quill value = -300).

Secondary axis – how to get the fixed value?
In the simulation, the machine is defined with all the axes set to the zero position.
Secondary axis – how to get the fixed value?

The position of the secondary co-linear axis is measured from its zero position, therefore the upper position is at Z=0
and the lower position is at Z=-300
ESPRIT FX™
Introduced in ESPRIT 2007, ESPRIT FX™ keeps moving forward with three
new CAD formats: ESPRIT FX™ At-A-Glance
• ESPRIT FX™ for CATIA • ESPRIT FX™ for CATIA
• ESPRIT FX™ for Pro Engineer • ESPRIT FX™ for Pro Engineer
• ESPRIT FX™ for Inventor • ESPRIT FX™ for Inventor
In ESPRIT 2008, the ESPRIT FX™ was not working with assemblies and • Support for Multiple Body and
multiple CAD Models. When the user was merging two CAD Models Assemblies
(whether or not they are of the same CAD type), ESPRIT was always loading
only the FX tree of the last model.
With ESPRIT 2009, the ESPRIT FX™ Tree now supports assemblies and
multiple CAD Models. The tree itself has been improved with better
rendering and visualization options.
The new “Associativity” technology introduced in ESPRIT 2009 is also fully
integrated into the ESPRIT FX™ Tree.
ESPRIT FX™ for CATIA

ESPRIT FX™ now supports CATIA V5 without any add-in in CATIA.
ESPRIT FX™ for CATIA – CAD features in ESPRIT

When loading a CATIA file in ESPRIT, the CAD Feature
Tree will be loaded directly from the file.

ESPRIT FX™ for CATIA – CAD Feature Properties
When selecting a CAD Feature in the tree, the CAD
Feature Properties of the selection will be displayed in the
Property Browser. For example, on a Hole CAD Feature,
ESPRIT FX™ will carry the following properties:
• Hole Type (for example Counter Bore)
• Thread Depth
• Thread Diameter
• Pitch
• Thread Type (for example Metric Thick Pitch)
• Hole Standard (for example M12)
ESPRIT FX™ for Pro Engineer
ESPRIT FX™ for Pro Engineer was released in ESPRIT 2008 Service Pack 1. It does not require any add-in installed inside
Pro Engineer.
ESPRIT FX™ for Pro Engineer – CAD features in ESPRIT

When loading a Pro Engineer file in ESPRIT, the CAD
Feature Tree will be loaded directly from the file.
ESPRIT FX™ for Pro Engineer – CAD Feature Properties

When selecting a CAD Feature in the tree, the CAD • Nominal Size
Feature Properties of the selection will be displayed in the • Thread Unit
Property Browser. For example, on a Hole CAD Feature, • Thread Orientation (for example Internal)
ESPRIT FX™ will carry the following properties:
• Pitch
• Thread Class (for example 6H)
• Thread Depth
• Thread Designation (for example M8x1.25)
• Thread Type (for example ANSI Metric M Profile)
• Thread Direction (for example Right Hand)

ESPRIT FX™ for Inventor
Loading an Inventor file in ESPRIT 2008 required that the user load or install the InventorLink add-in and ESPRIT FX™
was not compatible with Inventor.
In ESPRIT 2009, Inventor has been integrated into the product. Loading an Inventor file is now handled like any other
CAD Model.
Loading an Inventor File in ESPRIT 2009

Since Inventor has been added to ESPRIT, you can now
load Inventor part (*.ipt) and assembly (*.iam) files directly
from the ESPRIT Open dialog. The preview of the file is
also available.
Inventor Requirement
ESPRIT 2009 requires having either Inventor or Inventor dialog to prompt you to download the latest version of
Viewer installed on the same machine as ESPRIT in order the Apprentice Server (Autodesk Inventor Viewer) at the
to read the inventor files. Autodesk website.
When Inventor is missing on the computer, you will not
have any preview of the file and ESPRIT will display a
Inventor Compatibility
Since ESPRIT 2009 reader is based on the Autodesk If the Inventor file was saved on a version greater than the
Inventor Component, you need to have at least a version Inventor version installed on your machine, ESPRIT will
of Inventor (or Inventor Viewer) greater or equal to the prompt you to download the latest version of Inventor.
version of the file you want to load.
ESPRIT FX™ for Inventor - Requirements

With the integration of Inventor in ESPRIT 2009, ESPRIT
FX™ is now available for Inventor. The ESPRIT FX™ for
Inventor requires the installation of an add-in in Inventor
(same as SolidWorks and Solid Edge), and the file needs to
be saved in Inventor with the add-in loaded.

ESPRIT FX™ for Inventor – CAD Features in ESPRIT
When loading an Inventor file in ESPRIT, the CAD Feature The CAD Feature Tree works the same way as any other
Tree will be loaded directly from the file (when saved with CAD Models.
ESPRIT FX Autodesk Inventor Add-in).
ESPRIT FX™ for Inventor – CAD Feature Properties

When selecting a CAD Feature in the tree, the CAD • Thread Unit
Feature Properties of the selection will be displayed in the • Thread Orientation (for example Internal)
Property Browser. For example, on a Hole CAD Feature, • Pitch
the ESPRIT FXTM will carry the following properties:
• Thread Depth
• Thread Class (for example 6H)
• Thread Designation (for example M8x1.25)
• Thread Type (for example ANSI Metric M Profile)
• Thread Direction (for example Right Hand)
• Nominal Size
ESPRIT FX™ for Inventor – Faces Color in ESPRIT
When loading an Inventor file in ESPRIT 2008, the colors
of the faces were not carrying over in ESPRIT.
Using the ESPRIT FX™ Technology, ESPRIT is now able to
read the color of the faces.

ESPRIT FX™ — Multiple CAD Models and Assemblies
In ESPRIT 2008, only one CAD Feature Tree was allowed at a time. In ESPRIT 2009, the CAD Feature Tree has been
entirely refactored to handle multiple CAD Models (even of different types) and assemblies.
Now, in ESPRIT 2009 when loading an assembly file, the CAD Feature Tree will load all the available FX Data for each
part/assembly.
In order to have the FX tree for all sub-elements of an assembly, each part needs to be saved with the FX add-in on. The
ESPRIT FX SolidWorks Add-in does not save the FX for each sub-element when saving an assembly in SolidWorks.
ESPRIT FX™ Assemblies

When loading an assembly in ESPRIT, the FX Tree will create a top node for the assembly and a sub-node per part.
When selecting a part, ESPRIT will automatically select the solid in the document.
Load a Solid Edge File Merge a SolidWorks File Merge an Inventor File
ESPRIT FX™ – Merge Multiple CAD Models

In ESPRIT 2008, the CAD Feature is only available for the Note: There is no limitation on the format of the CAD
last valid CAD Model merged in the document. Model; you can merge a SolidWorks file with a Solid Edge
With ESPRIT 2009, you can merge as many CAD Models file if you want.
as you want and it will append each FX tree.
ESPRIT FX™ for SolidWorks Configuration Enhancement

In ESPRIT 2008, when the SolidWorks part had multiple configurations, the CAD Feature Tree was unique for all
configurations (the last active configuration).
In ESPRIT 2009 the “ESPRIT FX SolidWorks Add-in” and the CAD Feature Tree have been enhanced to support ESPRIT
FX on multiple configurations. Each time you save a file in SolidWorks, a new “ESPRIT FX” is created for the current
configuration.
Note: The configuration needs to be activated and saved to be compatible with ESPRIT FX. If you have an existing file
with 20 configurations, you will have to activate and save each configuration.

Configuration “Slot Type 15 - Hole M10” Configuration “Slot Type 18 - Hole M12”
Select the “FX Configuration”

When opening a SolidWorks with a configuration, ESPRIT ESPRIT will then load the FX Tree for the selected
will prompt the user to select the configuration. configuration.
ESPRIT 2008 Dialog
ESPRIT 2009 Dialog
SolidWorks Import Configuration Dialog

The “Import Configuration Dialog” for SolidWorks has The status of the configuration will also be marked in
been enhanced in ESPRIT 2009 to be clearer than in the third “Status” column of the dialog in addition to the
ESPRIT 2008. When a configuration is not valid, it will be icons.
grayed out and will not be selectable.
CAD File Manipulation
With the associativity introduced in ESPRIT 2009, the user now has a way to update any CAD Model in a document to
recreate the features and toolpath or just to reload a file.
Update/Restore/Delete a CAD File Update a CAD File

The CAD Feature Tree has been upgraded to this If the file is not up-to-date ( ), the command “Update
technology; the user can directly Update/Restore/ CAD File” ( ) will automatically reload the selected
Delete a CAD File from the Tree. CAD file in the document.
Restore a CAD File Link Delete a CAD File
If the file is missing ( ) or if you wish to replace The command “Delete Cad File” ( ) will delete the
the current CAD file with a different CAD File, the CAD file from the CAD Feature as well as from the
command “Restore Cad File Link…” ( ) will allow you active document (this action cannot be undone).
to browse for a new CAD file.
CAD Feature Tree - Miscellaneous Enhancements

With the associativity introduced in ESPRIT 2009, the user has now a way to update any CAD Model in a document to
recreate the features and toolpath or just to reload a file.
ESPRIT Solid to CAD File – CAD File to ESPRIT Solid Changing the background color of the CAD Feature Tree
The CAD File and the Solid in the document are now The CAD Feature Tree now supports any background
tied together. When one is selected, its corresponding color (even gradient) for your convenience. The colors
object will be also highlighted. can be changed in the Options dialog (right click on the
CAD Feature Tree).

CAD File Status CAD File “Live Update”
The CAD Feature Tree now displays the status of CAD The status of the CAD file in the CAD Feature Tree is
files with the following icons: set when the ESPRIT file is loaded. However, the CAD
: The Cad File is up to date Feature Tree has a built-in Auto Update function that
will check the status of the file every 5 minutes.
: The source of the Cad File is missing
You can change the time delay between status updates
: The source of the Cad File changed or even turn this off in the Options dialog.
When deleting the selected solid, the CAD Feature Tree is being refreshed to show only the valid CAD Features.
Solid – CAD Features Interactivity

When a CAD file has multiple bodies, the CAD Feature In ESPRIT 2009, the CAD Feature Tree will automatically
Tree will show all the CAD features of the CAD file update the CAD features based on the remaining solid(s).
across all of its solids.
In ESPRIT 2008, when deleting one of the solids, the CAD
Feature Tree was not updated, therefore some CAD
Feature became “invalid”.
SolidMill and SolidMillTurn FreeForm
5-Axis
This class is a must for 3D milling specialists. Find out about the new 5-axis cycles in SolidMill and SolidMillTurn.
ESPRIT 2009 introduces 3 new 5-axis cycles:
• 5-Axis Swarf cycle for machining with the flank of the tool
• 5-Axis Contour cycle for 5-axis contouring along a profile
• 5-Axis Composite cycle offers flexibility and performance with different types of 5-axis strategies.
Based on the ESPRIT Mold 5-axis cycles, these cycles are using a new user interface and new type of features.

9 9 How to use the new 5-axis cycles
9 9 How to create and edit FreeForm features
9 9 How to create a Ruled feature for 5-axis Swarf
machining
9 9 The possibilities of the 5-axis Swarf cycle
9 9 The possibilities of the 5-axis Contour cycle
9 9 The possibilities of the 5-axis Composite cycle
9 9 How to handle all transition moves of the tool in
between operations and within an operation

5-Axis cycles overview
ESPRIT 2009 offers three new 5-axis cycles on top of the of the existing
5-axis functionalities of SolidMill FreeForm. 5-Axis Cycles At-A-Glance
These cycles are available in Milling and in Turning modes. • Two new features
The 3 new 5-axis cycles are similar to the 5-axis cycles of ESPRIT Mold V10. • Three new 5-axis cycles
Like other ESPRIT cycles, these new 5 axis cycles are feature based. They • All operations are feature-based
require a new type of feature called a FreeForm feature. The new FreeForm • New interface in the Project
feature lets you group the surfaces that are used for the calculation of the Manager
machining.
The new commands used for the creation of 5-axis machining operations
introduce a new type of interface: All information and user input is located
under a tab of the Project Manager.
SolidMill and SolidMillTurn Mold 5-Axis Toolbar Integrated into the Smart toolbar
All the commands for 1. FreeForm Feature The 5-axis Mold toolbar
the new 5-Axis cycles 2. Ruled Feature can be displayed using the
are grouped on the Mold Smart toolbar.
5-axis toolbar. 3. 5-Axis Swarf Milling
Select SolidMill FreeForm
4. 5-Axis Contour Milling or SolidMillTurn FreeForm
5. 5-Axis Composite to show the 5-axis Mold
toolbar.
Those commands are:
86 SolidMill and SolidMillTurn FreeForm 5-Axis

5-Axis operations are feature based New Interface through the Project Manager
All the new 5-Axis cycles The 5 commands of the parameters on the
apply on a FreeForm 5-axis tool bar use a tab screen
feature. of the project manager • In case of incorrect
The FreeForm feature to display the command parameters this
defines what is cut. parameters and options. interface let you fix the
This tab is dynamic. problems.
The FreeForm feature
must exist before creating It displays only when • There is no dialog box
the operation. Deleting required. to block the view.
the feature deletes the There are multiple • Parameters in the tab
operation. advantages with this new have a dynamic layout.
interface: Anything that is not
5-axis Swarf cycle requires used is hidden from
a Ruled feature as a guide. • Selections are made
while keeping the view.
5-axis page layout Tool Selection

In the 5-axis operation • Tool Path: All Tool Selection sorts the
definition, the 3 vertical parameters for the tool tool by station, by tool
tabs are organized the path definition and the types or with a single list.
same way for all 3 5-axis tool orientation In millturn, picking the
cycles: • Retract: Definition of tool selects the turret.
• General: Groups the transition movement
general parameters and approach/detach
common to all movements.
operations

Stock Allowance and Tolerance Options in the 5-axis operation tab
On the Tool Path tab, cut will be accurate at plus Next to the Cancel Other parameters control
Stock Allowance and or minus the tolerance button, a menu contains the display or reset all
Tolerance are shown value from the model options available on the parameters of the cycle.
under the Accuracy group. definition. operation page.
The Tolerance is a global Stock Allowance defines Open: Load a previously
machining tolerance. a 3D offset of the model saved PRC file.
It sets several internal surfaces. Stock allowance Save: Save a PRC file.
tolerances that are used can be positive or
to calculate the tool path. negative. Print: Print a list of the
It guaranties that the final technology settings

FreeForm Features
The FreeForm feature is a new type of feature used for the input of the new
5-axis cycles. The FreeForm feature defines WHAT is cut, while the cycle FreeForm Features At-A-
defines HOW it will be cut. Glance
The FreeForm feature lets you group all the surfaces for the calculation of an • Define surfaces as ‘Part’ or
operation using the same type of user interface as the 5-axis cycles. ‘Check’
FreeForm features can be edited so the surfaces can be changed after the • Part surfaces display in green
operation has been calculated. • Check surfaces display in red
FreeForm feature command FreeForm feature tab

Select the first icon of the SolidMillFreeForm FreeForm feature tab is
Mold 5-axis tool bar to operations do not work composed of collapsible
start the FreeForm feature with the FreeForm boxes for inputting:
command. features. • The feature name
FreeForm feature has • The part elements
to exist for a 5-Axis • The check elements
operation.

Part versus Check element Element type
Part elements are surfaces calculation but the tool Valid element types for • STL
to be machined. will stop cutting when it part and check element Note: When selecting a
Check elements are reaches a check element. are: composite all the surfaces
surfaces to be avoided. Note: Check element • Face from the composite gets
Check elements are taken are considered as part • Solid added to the FreeForm
into account during the element for the 5-axis • Surface feature.
swarf cycle.
Selection
Select inside the list area of the surface type you want to Select again the same element to unselect or select the
define (Part or Check). By default, the Part surface type is element in the list and press the delete key.
active.
When selecting elements, you can use many selection
tools: Filter, Group box, FX CAD features and
propagation.

Reversing Surface Orientation Using a FreeForm feature with an operation
When selecting surfaces To inverse the orientation, When creating a 5-axis showing the operation
as part element of the right click on the operation, select the parameters.
feature, you need to verify surface in the list and FreeForm feature
the orientation of the select reverse surface you want to apply the
surface. orientation. operation to.
Select a surface in the Faces, solids and STLs do If a FreeForm feature is
list. ESPRIT highlight the not have an orientation in not selected then ESPRIT
selected surface on the the FreeForm feature. will start the FreeForm
screen and an arrow feature creation before
display its orientation.
Editing a FreeForm Feature

From the project manager, After edition, operations
double click a FreeForm must be rebuilt manually.
feature to edit.
Even after operations have
been created, you can modify
the FreeForm feature.

Lesson 1: Create FreeForm features
Lesson Summary
• Create a FreeForm feature from a
solid model
• Create another FreeForm feature
using the CAD feature tree
• Create a FreeForm feature from a
group of surfaces
• Check that the surface normals
are pointing in the correct
direction
1 Open the part file

Open the file: 1_FreeFormFeature.esp
2 Start a FreeForm feature

Click the FreeForm Feature command in the SolidMill Mold 5-Axis toolbar.
Click Grouping Properties.
Set the Face Propagation to Tangent Faces.

3 Select Part elements to machine
Click in the Part Input box of the FreeForm tab, the hold down the Shift key and select one of the faces inside the part.
Notice that all faces tangent with the selected face are added to the part.
4 Select Check elements to avoid

Click in the Check box and select the solid body of the part.
5 Name the feature

Set the feature name to “Inside” and click OK.
The FreeForm feature is created and added to the feature
manager.

6 Select a feature in the CAD feature tree
Click the FreeForm Feature command again in the SolidMill Mold 5-Axis toolbar.
Switch to the CAD Feature Tree and select “VarFillet2” in the tree.
7 Create the feature

Switch back to the FreeForm feature tab and click in the Check box.
Select the solid body of the part.
Rename the feature to “Variable Fillet” and click OK.
Adding the whole body as check is important to have the transition movement calculated based on the whole part
geometry.

8 Create a FreeForm feature from surfaces
Open the file: 1_FreeFormFeature_Surfaces.esp
This file contains only surfaces.
9 Start a FreeForm feature

Start a FreeForm feature and group all the surfaces using a group box.
All surfaces are added to the part section.

10 Verify the orientation of the surfaces
Select items in the part group box and look at the graphic area. Selected surface displays with a darker color and an
arrow shows the normal to the surface.
For machining, normal must be pointing outside of the part.
To reverse the direction, click right on the item of the list and select “Reverse Surface Normal”
Click OK to create the feature once all surfaces are correctly oriented.

5-Axis Swarf Cycle
The Swarf cycle is a cycle that’s cutting with the side of the tool. The flank of
the tool is removing material while the bottom of the tool can be in the air or 5-Axis Swarf At-A-Glance
moving along the “floor” of the part. • New Ruled feature for swarf cuts
The Swarf cycle applies on a FreeForm feature but a second feature is used to • New Swarf 5-axis cycle
guide the tool.
• Cut to a floor surface or extend a
This second feature is a ruled feature. A new command is available to create a wall when no floor is present
ruled feature for 5-axis swarf operation.
• Cut in a single pass or at multiple
The ruled feature defines the “wall” to cut and it defines also the tool incremental depths
orientation along this wall. • Cut in the standard tool
orientation or invert the
orientation
Swarf Cycle and Ruled feature commands The Ruled Feature

The second icon of the creating a 5-axis swarf The ruled feature for The lower and upper
5-axis tool bar is the Ruled operation. 5-axis swarf operation is profile sets the limits for
feature command. the same type of feature the wall to cut. Matchlines
The third icon will create a as the 4-axis EDM feature. are used for tool
5-axis swarf cycle. It includes a lower profile orientation during the cut.
(XY profile) and an upper
A ruled feature must be profile (UV) and match
previously defined before lines that synchronize the
2 profiles.

Ruled feature from Wire Frame geometry
In the Ruled feature tab, set Recognize From to Wire Then set the Cutting Side and name the feature.
Frame Geometry. The cutting side defines on which side of the feature the
Then select successively the Upper Chain and the Lower tool will be cutting.
Chain input boxes and digitize on the graphic the 2 feature Cutting side is usually Left to create a Climb cut with a
chains. Chains are the only valid element for the profiles. tool spinning clockwise.
A chain is required because the direction and the start
point of the profile is important for creating the ruled
feature.
Ruled feature from Solid Faces

In the Ruled feature tab, set Recognize From to Solid Determination of the upper and lower profile is made by
Faces. the selection of an edge on one of the faces.
Then click in the input “Faces” box and select all the faces If selected faces form a looping (closed) shape then the
to recognize. edge selection will also determine the start element of the
Faces have to be continuously connected. ruled feature.
Edges were faces connect define the match lines of the Then set the Cutting Side and name the feature.
Ruled feature. Other edges define the lower and upper The cutting side defines the direction of the ruled feature.
profile of the ruled feature. Cutting side is usually Left to create a Climb cut with a
tool spinning clockwise.

Reversing a Ruled Feature Adding/Removing match lines
If the direction of the Like with a 4-axis EDM select the ruled feature
ruled feature is incorrect feature, you can add and you want to edit.
then select the ruled remove match line using Select a point or SNAP
feature and in the copy the commands in the Edit location defining the start
dialog select Reverse. feature tool bar. point for the new match
Reversing a feature can To remove a matchline, line.
also be done with the select the command Select a point or SNAP
Reverse command in the Remove Match Line then location defining the end
Edit feature tool bar. select the match line to point for the new match
remove. line.
To add Match Line, click
Add Match Line then
Smashing a Ruled Feature

Sometimes it can be useful to
modify a ruled feature created
from the faces of a solid.
Group a ruled feature and in the
copy dialog select Smash.
It smashes the ruled feature into
wire frame geometry.

Swarf Cut without “Floor” Swarf cut with “Floor”
When cutting a wall down past the lower edge If the tool position is Input a negative floor
without surfaces limiting of the wall. limited down by surfaces stock allowance for the
the tool position down, Bottom wall extension then set Stop at Floor to tool to penetrate in the
set Stop at Floor to No. is measured from the No. floor.
Then input a Bottom Wall lower profile of the ruled Input a floor stock
Extension to specify how feature. allowance to stop the tool
much the tool moves at a distance from the
floor.
Incremental Depths / Single cut Cutting non-ruled surfaces

If Single Cut is set to yes, distance between the When applying an
ESPRIT creates a single upper and lower profile incremental depth it’s
pass. decreases. possible to cut non ruled
Set Single Cut to No Alternate cutting direction surface (Single contact
to apply an incremental will create and back and point instead of a line of
depth. forth motion. By default contact).
Incremental depth is a the tool cuts one way. Set Adapt orientation to
maximum incremental Curvature to have the tool
depth. Depth of cut orientation changing with
decreases when the the part curvature.

Cutting Side and Offset Tool Radius Invert Tool Direction
The cutting side defines Offset tool radius offset By default the bottom of orientation. Change also
the side of the ruled the tool and position the the tool is on the lower the cutting direction when
feature that the tool is edge of the tool on the profile side and the tool inverting the tool to keep
cutting. wall. holder is on the upper the tool on the same side.
The cutting side is set to If offset tool radius is no, profile side.
the ruled feature cutting the tool center is on the Set Invert Tool
side after digitizing a ruled ruled feature. Orientation to Yes
feature. to reverse the tool
Loop Around the Corner

If checked, when the tool
approaches a convex
corner, the tool will
leave the contact with
the model and execute a
loop with tangent detach
movement and tangent
approach movement.

Lesson 2: Creating Swarf Cut operations
Lesson Summary
• Create a Ruled feature from
wireframe geometry
• Create a Ruled feature from solid
faces
• Create a Swarf operation with
floor surfaces
• Create a Swarf operation without
floor surfaces

Open the file: 2_SwarfOperation.esp Show the following layers and work on the Default layer
#0.

2 Create a Ruled feature from the wireframe geometry
Select the Ruled Feature command in the Mold 5-Axis Click in the input box for the match lines and digitize all
tool bar. the segments that link the upper to the lower profile.
Set “Recognize From” to “Wire Frame Geometry” Change the feature name to “Inside1”
Click in the input box for the Upper Chain and digitize the Set the Cutting Side to left and click OK.
chain called “UpperProfile”. The ruled feature is added to the feature manager.
Click in the input box for the Lower Chain and digitize the
chain called “LowerProfile”.
3 Create a Ruled feature from solid faces

In the same file, turn on the visibility of the layer “Solid”. Click in the input box for the Lower Edge and one of the
Select the Ruled Feature command. edges at a bottom of the outer wall.
Set “Recognize From” to “Solid Faces”. Change the feature name to “Outside2”
Click in the input box “Faces” and select all the faces on Set the Cutting Side to left and click OK.
the outer wall of the part. The ruled feature is added to the feature manager.
Use the shift key to propagate the selection to tangent
faces.

4 Create a Swarf operation with floor surfaces
In this step we will apply an operation on feature “Inside1” Because we haven’t selected a FreeFrom feature first,
created in step 2. ESPRIT starts the creation of a new FreeForm feature.
Click on 5-Axis Swarf Milling in the SolidMill Mold 5-axis Digitize the internal faces of the solid.
tool bar. Click OK.
5 Select a tool 6 Set the toolpath parameters

In the General tab of the Then switch to the Tool Stop At Floor = Yes
Swarf page, select tool Path tab and set the Floor Allowance = 0
“BM6”. following parameters:
Single Cut = Yes
Tolerance = 0.1
Invert Tool Direction =
Stock Allowance = 0 No
Ruled Feature = Digitize Loop Around Corners =
Ruled Feature “Inside1” NO
Offset Tool Radius = Yes

7 Set the approach type 8 Simulate
Finally switch to Retract tab and add a Radius approach Simulate to verify the tool path.
to the approach list.
Arc Angle = 45
Arc Radius = 5
Click OK to create the cycle.
9 Modify the toolpath parameters 10 Create a Swarf operation without floor surfaces
Double click on the operation in the operation manager In this last step we will create the tool path for the
and change the following settings: external wall of the part using the ruled feature created
Single Cut = No in step 2.
Incremental Depth = 2 Click on 5-Axis Swarf Milling in the SolidMill Mold
5-axis tool bar.
Alternate Cut Direction = Yes
Because we haven’t selected a FreeFrom feature first,
Click OK and simulate the new tool path. ESPRIT starts the creation of a new FreeForm feature.
Digitize the external faces of the solid.
In the General tab of the Swarf page, select tool “BM3”.

11 Set the toolpath parameters
Then switch to the Tool Path tab and set the following Alternate Cut Direction = No
parameters: Invert Tool Direction = No
Tolerance = 0.1 Loop Around Corners = Yes
Stock Allowance = 0 Finally switch to the latest tab and add a Radius approach
Ruled Feature = Digitize Ruled Feature “Outside2” to the approach list.
Offset Tool Radius = Yes Arc Angle = 90
Stop At Floor = No Arc Radius = 8
Bottom Wall Extension = 2 Click OK to create the cycle.
Single Cut = No
Incremental Depth = 2

5-Axis Contour Cycle
The 5-axis contour cycle produces a toolpath that follows a given profile.
5-Axis Contour At-A-Glance
This profile must belong to the surface of the model and each tool position
is characterized by a tool orientation which is parallel to the surface normal • New cycle
direction. • The tool follows a defined drive
profile, even when the surface
normal is not well defined
• Cut in the standard tool
orientation or invert the
orientation
• Tilt the tool forward or backward
during the cut
Drive Profile Drive feature on Edge

The Drive profile is the contact with the model is Enable this option when the drive curve is always
profile the tool follows. achieved. the drive curve lies along well defined.
The Drive profile defines The drive profile must lie the joint between two This will assist the system
a theoretical tool position; entirely on the surface surfaces (zone where the in determining the correct
tool path is obtained by (it must belong to the surface normal is not well surface normal direction
shifting the tool along surface at least within the defined). Do not enable and therefore the correct
its axis (in a positive or machining tolerance). this option if the normal toolpath.
negative direction) until a to the model surface along

Reverse Tool Direction Cutting Side and Drive Profile Offset
By default the tool axis is Cutting Side controls The drive profile offset
parallel with the normal to the position of the tool shifts the tool center
the surface of the model relatively to the profile sideways from the drive
and the tool is on the side when there is a profile profile.
the normal is showing. offset.
Set Reverse Tool Cutting Side is also use to
Direction if the tool is not control the approach side.
correctly oriented.
Penetration Distance In-line Angle

Penetration distance In-line Angle: Orient the
controls how much the tool forward or backward
tool deeps in the model. in the infeed direction. A
Penetration combines with positive value results in a
the stock allowance. ‘pulling cut’ as shown in
the picture.
If using same value for
both then the tool will be
on the surface.

Lesson 3: Creating a 5-axis Contouring operation
Lesson Summary
• Create a FreeForm feature
• Create a 5-axis Contour
operation along a chain feature at
a depth of 1.5mm

Open the file: 3_ContourOperation.esp Click on 5-Axis Contour Milling in the SolidMill Mold
5-axis tool bar.
2 Create a 5-axis Contour operation

Because we haven’t selected a FreeFrom feature first, ESPRIT starts the creation of a new FreeForm feature.
Digitize the whole solid body of the part and click OK.

3 Set the toolpath parameters
Select tool EM2 and move to the tool path page. Penetration Distance = 1.5mm (Penetration distance is
Set the following parameters: bigger to the thickness of the metal sheet)
Tolerance = 0.1 In Retract page, add a Lateral approach to the approach
list with:
Stock allowance = 0
Lateral Distance = 10mm
Drive Profile: Digitize the “2 Chain” on the graphics.
Click OK to calculate the tool path and simulate.
Drive Feature on Edge = No
Reverse Tool Direction = No
Cutting Side = Left
Drive Profile Offset = 1mm (equal to the tool radius)

5-Axis Composite Cycle
The 5-axis composite cycle is a tip finishing 5-axis cycle that offers a lot of
possibilities. 5-Axis Composite At-A-Glance
The concept of the composite cycle is that the user can define independently • New cycle
the tool path pattern and the tool orientation. • 5 unique machining patterns
The tool path pattern defines the tool path flow along the part; the tool • 4 tool orientation strategies
orientation defines the orientation of the tool while machining.
• Dynamic technology that only
This cycle can be used in many applications. It provides the maximum shows the necessary parameters
flexibility by allowing the user to select from a wide range of machining to guide the user
patterns and, likewise, a wide range of tool axis direction rules. The variety of • Tilt the tool forward, backward
choices gives the user the creativity to compose any complex 5-axis function or to the side
with few limitations.
• Limit a tool axis angle. This
With the composite cycle the tool stops when it touches a check surface. is especially useful for 4-axis
machining.
The Composite cycle is also new in ESPRIT Mold V10.
Machining Pattern Tool Orientation Strategy

The machining pattern • Parametric The Tool Orientation • From Fixed Vector
defines the tool path • Project parametric strategy defines the way • From profile
shape. Curves are plotted • Paralllel Planes the tool gets oriented
on the model defining along the tool path.
the tool path flow. The • Planes Intersection with
Spine Curve There are 4 orientation
machining pattern defines strategies:
the way those curves are • Contour Offset
generated. • Perpendicular to Drive
Surface
There are 5 machining • Through Point
patterns:

Machining Pattern = Parametric Pattern
Tool path is generated from the parametric curve of the The drive surface must belong to the model being cut.
selected drive surface.
If cutting more than one surface, curves are propagated
side by side to the next surfaces. The propagation tries to
keep the fluid flow to the machining.
Parametric Pattern Parameters

Cutting Direction: Select the main cutting direction. U Reverse Step over Direction: If unchecked the step over
Direction is the red arrow direction on the drive surface. goes in the same direction as the arrow on the screen. If
V direction is the green arrow direction. If U direction is checked, the step over happens in the opposite direction.
selected then V is the step over direction. If V is selected Step Increment: Pass increment in between 2 passes.
then U is the step over direction.
Pass Movement: Defines the transition between passes
Reverse Cutting Direction: By default the tool follows and the cutting direction for subsequent passes.
the main cutting direction in the direction of the arrow.
Check this option to reverse the cutting direction

Machining Pattern = Project Parametric Pattern
A set of curve is created by projection of the parametric The projection is normal to the drive surface.
lines of the drive surface onto the model. The drive
surface is an auxiliary surface that doesn’t belong to the
part.
Project Parametric parameters

Cutting Direction, Reverse Cutting Direction, Reverse surface. That means that if the normal of the dirve surface
Step over Direction, Step Increment, Pass Movement is pointing ‘up’, points will be projected toward the ‘down’
Work the same way as for the parametric pattern. direction. Check Reverse Projection side if the direction is
not correct.
When selecting the drive surface, a white arrow shows
the normal direction to the drive surface. Projection Distance controls the maximum distance when
projecting points on the model. This value can be reduced
The direction of projection is by default the opposite if you see that points are projected on undesired surfaces
direction of the natural Normal direction of the drive that are behind the target surface.

Machining Pattern = Parallel Planes Pattern
Curves are created by intersection of the part with a set Plane direction is set from an existing work plane that
of parallel planes. must be previously saved.
Tool is then driven along those curves.
Parallel Planes Pattern Parameters

Work Plane controls the direction of the set of planes. Ending Distance: Define the distance between the first
Select one of the work plane of the document. and the last plane of the set. Set a negative distance to
Note that the work plane must have been previously move in the opposite direction of the W direction of the
saved to be used. work plane.
Start Point: Define the position of the first plane of the Step Increment is the distance between two consecutive
set. planes of the set. The stepover of the calculated toolpath
will depend on this value.

Machining Pattern = Planes Intersection With Spine Curve Pattern
Curves are created from intersection of the part with a Spine profile can be a chain feature, an edge, a face loop, a
set of planes that are perpendicular to a spine curve and curve, a segment, an arc or a circle.
equidistant.
Planes Intersection With Spine Curve Pattern Parameters

Start Point: The first intersecting plane will pass through Step Increment: The distance between two consecutive
this point. This point should belong to the selected curve, planes of the set, calculated on the curve points. The
but it does not necessarily need to be the initial point of stepover of the calculated toolpath will depend on this
the curve itself. value plus the curvature of the curve and the distance
End Point: The last intersecting plane will pass through between the curve and the surfaces to be machined
this point. This point should belong to the selected curve,
but it does not necessarily need to be the ending point of
the curve itself.

Machining Pattern = Contour Offset Pattern
Tool path is generated from a progressive offset of the
boundary of the part surfaces. This produces a sort of a
concentric tool path.
Contour Offset Pattern Parameters

Use Approach Point, Approach Point XYZ: This option Alternate: The progressive offset will be calculated in an
controls the starting point for the concentric toolpath. alternating inner-outer order. This option is suitable for
If not specified, it will be automatically defined by the machining areas with islands
system. Step Increment: The distance between the curves in the
Pass Movement: Control the pass order. pattern, measured on the surfaces to be machined. The
Inside Out: The progressive offset will start on the inside stepover of the calculated toolpath will depend on this
of the area, proceeding outward toward the external value.
border. Select this option if you want to climb cut convex
areas.
Outside In: The progressive offset will start at the
external border, proceeding inward toward the center of
the area to be machined. Select this option if you want to
climb cut concave areas.

Tool Position Loop Around Corner
Let you specify how the contact point is some When this control is
tool tip will be positioned point ‘around’ the tool checked, the tool will
on the points of the center, depending on the leave contact with
generated pattern of shape and slope of the the model when the
curves. machined surface. toolpath approaches a
Tool Center On Curve: Contact Point On Curve: convex corner, executing
The tool will be positioned The tool will be positioned a tangent detach and
with its center ‘ON’ the to keep the tool in contact approach, in order to
calculated point, along the with the calculated points make a fluent air loop
direction specified for the of the curve pattern. around the corner itself.
tool axis. The effective
Change Pass Start Position

When this option is approach on the final work
enabled, approaches and piece.
connections are shifted
forward for consecutive
profiles in the same
zone. This minimizes the
appearance of a witness
line from each tool

One Way Zigzag
Optimized Alternate
Pass Movement
One Way: the direction used will match the isoparametric Optimized: the toolpath sequence will follow a ‘minimum
curves of the driving surface. Original sequence means distance’ criterium of refastening in order to keep links as
that the tool will move through the interpolated curves short as possible (rapid minimization), but work profiles
while respecting the order of the original interpolation. will always be machined in the original direction.
Zigzag: the toolpath sequence will follow a ‘minimum Alternate: this option forces the tool to alternate
distance’ criterium of refastening in order to minimize between the leading isoparametrics of the opposite sides
jumps and repositioning moves. Inversion of the of the Drive Surface.
interpolated curves is allowed, so work profiles can be
machined in a back and forth motion when necessary.
Tool Orientation Strategies

The tool orientation strategies is very important for the The tool orientation strategy is a defines the base angle
composite cycle. orientation that is then modified by the the in-line angle
It defines the rules to calculate the orientation of the tool and cross angle and also by the angle limits.
relatively to the part. Note: Visualize the tool orientation by checking in Masks/
There are 4 orientation strategies. Tool Path, “Tool Point-Axis”. Arrows on the screen show
the tool orientation relatively to the part.

Perpendicular to Drive Surface
This rule will keep the tool axis perpendicular to the drive In that case the tool stays perpendicular to the selected
surfaces. drive surface.
Drive surfaces are usually the machined surfaces except This can be very useful for creating 4+1 axis machining (1
when using the project parametric machining pattern. rotary axis is fixed).
Through Point
During machining, the tool axis will be forced to pass It can also be digitized from an existing point.
through a specified fixed point.
The point the tool axis is passing through must be
specified in the global XYZ coordinate system.

From Fixed Vector
During the machining the tool axis will keep a fixed When using this option, enter the tool vector in the global
direction. XYZ coordinate system.
5-axis cycle creates a 3-axis tool path when using this Tool vector must be pointing towards the tool.
option.
From Profile
During the machining, the tool axis will be forced to pass direction.This plane normally intersects the curve in one
through the points of a 3D curve. or more points.
The curve can be a chain feature, an edge, a face loop, a If there is only one intersection point, this is the point the
segment, an arc, a circle. tool axis will pass through.
The parameter “Selection Point On Profile” controls how If there are multiple intersections and if you are machining
the points on the curve are selected: a convex part (male) select External so the point nearest
Minimum distance : The point on the curve nearest to the to the contact point will be selected. If you are machining
contact point will be used as the point for the tool axis to a concave (female) part, select Internal so the selected
pass through. point will be the farthest from the contact point.
Plane intersection: To understand how the system decides If there are no intersections between the plane and the
which point on the curve has to pass through, imagine a curve, the system will keep the last valid intersection
plane passing through the contact point on the surface point as the point to pass through.
that contains the Normal vector of the surface in the
contact point itself, and perpendicular to the infeed

In-line Angle and Cross Angle
In-line Angle: Orient the tool forward or backward in the direction. A positive value results in a slope toward the
infeed direction. A positive value results in a ‘pulling cut’ right side with respect to the infeed direction.
as shown in the picture.
Cross Angle: This option allows you to keep a slope
angle in the lateral direction with respect to the infeed
No Limit
Limit Angle With
Fixed Angle With
Tool orientation Angle Limits

No Limit : the tool axis will be free to assume the slope Fixed Angle With : the tool axis will keep a fixed slope
defined by the selected rule for the tool axis. with respect to the specified direction. This is useful
Limit Angle With: during the toolpath calculation, the when performing 4-axis machining on Mill-Turn machine
tool axis orientation will never exceed the minimum and tools because you can ‘lock’ the head with respect to the
maximum angle with respect to the specified axis (X, Y or turning axis.
Z) of the actual working plane. Note: Reference axis is in the global XYZ coordinate
system. Select X-axis for reference axis to lock the B-axis
in position for a millturn machine.

Feed Link Fluent Cubic Link
Feed links control the type will try to apply the first At the end of the cut will be generated in order
of connection between link that appears in the list. the tool will leave the to avoid edges and sharp
adjacent cuts in the If the link is not possible machined surface with a inversions.
toolpath. (due to a collision, out of radiused detach, and the
You can choose multiple limits, etc.) it will try the next cut will start with
options, with the system second link, and so on. a radiused approach.
using each option in Between the detach and
priority order. The system reapproach arcs, a cubic
(fluent spline) connection
Bridge Link Adaptive Cubic Link

Two subsequent cuts are At the end of the cut
connected with a direct the tool will leave the
workfeed movement. machined surface and
connect to the next cut
with a cubic (fluent spline)
connection for a smooth
transition.

Lesson 4: Creating 5-axis Composite operations
Lesson Summary
• Create a Composite cycle with
Parallel Plane Intersection and
tool orientation Through Point
Plane Intersection with Spine
Curve and tool orientation
Normal to Drive Surface
Parametric Pattern
Project Parametric Pattern
Contour Offset
1 Create a Composite cycle with Parallel Plane Intersection and Tool Orientation through Point
Open the file: 4_Composite_ParallelPlane_ThroughPoint.esp
Start by creating a point at: X=20 ; Y=0 ; Z=0
This point will be used for the tool orientation definition.
2 Create a FreeForm feature

Then create a FreeForm feature that groups the internal Set the solid as check element.
tangent faces of the part.

3 Define a Composite cycle
Select the FreeForm feature and click on 5-Axis
Composite cycle in the SolidMillTurn tool bar.
4 Define the toolpath parameters

Set the parameters on the Tool Path page:
Tolerance = 0.2
Stock Allowance = 0
Machining Pattern = Parallel Planes Intersection
Loop Around Corners = No
Work Plane = YZX (Work plane is set using the existing
work planes of the document.)
Start Point X, Y, Z = 0,0,0
Ending Distance = -80 (Negative Ending distance will go in
the opposite direction of the W direction of the selected
work plane.)
Pass Movement = One Way
Change Pass Start Position = Yes
Step Increment = 3
Orientation Strategy = Through Point
Through Point X, Y, Z = 20,0,0 (Point can be digitized
from the graphic.)
In-Line Angle = 0
Cross Angle = 0
Angle Limitation = No Limit

5 Define the links 6 Simulate
In Retract page, add a Vertical approach with 60mm Simulate to verify the tool path.
approach distance.
In Feed Link, add an Adaptive Cubic Link and set the
Maximum Link Distance to 20mm.
Finally click OK to calculate the tool path.
7 Create a Composite cycle with Plane Intersection with Spine Curve and tool Normal to Drive Surface
Open the file: 4_Composite_PlanesWithSpineCurve_NormalToDriveSurface.esp
Select FreeForm feature “1 FreeForm” in the feature manager and start a new composite cycle in the SolidMillTurn
Mold 5-axis tool bar.

8 Select a tool
In the General page, select tool “BM20”.

Set the following parameters:
Tolerance = 0.1
Stock Allowance = 0
Machining Pattern = Planes Intersection With Spine
Curve
Tool Position = Contact Point On Curve
Spine Profile = 1 Chain
Start Point X, Y, Z: Digitize 1 Chain start point
End Point X, Y Z: Digitize 1 Chain end point
Pass Movement = Optimized Direction
Step Increment = 3
Orientation Strategy= Perpendicular to Drive Surface
In-line Angle = 0
Cross Angle = 0
Angle Limitation = Fixed Angle With
Reference Axis = X-Axis
Fixed Angle = 75
Angle Limitation is used to lock the B-axis at -15 degree.
Reference axis is set to X-axis because the reference axis
is in the global XYZ system.
10 Define the links

Go to the Retract tab.
Add a Fluent Cubic Link in the Feed Link List with:
Maximum Link Distance = 10
Start Arc Angle = 30; Start Arc Radius 5
End Arc Angle = 30; End Arc Radius 5
Then click OK to calculate the tool path.

11 Create a Composite cycle with Parametric Pattern
Open the file: 4_Composite_ParametricPattern.esp
Select FreeForm feature “1 FreeForm” in the feature
manager and start a new composite cycle in the SolidMill
Mold 5-axis tool bar.
In the General page, select tool “BM20”.

Tolerance = 0.1
Stock Allowance = 0
Machining Pattern = Parametric Pattern
Tool Position = Tool Center On Curve
Drive Profile: Digitize the face from the solid
Cutting Direction = V Direction

Reverse Cutting Direction = Yes
Reverse Step Over Direction = Yes
Pass Movement = Optimized Direction
Change Pass Start Position = No
Step Increment = 1
In-line Angle = 0
Cross Angle = 0

13 Define the links
Add a Bridge Link in the Feed Link List with:
14 Create a Composite cycle with Project Parametric Pattern

Open the file: 4_Composite_ProjectParametricPattern.esp
Select FreeForm feature “1 FreeForm” in the feature manager and start a new composite cycle in the SolidMill Mold
5-axis tool bar.
In the General page, select tool “BM5”

Tolerance = 0.25
Stock Allowance = 0
Machining Pattern = Project Parametric Pattern
Drive Surface = Digitize 2 Nurb Surface
Cutting Direction = V Direction

Reverse Cutting Direction = Yes
Reverse Step Over Direction = Yes
Reverse Projection Side = Yes
Projection Distance = 10
Pass Movement = Zigzag
Step Increment = 2
In-line Angle = 0
Cross Angle = 0
16 Calculate the toolpath

Notice how the tool stays perpendicular to the Drive
surface and not to the model.

17 Create a Composite cycle with Contour Offset pattern
Open the file: 4_Composite_ContourOffset.esp
Select FreeForm feature “1 FreeForm” in the feature manager and start a new composite cycle in the SolidMill Mold
5-axis tool bar.
In the General page, select tool “BM5”

Tolerance = 0.25
Stock Allowance = 0
Machining Pattern = Contour Offset
Use Approach Point = No
Pass Movement = Inside Out
Step Increment = 1
In-line Angle = 0
Cross Angle = 0

19 Define the links
Add an adaptive Cubi Link in the Feed Link List with:

5-axis Links, 5-axis Approaches, Tool Retract and
Clearance Plane
The last tab of the 5-axis cycle definition groups all the parameters relative to:
• Return plane 5-Axis Auxiliary Movements
• Approaches (approach and detach feed movement)
At-A-Glance
• Rapid transition in between passes: Rapid Links • Optimize retract movements
• Choose multiple options for
approaches and retracts and
set the priority order for which
option to apply first, second, and
so on
Clearance Retract Optimisation and Full Clearance

The clearance is a safety If Retract Optimization height is optimized locally
distance that defines how is set to NO, the tool on the model.
far away from the model retracts to a “safe” The minimum distance
the tool starts feeding height defined by the Full between the model and
down along the tool axis Clearance value. The safe the tool is set by the
direction. height distance is relative clearance.
Before the clearance to P0.
Be sure to include all the
distance the tool is in If Retract Optimisation is elements to consider
rapid motion. enabled, then the retract for the retract in the
FreeFrom feature.

Approaches for Swarf and Contour Approaches for Composite
The 5-axis Swarf 2- Lateral: The tool The 5-axis Composite 2- Lateral: The tool
cycle offers 2 types of approaches and leaves cycle offers 2 types of approaches and leaves
approaches: contact with the part approaches: contact with the part with
1- Radius: The tool with a linear move, 1- Radius: The tool a linear move, along the
approaches and leaves perpendicular to the approaches and leaves tool axis.
contact with the part with model. contact with the part with
an arc tangent to the last an arc tangent to the last
move. move.
Prioritized List
You can choose multiple etc.) it will try the second
options, with the system approach, and so on.
using each option in
priority order. The system
will try to apply the first
approach that appears in
the list. If the approach
is not possible (due to
a collision, out of limits,

Rapid Links
Rapid Links are used for rapid transition between passes Lateral straightening no Z negative
or when the tool needs to leave the contact with the Tool path connects with a set of rapid feed movements
model. bringing the tool outside of a box containing the whole
Like Feed Links and Approaches, Rapid links are set model; throughout the movement which take place out of
through a prioritized list. the box the tool axis will always be orthogonal to the face
You can choose multiple options, with the system using along which it is moving.
each option in priority order. The system will try to apply This link fails if the angle between the tool axis at one of
the first rapid link that appears in the list. If the rapid link the connection points and the Z negative axis is bigger
is not possible (due to a collision, out of limits, etc.) it will than the Maximum Angle.
try the second rapid link, and so on. Lateral no straightening
There are 14 links available: Tool path connects with a set of rapid feed movements
Short Work bringing the tool outside of a box containing the whole
Tool path connects with a feed movement if the distance model; throughout the movement which takes place out
is smaller the the maximum link distance. of the box the tool axis keeps the same orientation as at
the connection point.
The tool retracts of the axial length before the
connection. Radial around X axis
Rapid Tool path connects with a set of rapid movements
bringing the tool around a cylindrical surface that wraps
Tool path connects with a rapid feed “bridge-like” the whole model around the X axis; throughout the
movement bringing the tool to a safe or to an optimized movements which take place out of the envelope the tool
height; tool axis is aligned with Z axis throughout the axis is interpolated.
whole “bridge” movement.
Radial around Y axis
This link fails if one or both of the positionings to connect
have a tool axis with z negative component. Tool path connects with a set of rapid movements
bringing the tool around a cylindrical surface that wraps
Rapid Straightening Above the whole model around the Y axis; throughout the
Tool path connects with a rapid feed “bridge-like” movements which take place out of the envelope the tool
movement bringing the tool to a safe or to an optimized axis is interpolated.
height; tool axis is aligned with Z axis only for the length Radial around Z axis
of the movement at safe or optimized height.
Tool path connects with a set of rapid movements
This link fails if one or both of the positionings to connect bringing the tool around a cylindrical surface that wraps
have a tool axis with z negative component. the whole model around the Z axis; throughout the
No Straightening movements which take place out of the envelope the tool
axis is interpolated.
Tool path connects with a rapid feed “bridge-like”
movement bringing the tool to a safe or to an optimized Link table-table
height; tool axis is NOT aligned with Z axis throughout Rapid feed movement connection for table-table
the whole “bridge” movement. machines: the tool movements are only along X, Y, Z
This link fails if the angle between the tool axes relating coordinates axes.
the two points to connect is greater than the given Tool path connects with a set of rapid feed movements
Maximum Angle. which bring the tool to a safe height, moving along tool
Out of model box axis relating to the first point to connect, then change
the tool axis aligning it to the one relating to the second
Tool path connects with a rapid feed “bridge-like” point to connect, hence move the tool orthogonal to the
movement bringing the tool to a height greater than the current axis and in order to reach the position over the
maximum model height; tool axis is aligned to Z axis only point to connect.
for the length of the movement that takes place out of the
box containing the whole model. Collisions against the target part are not checked.
This link fails if one or both of the positioning to connect Link table-table one move
has a tool axis with z negative component. Rapid feed movement connection for table-table
Lateral straightening machines: the tool movements are only along X, Y, Z
coordinates axes.
Tool path connects with a set of rapid feed movements
bringing the tool outside of a box containing the whole Table rotation occurs WHILE the tool is being moved to
model; throughout the movement which take place out of the next position.
the box the tool axis will always be orthogonal to the face Collisions against the target part are not checked.
along which it is moving.

SolidMillTurn for Mori Seiki
During this two hour session, you will learn how to program a part for a Mori Seiki NZ MillTurn machine using ESPRIT
2009.
In this technical lecture, you will be given some additional advanced technical information on specific turning cycles. Some
of theses cycles have been developed by and/or for Mori Seiki.
You will also find here some general information to better program your Mori Seiki MillTurn machines with ESPRIT 2009.

9 9 How to use the Spinning Turning Tool add-in
9 9 How to create a Balanced Roughing operation
9 9 How to program part transfers
9 9 How to work with long parts
9 9 How to use the Expression Builder to simplify programming

Mori Seiki and ESPRIT
Mori Seiki NZ
Up to 3 turrets and the Y-axis structure can be installed, and the
BMT (Built-in Motor Turret) is used for all turrets. Also, Mori Seiki’s
original technology, the ORC (Octogonal Ram Construction) is used
for the Turret 2 Y-axis structure, controlling thermal displacement and
improving chip disposal.
Model Turret 1 Turret 2 Turret 3

NZ1500 T3Y2 X1, Z1, Y1 X2, Z2, Y2 X3, Z3
NZ2000 T3Y2
NZ1500 T3Y3 X1, Z1, Y1 X2, Z2, Y2 X3, Z3, Y3
NZ2000 T3Y3
Three heads post processors and inch or metric machine setups are
available.
Mori Seiki NT
DCG (Driven at the Center of Gravity) technology in machining
centers. Turrets with built-in milling motors for lathes. Machine
equipped with a top B-axis magazine turret, a bottom index turret
with live tools and a main and a sub spindle.
Two heads post processors and inch or metric machine setups are
available.
Mori Seiki NL
Machine equipped with an upper index turret with Y-axis and a main and sub
spindle.
Post processor and inch or metric machine setup are available.
Mori Seiki DuraTurn

This 2-axis turning machine is equipped with 1 turret and 1 spindle.
Post processor and inch or metric machine setup are available.
Other machines
Mori Seiki DL, Mori Seiki MT, Mori Seiki SL, Mori Seiki ZL, Mori Seiki ZT
Post processors and machine setups are available for these machines.
136 SolidMillTurn for Mori Seiki

Programming a Mori Seiki MillTurn with ESPRIT
Add-ins
AutoSubStock
The AutoSubStock add-in needs to be turned on prior to open a file. This add-in will allow you to correctly simulate the
sub spindle work.
The AutoSubStock icon is located on the Advanced Simulation toolbar.
When you are done programming a part, run the simulation and at the end, click on the AutoSubStock icon.
This will stop the simulation and save the stock for the sub-spindle side. Run the simulation one more time to see the
difference.
NC Code MultiHead Dialog

The NC Code MultiHead Dialog add-in will allow you to post the NC code of multiple heads machines.
The NC Code MultiHead Dialog icon is located on the Common Machining toolbar.
You have the possibility to split the NC code by head or create a single NC code file.
Turning Work Coordinates

The Turning Work Coordinate add-in will sort your operations in the appropriate work coordinates and also offset the
NC code for the sub spindle operations.
In ESPRIT, go to Create > Turning Work Coordinates.

In WC Name, you can name the work coordinates for the main spindle side (G54 in this case) and the sub spindle side
(G55 in this case). So the operations located on the main spindle side will be moved in the G54 work coordinate and on
the sub spindle side in G55.
WC Numbers allows you to define the number of your work coordinate that will be output in the NC code. In this case,
G54 for the main spindle side and G55 for the sub spindle side.
Z Offset is read from the Part Stock Length field of the Machine Setup (on the General tab).
The sub spindle work coordinate will be offset by minus this amount from the main spindle work coordinate. That is why
the value you enter in the machine setup is critical. A wrong value will cause a wrong offset and as a conclusion a part not
cut correctly.
Spinning Turning Tool

The Spinning Turning Tool add-in will allow you to create spinning turning tools and use them on turning operations.
Please see for more details the section bellow called Spinning Turning Tools.
Machine Setup
When you start to program a new file, the very first programming step is to choose the machine setup file of your Mori
Seiki machine and also to configure your turning stock. To do so in ESPRIT, go to Machining > Common > Machining >
Machine Setup.
A right click over on the page will allow you to open your machine setup (*.EMS) file. You can define your turning stock
on the Stock Configuration field.

The Assembly tab of the machine setup groups the machine components used for the simulation: Machine base, Turrets,
Spindles, Tailstock and Steady Rest.
Stock Automation
With ESPRIT 2008, we introduced the Stock Automation that maintains awareness of the state of lathe stock at any
moment during the machining process. After a turning operation has been created, ESPRIT keeps track of the material
removed from the initial stock.
This knowledge of the stock is used for:
• User visualization of the current stock
• Calculation of the toolpath
Benefits include greater automation and ease-of-use since the user can rely on the system to calculate the stock for any
SolidTurn operation. Stock automation is available in ESPRIT 2009 with all SolidTurn operations.
To enable Stock Automation for the toolpath calculation, select Automation as the Stock Type in any SolidTurn operation.
With the Automation option, no additional settings are needed for the stock definition. The toolpath calculation then
works the same way as if Stock Type was set to Casting and the casting feature was the profile of the stock on the screen.
The following types of stock are valid with stock automation:
• Any stock remaining from any previous turning operation.
• Any stock type defined in Machine Setup. This includes Bar, Tube, or Casting.
• Stock defined in Simulation Parameters. This includes:
• Stock created from a Revolution.
• Stock created from a Cylinder.
• Stock created from a Solid.
• Stock created from a File.
• Stock created from an Extrusion.
• Stock created from a Block.
Note: To use the stock defined in Simulation Parameters, uncheck the Simulate Turning Stock option on the Options tab.

Lesson 1: Spinning Turning Tools
For turning machines with a live spindle, a standard turning operation can be
performed with a spinning turning tool. A spinning turning tool is similar to a Turning Spinning Tools At-A-
round insert (full radius) except that the tool is spinning about the center of Glance
the nose radius.
• Improved Tool Life
The tool rotation distributes tool wear and heat, resulting in a better tool life
• Improved productivity especially
and a higher surface finish. in harder to machine materials
Because of the machine kinematics, the tool cuts on the YZ plane instead of • In finishing, consistently higher
the XZ plane. The tool can also be tilted (B-axis or angular holder) or moved surface finish
above or below the center line.
• Dry Machining
• Reduced Chatter & vibration
Single Point Tool Spinning Tool

• All forces try to bend the tool • Axially loaded tool
Vibration and chatter Cutting forces directed axially into the tool spindle
• Single point cutting • Tool Rotation
One point takes all the wear, the same point absorbs Distributes tool wear and heat with a constantly
all the heat changing contact point plus air cooling
• Cutting conditions limited by heat • Cutting conditions limited by machine
Cutting conditions dependant on the material Cutting conditions limited by power available in the
machine

Tool Definition
The add-in places a new Turning Spinning Tool icon on the Turning Tools toolbar
and on the Machining > Turning Tools menu.
The tool definition is similar to other turning tools except for the tool
geometry. The tool geometry is based on parametric geometry and the
following parameters:
• D = Tool Diameter
• SD = Shank Diameter
• TL = Tool Length
• CL = Cutting Length
• L1 = Shank Bottom Length
• L2 = Shank Top Length
• A1 = Bottom Angle
• A2 = Side Angle
Note: The turning spinning tool is handled internally by ESPRIT as a regular
turning tool with a round insert. If the Turning Spinning Tool add-in is not
loaded, the tool will be recognized as a turning insert and the operation will not
be rebuilt correctly.
Tool shifts
Use the Tool Shift X, Z, Y parameter on the General tab to shift the tool
position. By default the tool reference point in the station is the top of the
insert. Usually a tool in an upper turret would need to be shifted in X by minus
the tool length.
Machining Parameters
A turning spinning tool is compatible with the following operations:
• SolidTurn Roughing
• SolidTurn Contouring
• SolidTurn Grooving
The add-in creates two new parameters on the Custom tab of these operations
that let you control the spinning turning tool. To display the Custom tab, click KENNAMETAL Spinning Tool
Options on the Tools menu. On the Machining tab, check Custom Page in the
Tech Page Defaults group.
Tool Spindle Speed RPM

This parameter lets you input the speed for the live tool spindle.
Rotation Angle About Z

By default, the tool path is created in the YZ plane instead of the XZ plane.
This parameter lets you rotate the cutting plane about the Z axis. The default
rotation angle is 0, which means the tool tip is at X0. Enter an angle to rotate
the cutting plane.

Compensation of the tool
When the tool is tilted on the B-axis, the compensation is accurate for faces and diameters. Cones and torus are slightly
overcut.
When the tool is above or below the center line, compensation for faces and diameters is accurate but the Rotation
Angle must be small. Cones and torus are slightly overcut.
Create an operation with a turning spinning tool

1. Select the feature you want to machine.
2. On the SolidTurn toolbar, click one of the following operations: Roughing, Contouring, or Grooving.
3. Under Tool Selection, select a turning spinning tool. The tool orientation works the same way as for other turning
tools. An Orientation Angle can be used in order to tilt the tool with a B-axis head and improve the cutting conditions.
• For cutting with this tool on the sub spindle, set Orientation to Reverse Angle and enter a positive value in
Orientation Angle.
• When the tool is tilted, ESPRIT compensates the tool path to cut faces.
4. On the Custom tab, enter the spindle speed for the live tool spindle in Tool Spindle Speed RPM. If you want to rotate
the cutting plane about the Z axis, enter a value in Rotation Angle About Z.
5. Define the other machining parameters for the operation and click OK.

Lesson 2: Balanced Roughing
Balanced Roughing performs a roughing operation about twice as fast as a normal roughing operation by using two tools
mounted on separate turrets. The two tools can cut simultaneously or one tool can lead and the other trail behind by a
specified distance. When the two tools cut simultaneously, the feedrate can be doubled while maintaining the same tool
load.
This advanced roughing cycle can be used on any Mori Seiki with non independent lower and upper turret. With the Mori
Seiki NT, a Balanced Roughing cycle can be programmed on the main and sub spindle sides using the B-axis head and the
lower turret. On the Mori Seiki NZ, it can be programmed on the main spindle side using the upper left turret and the
lower turret and on the sub spindle side using the upper right turret and the lower turret.
In ESPRIT, the SolidTurn Balanced Roughing Command creates two separate roughing operations using two tools, each
on a different turret.

There are two Balanced Modes to control the offset between the two cutting tools:
• Trailing Tool: A constant distance is maintained between the leading tool and the trailing tool. When this option is
chosen, enter a value in Trailing Distance. Both tools start at the same position, but the trailing tool waits until the
leading tool reaches the trailing distance before it starts cutting. This produces two sync codes in the NC code. During
the rough cut, the leading tool and the trailing tool do not cut at the same depth. For balanced finishing, separate finish
stock can be defined for each tool on the Finish page. The leading tool uses the Tool1 Stock Z, X value and the trailing
tool uses the Tool2 Stock Z, X value.
• Simultaneous: This mode is equivalent to the Trailing Tool mode with a Trailing Distance set to 0. The two tools cut
together at the same depth during the rough or the finish cut. This option lets you double the feedrate with the same
tool load. For balanced finishing, both tools use the value entered in Tool1 Stock Z, X for the finish stock.
Tool Selection
The turning inserts must be mounted on a separate turret. For roughing passes, the two tools must be the same type and
have the same nose radius.
Synchronization
When working with two turrets on the same spindle, their synchronization is crucial.
In the following picture, the Hard Syncs are pointed with the red arrow. In the NC code, a wait code will be output for
each turret before the start of the operation. We need to make sure that both turrets are ready to cut at the start of the
operation.
As an example, the tool changing time of the B-axis head on a Mori Seiki NT is 1s while it is 0.25s on its lower turret. So
since the lower turret will be ready quicker, the hard sync will prevent any offset between the two turrets.

The synchronization between each pass is called the Soft Synchronization. There is no representation of it on the
Operations Tab of the Project Manager. In the NC code, a wait code will be output for each turret before each cutting
pass within the Balanced Roughing operation.
Create a Balanced Roughing operation

1. Select the feature you want to machine. If your leading tool is located on the upper turret, your feature needs to be
above the center line and vice versa.
2. On the SolidTurn toolbar, click on Balanced Roughing. Select your Leading and Trailing Tools and define the other
machining parameters for the operation. The Balanced Roughing operation is similar to the SolidTurn Roughing
operation.
3. On the Advanced tab of the technology page, set Auto Hard Sync and Auto Soft Sync to No if you want to manually
define the synchronizations.
4. Click on OK and your roughing operations will be created in the selected turrets.

Lesson 3: How to program part transfers
In this following part, you will be given instructions on how to program various part transfers in ESPRIT for the Mori Seiki
NT (ZT and MT work the same way). A correct program is necessary to have a correct NC code.
Part transfer from MAIN to SUB with cut-off

Generally this operation is the last operation of the operation list.
The regular steps to follow are:
1. Machining parts in main and sub
2. Catching the finish part in the sub spindle
3. Picking the part in main with the sub spindle
4. Pulling the bar with the sub spindle
5. Cut-off and sub spindle going back home
6. Looping for next parts
For programming that in Esprit:
1. Machining on main and sub spindles.
Note: Operations on the sub spindle are output with origin shift on the other face of the part. During operations only
positive Z coordinates are output.
The setting “Part Stock Length” from Machine Setup is used as default value for Turning Work Coordinates Sub Spindle
Z offset.
CAUTION !!! Part Stock Length = Finished Part Length. You must run Turning Work Coordinates add-in prior to
posting NC Code.
2. Use operation Release with SubSpindle and BottomTurret.
(BottomTurret because the lower turret program controls the part catcher)
If “Part Chute” is set to Yes: Automatic part catching is programmed.
If “Part Chute” is set to No: M00 is output in the code to manually remove the part.
3. Use operation Pickup with SubSpindle and TopTurret, select the pickup point.
Pickup operation has to be programmed with TopTurret because of the way the postprocessor works.
Before operation Pickup for TopTurret and after Release of BottomTurret, add regular Sync Codes.
4. Pull the bar with SubSpindle:
Use operation Barfeed by Spindle on MainSpindle by SubSpindle.
Set Turret on TopTurret.
Bar feed distance = Length of the part + Part-off tool width + Length of stock for facing the front side and the backside of the
part.
Select the same point as for the pickup operation.
If the point is different, chucks will unclamp and clamp before pulling the bar.
Programming a Pickup before the Barfeed makes the SubSpindle stay at the same location after the bar feeds. Without
pickup operation, sub spindle goes home after bar feeds.
5. Part-Off:
Use operation Cutoff using TopTurret tool on MainSpindle.
Cut off tool is always loaded in the upper turret (#1) for Mori Seiki MT and ZT Series. Postprocessors handle cut off
tool in upper turret only.
Sub spindle automatically goes home after cut off.
Sample operation list with transfer and part-off:

Part Transfer
Main to Sub with
Barfeed and Cutoff
Part transfer from MAIN to SUB without cut-off

The stock is manually loaded in the main spindle; the part is not pulled.
An Automatic part catcher or a manual catch could be programmed on sub spindle.
This transfer is generally programmed at the end.
3. Picking the part in main spindle with the sub spindle
4. Release the part from the main spindle and the sub spindle goes home
5. Stop for loading a new stock in the main
Z offset.
posting NC Code.
2. Use operation Pickup with SubSpindle and TopTurret and select the pickup point.
Before operation pickup for TopTurret and after Release of BottomTurret, add regular Sync Codes.
3. Use operation Release with TopTurret on MainSpindle to release the part from the main.
This Release operation has to be programmed with TopTurret because of the way the postprocessor works.
Sub spindle goes home automatically.

Sample operation list with transfer:
Part Transfer
Main to Sub
No Cutoff
Part transfer from SUB to MAIN without cut-off

Stock is manually loaded in the sub spindle; Part is not pulled.
Automatic part catcher or manual catch could be programmed on main spindle.
It’s generally programmed at the end.
2. Catching the finish part in the main spindle
3. Picking the part in sub spindle with the main spindle (main spindle is empty)
4. Release the part from the sub spindle and the sub spindle goes home
5. Stop for loading a new stock in the sub
Z offset.
posting NC Code.
2. Use operation Release with MainSpindle and BottomTurret.
3. Use operation Pickup with MainSpindle and TopTurret and select the pickup point.
Before operation Pickup for TopTurret and after Release of BottomTurret, add regular Sync Codes.
4. Use operation Release with TopTurret on SubSpindle to release the part from the sub.
This Release operation has to be programmed with TopTurret because of the way the postprocessor works.
Sub spindle automatically goes home during simulation. Sub Spindle always goes home in the code!

Sample operation list with transfer:
Part Transfer
Sub to Main
No Cutoff
Working with a long part: pull the bar and simultaneous machining
Here are sample steps of machining a long part. The part is hold by both spindles during machining.
1. Program starts machining part in the main spindle. Sub spindle is not loaded.
2. The sub spindle catches the part
3. The sub spindle pulls the part and holds the part
4. Spindles are synchronized and next operations are synchronous machining.
5. New pickup by the sub. The sub spindle goes closer to the main before the cut-off
6. Cut off
7. Finishing the part in the sub spindle
1. Machining bar in main spindle.
2. Use operation Pickup with SubSpindle and TopTurret, select the pickup point.
Before operation pickup for TopTurret add regular Sync Codes.
3. Pull the bar with Sub spindle:
Use operation Barfeed by Spindle on MainSpindle by SubSpindle.
Set Turret on TopTurret.
Bar feed distance = Length of the part + Part-off tool width + Length of stock for facing the front side and the backside of the
part.
Select the same point as for the pickup operation.
If the point is different, chucks will unclamp and clamp before pulling the bar.
Programming a pickup before the barfeed makes the subspindle stay at the same location after the bar feeds. Without
pickup operation, sub spindle goes home after bar feeds.
When pulling the bar, the origin stays at the same location; the program is still using G54.
4. Program operations only in main spindle. Both spindles are holding the part.
5. Second Pickup with SubSpindle and TopTurret.
Select the new pickup point.

6. Cut-Off:
Use operation Cutoff using TopTurret tool on MainSpindle.
Cut off tool is always loaded in the upper turret (#1) for Mori Seiki MT and ZT Series. Postprocessors handle cut off
tool in upper turret only.
Sub spindle automatically goes home after cut off.
7. Regular operations on the sub spindle.
8. Use operation Release with SubSpindle and BottomTurret.
Note: If working on two parts simultaneously, 8) is before 2) and 7) is at the beginning in the same time than 1).
Part feeds and part is held

by both spindles
Spindles are synchronized
New Pickup and Cutoff
Finished part is released

from the sub spindle

Tips and Tricks: Expression Builder
On a technology page, when you right-click over a field and then click on Edit properties.
You can type some mathematical expression or Visual Basic expressions. These expressions can be entered to simplify
the programming or even automate the processes.
To build the VB expressions, you can use the Expression Builder.

Note that you can directly enter =”Your expression” in the field of the technology page rather than opening the Edit
Property window.
Example: Feature Start Extension/End Extension

Here is an example of expressions you could enter in the Feature Start/End Extension fields for a SolidTurn Contouring
operation.
Feature Start Extension:

Document.LatheMachineSetup.BarDiameter/2-ABS(GetFeatureStartPointY(Feature))+Tool1(“ToolNoseRadius”).value+IM(0.05,1)
With the above rule, the Feature Start Extension will be automatically calculated based on the Bar Diameter from the
Lathe Machine Setup, the start extremity of the Feature Chain and the Tool Nose Radius.
The tool nose radius is added to make it easier for the operator to read the NC code. With Corner Compensation and
a Feature Start Extension of zero, the center of the nose radius is first positioned at the start point of the Feature Chain.
In other words the corner control point is will be below your Feature start point by the Tool Nose Radius.
IM(0.05,1) is a clearance distance.

X with the tool nose radius has a round value:
X without the tool nose radius does not have a round value:

Feature End Extension:
ABS(GetFeatureEndPointY(Feature))
With Corner Compensation and a Feature End Extension of zero, the center of the nose radius is positioned at the end
point of the Feature Chain.
So for facing, only the end extremity of the Feature Chain is need for the Feature End Extension.
You can use this method to build many other rules than can make programming more efficient. Please also note that you
can save these rules. If you would like to see more information regarding VB expressions, please see the ESPRIT help files.

SolidMillTurn for Mazak
This specialized course focuses on the best techniques for programming Mazak Integrex machines.

9 9 How to program Mazak Integrex machines
9 9 How to use ESRPIT Mazak specific technology options
9 9 How to handshake the ESPRIT post processor with certain Mazak control options

Mazak Integrex 100/200/300/400 Mark IV
Control: Matrix (older Mark III models have Fusion 640MT control)
Figure 1
S = SubSpindle
T = Lower Turret
Top Turret - B-axis magazine style tools which can mill and turn on both spindles
Lower turret – 9 station turning only turret. It can machine on both spindles
Esprit programming tips:
• Top Turret Tools - on the tool technology page define all tools how they are mounted in B0 position
• Turning Tools > 2H position. If this tool requires the different orientation, specify that orientation on operation
technology Orientation.
• Milling Tools > Z+ orientation. If this tool requires different orientation, ESPRIT work plane W vector of the feature
will orientate that tool in the correct position
• Lower Turret – since the lower turret tools can machine on both spindles, by spinning the turret around, “fake” axis
needs to be created.
Open the file: MazakIntegrexST.esp
156 SolidMillTurn for Mazak

Mazak Integrex e-Series
Control: Matrix (older models have Fusion 640M milling control)
Figure 2
Horizontal: 410H, 420H, 500H, 650H Vertical: 800V, 1060V, 1550V, 1850V
Horizontal options:
• SubSpindle or Tailstock
• LowerTurret or SteadyRest
Top Turret - B-axis magazine style tools which can mill and turn on both spindles
Lower turret – 9 station turning only turret. It can machine on both spindles
Esprit programming tips:
• Top Turret Tools - on the tool technology page define all tools how they are mounted in B0 position
• Turning Tools > 2H position. If this tool requires the different orientation, specify that orientation on operation
technology Orientation.
• Milling Tools > Z+ orientation. If this tool requires different orientation, ESPRIT work plane W vector of the feature
will orientate that tool in the correct position
• Lower Turret – since the lower turret tools can machine on both spindles, by spinning the turret around, “fake” axis
needs to be created.
Open esp file: MazakIntegrex_eSeriesH.esp
Open esp file: MazakIntegrex_eSeriesV.esp

B-axis and work coordinates
When working with the B-axis tilted, a local work system is set to keep the Z-axis parallel to the tool axis.
For new Integrex with Matrix control, the G code for changing (tilting) the work system is G68.5
G68.5 X_ Y_ Z_ I0 J1 K0 R_
X, Y, Z – specifies the coordinate values of the center of rotation (absolute value). By the execution of the 3D
coordinate conversion, the work piece zero point is changed to this point.
I0 J1 K0 – Rotary axis vector of the B-axis (J1 = Y-axis vector)
R – Specifies the B-axis angle
For older Integrex with Fusion640MT control, the G-code for changing (tilting) the work system is G128
Figure 3

Figure 4

Turning Work Coordinates
ESPRIT will automatically create B-axis tilted work coordinate and SubSpindle Z0 work coordinate. If have operations
SubSpindle and/or B-axis is tilted (not at B0, B90 or B180), then you must execute Turning Work Coordinates.
Enable Turning Work Coordinates under Tools > AddIns…
Figure 5
Run Turning Work Coordinates under Create pull-down menu
Figure 6

Figure 7
Notes:
SubSpindle Z Offset - must be equal to finished part length – NC code Z Shift amount (from ESPRIT Global Z0) for
SubSpindle front face Z0. Note that the SubSpindle Z Offset is a negative number
Keep Z parallel with Tool axis
• With Tilted Orientation – G68.5/G128 work coordinate will be created for all B-axis milling operations EXCEPT at
B0, B90, B180. Milling operations at B0, B90 and B180 will be output in regular turning work coordinate system.
• With Tilted and Vertical Orientation – G68.5/G128 work coordinate will be created for all B-axis milling
operations EXCEPT which are at B0, B180.
• Always – G68.5/G128 work coordinate will be created for all B-axis milling operations.
For Mazak Integrex 100/200/300/400, With Tilted Orientation is typically used.
For Mazak Integrex e-Series, With Tilted and Vertical Orientation is typically used.
B-axis sample nc output for Integrex Matrix:
M250 ## B-axis unclamp

G00 B10. ## Rotate B-axis
M251 ## B-axis clamp
G53.5 ## Mazatrol Coordinate System
G68.5 X0 Y0 Z0 I0 J1. K0 R10. ## Coordinate Conversion Tilt

Tool Call Statements
Integrex Matrix
T(tool#).(tool-id) T(next tool) M06 D(offset#)
Example: T01.01 T02 M06 D(101)
Tool ID and orientation should be defined on the Mazak Tool Data Page, on the machine.
Tool at (deg) Insert at (deg) Tool ID Tool Suffix

B0 0 A .01
B90 0 B .02
B180 0 C .03
B0 180 D .04
B90 180 E .05
B180 180 F .06
Tool Suffix in ESPRIT is controlled by the post processor.
MISCFORMAT1 : ToolOrient N 0 Y Y 2 N 0 Y Y 2 6 - - - -
DEFINE ToolOrientation \\
IF (MillTurnCode=TurnCycle) \\ ## TURN CYCLE
IF (cyclecode<>(1022)) \\ ## IS NOT LATHE DRILL
IF ( nextclfile(2502)=16 ) ToolOrient*(.01) BValue=(0) ENDIF \\ ##2H
IF ( nextclfile(2502)=13 ) ToolOrient*(.02) BValue=(90) ENDIF \\ ##3V
IF ( nextclfile(2502)=14 ) ToolOrient*(.05) BValue=(90) ENDIF \\ ##4V
ENDIF ENDIF \\
ENDDEFINE
Tool Offsets use the Tool Number and Suffix x 100

T01.01 M06 D101
TO1.02 M06 D201
T01.03 M06 D301
T01.04 M06 D401
T01.05 M06 D501
T01.06 M06 D601

Tool Offsets should also be defined inside the post processor
MISCFORMAT2 : ToolOffset N 3 N N 0 N 3 N N 0 6 - - - -
DEFINE ToolOffsetDefinition
IF (MillTurnCode=TurnCycle) \\ ## TURN CYCLE
IF (cyclecode<>(1022)) \\ ## IS NOT LATHE DRILL
IF ( nextclfile(2502)=16 ) ToolOffset*(100+NextClFile(101)) ENDIF \\ ##2H
IF ( nextclfile(2502)=13 ) ToolOffset*(200+NextClFile(101)) ENDIF \\ ##3V
IF ( nextclfile(2502)=14 ) ToolOffset*(500+NextClFile(101)) ENDIF \\ ##4V
IF ( nextclfile(2502)=15 ) ToolOffset*(600+NextClFile(101)) ENDIF \\ ##1H ENDIF
ENDIF\\
ENDDEFINE
Now that ToolOrientation and ToolOffsetDefinition have been defined, we can call the tool:
DEFINE OutputNextTool \\
IF ((presenttool<>nexttool)&&(nexttool<>0)) T*(nexttool) ELSE \\
IF ((presenttool<>nexttool)&&(presenttool<>Firsttool)) T*(firsttool) ENDIF ENDIF \\
ENDDEFINE
DEFINE ToolCall \\
T*(presenttool) OUTPUTFORMATCODE(2) $ToolOrientation OUTPUTFORMATCODE(0) \\
$OutputNextTool \\
COOLANTCODE* \\
“D” OUTPUTFORMATCODE(2) $ToolOffsetDefinition OUTPUTFORMATCODE(0) \\
ENDDEFINE
EX _ xxxCHANGE : $ToolCall

Alternate Machining
Mazak Integrex Matrix control handles all alternate machining by spindle.
Main Spindle Top Turret Sub Spindle

Spindle Normal Rotation M03 M203 M303
Spindle Reverse Rotation M04 M204 M304
Spindle Stop M05 - M305
C-axis Engage M200 - M300
C-axis Disengage M202 - M302
Open Chuck M206 - M306
Close Chuck M207 M307
C-axis Clamp M210 - M310
C-axis Brake M212 - M312
Figure 8

Part Transfer
Transfer Main to Sub without Cut-off
1. Park Lower Turret under the Main Spindle (G30 P3 W0)
Figure 9
Park Tool can be a “dummy” tool used only for simulation – set Tool Change Movement X=None Z=None Y=None
2. Pickup part with Sub Spindle
Figure 10
3. Release Main Spindle
Figure 11
4. Sync operations
Figure 12
Transfer Main to Sub with Cut-off

1. Park Lower Turret under the Main Spindle (G30 P3 W0)
Figure 13
Park Tool can be a “dummy” tool used only for simulation – set Tool Change Movement X=None Z=None Y=None

2. Pickup part with Sub Spindle
Figure 14
3. Barpull part with Sub Spindle
Figure 15
Feed Length = Reposition Distance = Part Length + CutOff Insert Width + stock front face + stock back face
4. Cut-off
Figure 16
5. Sync Operations
Figure 17

What’s New for Matrix Control

Post Processor FreeForm 5-Axis
This session is about additions made to the postprocessor language for the 5-axis simultaneous cycles. It gives you an
overview of the Tool Center Point Control function very commonly used in 5-axis.
Then we’ll go over all the variables useful to implement Tool Center Point Control also called RTCP.

Tool Center Point Control in 5-Axis milling
ESPRIT 2009 supports Tool Center Point Control functions for milling and millturn machines.
Before looking at the postprocessor and the NC code, let see what’s Tool Center Point Control does on the machine and
how it influences the different machine types.
5-Axis machine configurations

Tool center point control is used for different 5-axis milling and turning centers with different types of kinematics.
The picture below shows different machine configurations.
MillTurn Table/Table MillTurn Table/Tool Mill Table/Table
Mill Table/Table Mill Table/Tool Mill Tool/Tool
172 Post Processor FreeForm 5-Axis

What’s Tool Center Point Control (RTCP)?
Tool Center Point Control is a machining function of the controller that is dedicated to 5 axis machining.
This function is commonly used with 5 axis continuous machining operation.
Tool Center Point Control is also commonly called RTCP (Rotate Tool Center Point) or TCP (Tool Center Point) or
TCPM (Tool Center Point Management). RTCP appellation is used in this document.
With RTCP:
• Tool position is given for the tool center point
• The tool rotates about its tool center point (and not about the pivot
position of the rotary axis)
• Linear motion command in the NC code moves the tool center point
on a linear path relatively to the work piece.
• Length compensation is dynamically applied along the tool axis while
rotary axes are moving
• Feed rate is relative to the work piece and is given for the tool center
point (no need for inverse time feed rate or advanced feed rate
correction)
• Programmed positions in the NC code can be specified either in a
coordinate system fixed on the table or in the work piece coordinate
system (fixed XYZ position from the machine origin machine).
Benefits of RTCP:
• On a machine with a rotary axis on the head, the program is
independent of the tool length.
• On a table/table machine, the program is independent of the position
of the part on the table
• It gives an accurate control of the cutting speed.
• NC program is usually shorter because it’s possible to program linear
path relatively to the work piece with tool rotation.
• When using RTCP with the tool vector information, the program is
independent of the machine configuration (table or head axes, A B or
C axis)
All this benefits make the RTCP function very important for 5 axis
machining.
Here are the different RTCP function names on the most common
controls:
• FANUC: G43.4
• HEIDENHAIN: TCMP
• SIEMENS: TRAORI
RTCP in ESPRIT 2009

RTCP was supported in ESPRIT 2008 for machines with at least one rotary axis on the head.
With the new 5-Axis Mold cycles, ESPRIT 2009 has now full support for RTCP functions.
RTCP is available in ESPRIT 2009 for all 5-axis operations:
• SolidMill and SolidMillTurn FreeForm operations
• SolidMill and SolidMillTurn 5-Axis mold operations
User interface and postprocessor have been upgraded to work with RTCP.

Enable RTCP
To use RTCP, the function must be
enabled at the operation level.
For SolidMill and SolidMillTurn FreeForm
operations, edit the operation pages and
set Enable RTCP to Yes in the 5-Axis
group of the 5-Axis tab.
For SolidMill and SolidMillTurn Mold

5-Axis operations, edit the operation
and set Enable RTCP to Yes in the
General tab.
RTCP Coordinate Mode

RTCP Coordinate System is an option of the mill machine setup and of the lathe machine setup.
This option controls the coordinate output mode when using RTCP.
It has 2 options:

1. Rotate With Part
Output Coordinates relatively to the table/spindle. The coordinate system is attached to the work piece and
rotates with the part.
After the RTCP command is specified the workpiece coordinate system that is fixed on the table at that point of time
becomes the programming coordinate system. Thereafter, the programming coordinate system rotates as the table turns
around.
It does not rotate with the tool head.
2. Fixed
Output Coordinates relatively to the current work piece origin (local work coordinate in ESPRIT).
In this case, the programming coordinate system does NOT rotate as the table turns around but remains fixed on the
workpiece coordinate system.
This mode changes the coordinate output by the postprocessor when there is at least one table rotary axis. For tool/tool
rotary axis configuration, this mode doesn’t matter.
With Rotate With Part option, XYZ coordinates in the NC code are similar to coordinates output for a machine with 2
rotary axes on the milling head (tool/tool configuration).
Usually this mode depends on the configuration of the machine.
For instance on a FANUC30i control, it corresponds to the parameter WPK (No. 19696#5). WPK set to 0 matches
option Fixed. WPK set to 1 matches Rotate With Part.

New Postprocessor Keywords
RTCPON / RTCPOFF / RTCPCODE
RTCPON and RTCPOFF are new symbolic codes.
RTCPON: Code used to turn RTCP on in the NC program.
RTCPOFF: Code used to turn RTCP off in the NC program.
RTCPCODE is a symbolic switch that switches between the codes used for RTCPON and RTCPOFF.
Example:
RTCPON : G43.4
RTCPOFF : G49
The value of the RTCPCODE switch matches the value of the parameter Enable RTCP of the operation:
If Enable RTCP = YES then RTCPCODE=RTCPON
If Enable RTCP = NO then RTCPCODE=RTCPOFF
TOOLVECTORX, TOOLVECTORY, TOOLVECTORZ

TOOLVECTORX, TOOLVECTORY, TOOLVECTORZ are new formatable codes and new system variables. They
correspond to the components of the tool vector orientation.
With RTCP, some controls can command the direction of the tool axis instead of the position of the rotary axes. Because
this format uses no axis name of rotary axis, the same part program can be applied to machine tools with different
composition of rotary axes.
ToolVectorX, ToolVectorY, ToolVectorZ output a normalized vector, collinear to the tool
axis and that goes towards the tool.
The tool vector is given relatively to the part.
Therefore these values are independent of the position and the configuration of the machine
axes (TOOLVECTORX value isn’t equal to the system variable GLOBALTOPNORMAL(1)).
In Turning, the vector is given in the lathe coordinate system.
The tool vector is independent of the coordinate system.
Example:
TOOLVECTORX : I_ N4YN4 N5YN3 1 1N00
TOOLVECTORY : J_ N4YN4 N5YN3 1 1N00
TOOLVECTORZ : K_ N4YN4 N5YN3 1 1N00
MISCFORMAT1 : VX N4YN4 N5YN3 1 1N00
MISCFORMAT2 : VY N4YN4 N5YN3 1 1N00
MISCFORMAT3 : VZ N4YN4 N5YN3 1 1N00
EX_RAPID_5AXIS : G0 X Y Z I_ J_ K_
: VX(ToolVectorX) VY(ToolVectorY) VZ(ToolVectorZ)

EX_LINEAR_5AXIS : G1 X Y Z I_ J_ K_ F

Transformation Angles: Euler, Roll Pitch Yaw and Yaw Pitch Roll
transformations
With RTCP, some controls can command a set of angles that defines a geometric transformation of the tool axis into its
new position instead of the position of the rotary axes.
When using tilted plane transformation (non 5-axis operations), the tilted plane is usually defined by a geometric
transformation.
In both cases the geometric transformation is defined by 3 successive rotations however the definition and the order of
the rotations vary with machine tools.
ESPRIT 2009 supports 3 different transformations:
1- Euler Transformation:
a. Rotation about Z-axis
b. Rotation about new X-axis
c. Rotation about new Z-axis
2- RollPitchYaw Transformation
a. Rotation about X-axis
b. Rotation about start Y-axis
c. Rotation about start Z-axis
3- YawPitchRoll Transformation
a. Rotation about Z-axis
b. Rotation about start Y-axis
c. Rotation about start X-axis
These transformation are the most common transformations.
ROLL ANGLE, PITCH ANGLE, YAW ANGLE, RPYANGLEMODE

New formatable codes: ROLLANGLE, PITCHANGLE, YAWANGLE
New system variables: ROLLANGLE, PITCHANGLE, YAWANGLE
New machine mode: RPYANGLEMODE
RollAngle corresponds to the rotation (in degrees) about the X-axis to go from the global coordinate system to the
output coordinate system.
PitchAngle corresponds to the rotation (in degrees) about the Y-axis to go from the global coordinate system to the
YawAngle corresponds to the rotation (in degrees) about the Z-axis to go from the global coordinate system to the
RPYAngleMode is a machine mode that controls the order of the rotation in the calculation of the RollAngle, PitchAngle
and YawAngle.
RPYAngleMode is equal to:

1- RollPitchYaw
2- YawPitchRoll

With RollPitchYaw mode, the transformation is the following:
1- Rotation of the RollAngle about the X axis
2- Rotation of the PitchAngle about the global Y axis
3- Rotation of the YawAngle about the global Z axis
With YawPitchRoll mode, the transformation is the following:

1- Rotation of the YawAngle about the Z axis
2- Rotation of the PitchAngle about the global Y axis
3- Rotation of the RollAngle about the global X axis
If the RPYAngleMode is missing the default mode is RollPitchYaw.
These angles are calculated for any milling cycles but these angles change per movement with 5 axis cycles and if
RTCPCoordinateSystemMode= espRTCPCoordinateSystemRotateWithPart.
EULERALPHAANGLE, EULERBETAANGLE, EULERGAMMAANGLE

New formatable codes: EULERALPHAANGLE, EULERBETAANGLE, EULERGAMMAANGLE
New system variables: EULERALPHAANGLE, EULERBETAANGLE, EULERGAMMAANGLE
These 3 angles correspond to the rotation angles of the Euler transformation that transforms the global XYZ coordinates
system into the local coordinate system.
The Euler transformation is the following:
1- Rotation of the EulerAlphaAngle about the Z axis
2- Rotation of the EulerBetaAngle about the current local X axis
3- Rotation of the EulerGammaAngle about the current local Z axis
These angles are calculated for any milling cycles but these angles change per movement with 5 axis cycles and if
RTCPCoordinateSystemMode= espRTCPCoordinateSystemRotateWithPart.

Post Processor SolidMillTurn
This course is designed to gain an understanding on how to build a post processor for MillTurn type machines

9 9 Post processor keywords
9 9 Post processor designated technology post examples
9 9 System variables
9 9 How to set up your own variables
9 9 How to set up arrays
9 9 Post processing Milling inside the Turning Environment

Getting the CL code number
There are 4 different way of getting an ESPRIT CL code number.
1) Edit Properties of a parameter
Right-click on a parameter in a technology page and select Set Expression Equal to Value. Then, right-click on the
technology parameter again, and select Edit Properties.
The CL code number is in the window’s title.
2) Show CL Code option in ESPRIT settings

Run EspritSettings.exe (make sure ESPRIT is closed) and check Show CL code.
Select an operation and CL code numbers are displayed between parentheses in the Property Browser.
3) CL code number from the CL file

Some CL codes cannot be accessed by the two previous methods.
Another way to access those CL codes is to look for them in the CL file. For instance, the CL code for the Part Stock
Length of Lathe Machine Setup.Type in a value easy to search in the CL file. For example, Part Stock Length = 123.456.
Then post out the CL-File and look for “123.456”
180 Post Processor SolidMillTurn

You can also look for the name of the setting, but sometimes the name of the setting in the CL-file might be slightly
different. Also, settings in the CL-file are all in English and they can be hard to find when you are used to ESPRIT in
another language.
4) Use ESPRIT Post Help
Turret/Spindle/Head dependant CL codes

Nextclfile() and Prevclfile() functions return the numerical value of a CL code. CLstring() function returns the string value
of a CL code. However these functions do not work to access the values of parameters of turret, spindle or head.
Because turrets, spindles and heads might not be unique there is a special function to specify from which component to
get the value.
• clfilehead, clfilesync, clfileturret functions return the numerical value of a CL Code.
• CLFILESPINDLESTR, CLFILESYNCSTR, CLFILETURRETSTR functions return the string value of a CL code.
All these functions have 2 arguments:
CLFILExxxxxxx ( CL code number , Component number )
The example below will return the Program Name (clfile 462) for Head 2.
EX_MACHINESETUP : clfileheadstr(462,2)
This example is for getting Machine Setup Turret ID number and Turret ID name
VARIABLE : TurretID
EX _ CYCLESTART : TurretID=(nextclfile(792))
: “(Turret “ clfileturret(1462,TurretID) “:” clfileturretstr(1463,TurretID) “)”
Note:
CLFILESPINDLESTR, CLFILESYNCSTR, CLFILETURRETSTR do not work like CLstring function. They should not be
between quotes.

Moves from Tool Change
These rapid moves are not output by the GP, so in order to match the simulation to these rapid moves of the tool, we’ll
have to build it inside the post.
First we need to find out what the cl file numbers are for these parameters. We can find this out if we post process any
esp lathe file and look at the cl file document
Now that we know this, we can setup a define statement and build a condition inside EX_RAPID
DEFINE MovesFromToolChange
: ## DEBUG*(clfileturret(2509, nextclfile(792))
: IF (clfileturret(2509, nextclfile(792))=0) ## XYZ
: RAPID* X* Y* Z*
: ENDIF
: IF (clfileturret(2509, nextclfile(792))=1) ## YZ Next X
: RAPID* Y* Z*
: X*
: ENDIF
: IF (clfileturret(2509, nextclfile(792))=2) ## XZ Next Y
: RAPID* X* Z*
: Y*
: ENDIF
: IF (clfileturret(2509, nextclfile(792))=3) ## XY Next Z
: RAPID* X* Y*
: Z*
: ENDIF
ENDDEFINE
EX _ RAPID : IF (Tchange=1)
$MovesFromToolChange
: ELSE
: RAPID X Y Z C B
: ENDIF
Moves to Tool Change

These rapid moves are not output by the GP either, so we’ll have to define them as well. In addition, we’ll output the
moves based on the user selection if the tool should go Home, to a specified Position or None.
First, let’s define each of the tool change axis
DEFINE XTCPosition (NextClFile(1770)=2) ENDDEFINE

DEFINE ZTCPosition (NextClFile(1772)=2) ENDDEFINE
DEFINE YTCPosition (NextClFile(1771)=2) ENDDEFINE
DEFINE XTCHome (NextClFile(1770)=1) ENDDEFINE

DEFINE ZTCHome (NextClFile(1772)=1) ENDDEFINE
DEFINE YTCHome (NextClFile(1771)=1) ENDDEFINE
DEFINE XTCNone (NextClFile(1770)=0) ENDDEFINE

DEFINE ZTCNone (NextClFile(1772)=0) ENDDEFINE
DEFINE YTCNone (NextClFile(1771)=0) ENDDEFINE
DEFINE MoveX \\
IF $XTCHome XGoHome* ELSE IF $XTCNone ELSE IF $XTCPosition X _ _ (NextClFile(158)*2)
ENDIF ENDIF ENDIF \\
ENDDEFINE
DEFINE MoveY \\
IF $YTCHome YGoHome* ELSE IF $YTCNone ELSE IF $YTCPosition Y _ _ (NextClFile(158)) ENDIF
ENDIF ENDIF \\
ENDDEFINE
DEFINE MoveZ \\
IF $ZTCHome ZGoHome* ELSE IF $ZTCNone ELSE IF $ZTCPosition Z _ _ (NextClFile(158)) ENDIF
ENDIF ENDIF \\
ENDDEFINE
Next, we’ll define the moves to tool change, and call it under EX_TOOLCANCEL
DEFINE MovesToToolChange
: ## DEBUG*(clfileturret(2508, nextclfile(792))
: IF (clfileturret(2508, nextclfile(792))=0) ## XYZ
: RAPID* $MoveX $MoveY $MoveZ
: ENDIF
: IF (clfileturret(2508, nextclfile(792))=1) ## X First
: RAPID* $MoveX
: $MoveZ $MoveY
: ENDIF
: IF (clfileturret(2508, nextclfile(792))=2) ## Y First
: RAPID* $MoveY
: $MoveX $MoveZ
: ENDIF
: IF (clfileturret(2508, nextclfile(792))=3) ## Z First
: RAPID* $MoveZ
: $MoveX $MoveY
: ENDIF
ENDDEFINE
EX _ TOOLCANCEL :
$MovesToToolChange

MillTurn Spindle Direction
In ESPRIT the spindle direction (output by SPINDLEDIRECTION switch) matches the spindle direction of the tool
definition.
Depending on the type of tool and of the working spindle, the SPINDLEDIRECTION switch takes the value of one of
these symbolic codes:
SPINDLECW
SPINDLECCW
SPINDLEOFF
AUXSPINDLECW
AUXSPINDLECCW
AUXSPINDLEOFF
LIVESPINDLECW
LIVESPINDLECCW
LIVESPINDLEOFF
LIVEAUXSPINDLECW
LIVEAUXSPINDLECCW
LIVEAUXSPINDLEOFF
This is fine for milling tools but it might have a problem when using turning tools. The common rule is that the spindle
direction is given for when looking at the rear of the spindle.
On a machine having two spindles facing each other, if both spindles spin clockwise, they’re spinning in opposite
directions. A right hand grooving tool with a 3V orientation cannot be used to cut a groove on main and sub spindle
with the same spindle orientation. Spindle orientation must be CW for the main spindle and it must be CCW for the
SubSpindle. It becomes obvious that the spindle orientation in the tool definition overrides the cutting conditions.
Now, based on the HAND of the tool, the tool orientation, the tool position during machining and the working spindle,
we can calculate the correct spindle orientation.

The table provides the spindle orientation:
Note:
The tool orientation is the tool orientation of the
operation page (CL2502).
LEFT and RIGHT refer to the spindle orientation in
the spindle properties.
User Choice means that the spindle direction cannot
be set. In this case we’ll use the spindle direction of
the tool page.
Postprocessor routine for outputting the spindle direction:

DEFINE LatheSpindleCW M3* ENDDEFINE
DEFINE LatheSpindleCCW M4* ENDDEFINE
DEFINE CustomSpindleDirection \\
IF (MillTurnCode=TurnCycle) \\
IF (nextclfile(2502)=11 || nextclfile(2502)=13 || nextclfile(2502)=16 ||
nextclfile(2502)=18 || nextclfile(2502)=23 ) \\ ## 1V,3V,2H,4H,ANGLE
IF (nextclfile(826)=1) \\ ## Right Hand Tool
IF (clfilespindle(1509,nextclfile(793))<=1) \\ ##Working on LeftSpindle
$LatheSpindleCW \\
ELSE $LatheSpindleCCW \\ ## Working on a Right Spindle
ENDIF \\
ELSE IF (nextclfile(826)=2) \\ ## Left Hand Tool
IF (clfilespindle(1509,nextclfile(793))<=1) \\
$LatheSpindleCCW \\
ELSE $LatheSpindleCW \\
ENDIF \\
ELSE \\ ## Neutral Tool
SPINDLEDIRECTION* \\
ENDIF \\
ENDIF \\
ELSE \\ ## 2V,4V,1H,3H,REVERSE ANGLE
IF (nextclfile(826)=1) \\ ## Right Hand Tool
IF (clfilespindle(1509,nextclfile(793))<=1) \\ ##Working on LeftSpindle
$LatheSpindleCCW \\
ELSE $LatheSpindleCW \\ ## Working on a Right Spindle
ENDIF \\
ELSE IF (nextclfile(826)=2) \\ ## Left Hand Tool
IF (clfilespindle(1509,nextclfile(793))<=1) \\
$LatheSpindleCW \\
ELSE $LatheSpindleCCW \\
ENDIF \\
ELSE \\ ## Neutral Tool
SPINDLEDIRECTION* \\
ENDIF \\
ENDIF \\
ENDIF \\
ELSE SPINDLEDIRECTION* \\
ENDIF \\
ENDDEFINE

CycleCodes
SolidTurn CycleCodes: SolidMillTurn CycleCodes:
Roughing 1027 Wrap Contouring 2098
Balanced Roughing 1028 Wrap Drilling 2088
Contouring 1029 Rotary Face Pocketing 2101
Cont B-axis Contouring 2105 Rotary Face Contouring 2099
Grooving 1012 Legacy Wrap Pocketing 2084
Drilling 1022 Legacy Wrap Contouring 2089
Threading 2106
Cutoff 2107 SolidMillTurn FreeForm Cycle Codes:
Bar Feed 1025 Roughing 2092
Pickup 2012 Variable-Z Roughing 2093
Release 2011 Finishing 2095
Steady Rest 2015 Z-Level Finishing 2091
Tailstock 2014 Projection Finishing 2094
Manual Turning 1040 Re-machining 2093
SolidMillTurn CycleCodes:
Facing 2087
Pocketing 2085
Trochoidal Pocketing 2071
Contouring 2090
Rest Machining 2083
Drilling 2097
Spiraling 2082
Threading 2081
Manual Milling 2086
Wire Frame Milling 2080
Wrap Pocketing 2104
Inside the post processor, you can distinguish if the cycle is turning, milling with Y-axis, milling with C-axis, 3D milling, or
5-axis simultaneous milling.
Example:
DEFINE ItIsTurning (MillTurnCode=TurnCycle) ENDDEIFNE
DEFINE ItIsMillingC \\
(CycleCode=2104 || CycleCode=2098 || CycleCode=2088 || CycleCode=2101 || CycleCode=2099 \\
CycleCode=2084 || CycleCode=2089) ENDDEFINE
DEFINE ItIsMillingY \\
(CycleCode=2087 || CycleCode=2085 || CycleCode=2071 || CycleCode=2090 || CycleCode=2083 || \\
CycleCode=2097 || CycleCode=2082 || CycleCode=2081 || CycleCode=2086 || 2080) ENDDEFINE
DEFNE ItIsMillingY3D \\
(CycleCode=2092 || CycleCode=2093 || CycleCode=2095 || CycleCode=2091 || \\
CycleCode=2094 || CycleCode=2093) ENDDEFINE

DEFINE ItIsMilling5x \\
((CycleCode=2095 || CycleCode=2094) \\
&& NextClFile(1225)<>0) \\ ## … and Direction of Tool Axis is not Vertical
ENDDEFINE
IF $ItIsTurning “it is turning cycle” ENDIF
IF $ItIsMillingC “it is C-axis milling cycle” ENDIF
Etc…
You can also check for NextCycleCode or you can define a group of next cycles
DEFINE ItIsMillingCNext \\
(NextCycleCode=2104 || NextCycleCode=2098 || NextCycleCode=2088 || NextCycleCode=2101 \\
|| NextCycleCode=2099 || NextCycleCode=2084 || CycleCode=2089) ENDDEFINE
It is recommended to check for NextCycleCode inside the EX_CYCLESTART post example (or after)
ANEXT BNEXT
Often it is necessary to know the start point of the machining cycle before EX_STARTPOINT. Currently we can get the
X, Y, and Z start point coordinates with the system variables XNEXT, YNEXT, and ZNEXT.
Same way, ANEXT and BNEXT system variables will return the angle values prior to EX_STARTPOINT.
ANEXT returns the value of the AAXIS coordinate (primary rotary axis) for the start point of the current machining
cycle. That is, whatever the value of dimension register 30 (nextdim(30)) is in the EX_STARTPOINT for the operation,
that value is contained in ANEXT in the examples prior to EX_STARTPOINT
BNEXT returns the value of the BAXIS coordinate (secondary rotary axis) for the start point of the current machining
cycle. That is, whatever the value of dimension register 31 (nextdim(31)) is in the EX_STARTPOINT for the operation,
that value is contained in ANEXT in the examples prior to EX_STARTPOINT
VARIABLE : CValue BValue
EX _ BEFORECYCLE : CValue=(ANEXT)
: BValue=(BNEXT)
EX _ STARTPOINT : CValue=(nextdim(30))
: BValue=(nextdim(31))
SolidTurn Roughing - Canned Cycle

1- Canned cycle profile is driven by canned cycle section in the cl file:
The Canned cycle profile is a function of:
• the feature
• the shape of the tool (collision detection)
• the undercutting mode and the collision detection
• the start and end feature extension
• the stock: the profile starts from outside of the stock
2- Casting Feature Canned Cycle coordinates:
The post examples below generate casting feature coordinates.
EX_STOCK_START
EX_STOCK_LINEAR
EX_STOCK_ARC
EX_STOCK_END

ESPRIT outputs the stock shape only if a casting stock is used.
The casting EXAMPLES are output right after EX_STOCKREMOVAL and right before the start of the canned cycle
profile.
3- Stock allowance is signed:
Depending on the quadrant the tool is working, XSTOCK and ZSTOCK can be positive or negative. Be sure the sign
code of the formatables XSTOCK and ZSTOCK allows the sign output.
4- Entry and Exit modes are explicit in the EXAMPLE flow.

Entry mode movement outputs with EX_RAPID before EX_STOCKREMOVAL.
Exit mode movement outputs with EX_RAPID after EX_STOCKREMOVALCANCEL.
Typical EXAMPLE flow when:
ENTRY MODE = Z_THEN_X or X_THEN_Z or X_ONLY or Z_ONLY
EXIT MODE = Z_THEN_X or X_THEN_Z or X_ONLY or Z_ONLY
EX _ CYCLESTART
EX _ RAPID (Pt1)
EX _ STARTPOINT (Pt1)
[EX _ RAPID(Pt1M)]
EX _ RAPID (Pt2)
EX _ STOCKREMOVAL
[EX _ STOCK _ START]
[…]
[EX _ STOCK _ END]
EX _ RAPID (Pt3)
…

{Canned cycle profile}
…
EX _ REMOVALCANCEL
[EX _ RAPID(Pt5M)]
EX _ RAPID (Pt5)
EX _ CYCLEEND
Typical EXAMPLE flow when:
ENTRY MODE = NONE or Z_THEN_X_FROM_PREVIOUS_POS or X_THEN_Z_FROM_PREVIOUS_POS
EXIT MODE = NONE or Z_THEN_X_FROM_PREVIOUS_POS or X_THEN_Z_FROM_PREVIOUS_POS
EX _ CYCLESTART
[EX _ RAPID(Pt1M)]
EX _ RAPID (Pt2)
EX _ STARTPOINT (Pt2)
EX _ STOCKREMOVAL
[EX _ STOCK _ START]
[…]
[EX _ STOCK _ END]
EX _ RAPID (Pt3)
…
{Canned cycle profile}
…
EX _ REMOVALCANCEL
EX _ CYCLEEND
Useful Keywords: Examples:

STOCKREMOVALCODE EX_STOCK_START
STARTSEQUENCENUMBER EX_STOCK_LINEAR
ENDSEQUENCENUMBER EX_STOCK_ARC
XSTOCKPARAMETER EX_STOCK_END
YSTOCKPARAMETER EX_REMOVALCANCEL
STEP EX_STOCKREMOVAL
EX_STOCKREMOVALFACE
EX_STOCKREMOVALTURN
EX_FINISH
Sample Postprocessor:
SolidMillTurn_Post_WC2008.asc

SolidTurn Grooving - Offset Shift
With the grooving cycle and the option Control Edge Shift Sample Postprocessor:
set to YES, the postprocessor needs to output the new
offset register each time the control edge changes.
Output the offset in the example EX_RAPID.
Add the formatable code used for the offset register
before moving the tool in EX_RAPID and the offset will
be output properly.
SolidTurn Grooving - Canned Cycle

ESPRIT supports Grooving canned cycle for the ROUGH Useful Keywords:
pass only.
XGROOVE, ZGROOVE, GROOVECYCLECODE,
Unlike the Roughing Canned cycle, the Grooving finish DWELLTIME, PECK, STEP
pass is never output as a canned cycle.
GROOVEALONGZ, GROOVEALONGX
The groove shape is limited to rectangular grooves.
Examples:
ESPRIT does not output the profile of the groove. It
EX_GROOVECANCEL
outputs only the groove width and the groove depth using
XGROOVE and ZGROOVE. EX_GROOVE
The output is based on the FANUC style output (G74/ Sample Postprocessor:
G75) SolidMillTurn_Post_WC2008.asc
SolidTurn Threading
Keywords: EX_CANNEDTHREADEND: Multipath thread canned
cycle end(G92)
DEPTH
EX_CONSTANTARCTHREAD: When threading an arc
RADIALDIFFERENCE on a profile with constant lead
FINISHCUTSNUMBER EX_VARIABLEARCTHREAD: When threading an arc on a
THREADENDCHAMFER profile with variable lead
THREADANGLE Symbolic Codes:
FINISHSTOCK MULTIPATH_CANNEDTHREAD: Corresponds to the
code used for Multi Path Canned Cycle
FIRSTDEPTH
CONSTANTARCTHREAD: Corresponds to the code
LEADVARIATION
used for cutting an arc with a constant thread
LEADVALUE
VARIABLEARCTHREAD: Corresponds to the code used
MINIMUMDEPTH for cutting an arc with a variable thread
Examples: Formatable codes:
EX_CANNEDTHREADSTART: Multipath thread canned THREADSTARTANGLE: used to output the thread start
cycle start (G92) angle from the tech page.
EX_CANNEDTHREADBODY: Multipath thread canned FINISHCUTSNUMBER: Number of programmed finish
cycle second pass and after(G92) passes.

ROUGHCUTSNUMBER: Number of programmed rough passes.
THREADSTARTCHAMFER: Chamfer distance when Lead-in is set to Chamfer. If Lead-in is not chamfer, this should
return 0.
THREADENDCHAMFER: Chamfer distance when Lead-out is set to Chamfer. If Lead-out is not chamfer, this should
return 0.
FIRSTDEPTH: Depth of cut of the first pass (CL Code 898)
MINIMUMDEPTH: Minimum depth of cut (CL Code 899)
THREADANGLE: Thread Angle (CL Code 216)
System Variables:
THREADARCINTERPOLATION:
Controls the approximation of arc by segments when EX_CONSTANTARCTHREAD and EX_VARIABLEARCTHREAD
do not exist in the postprocessor.
(EX_CONSTANTTHREAD instead of EX_CONSTANTARCTHREAD or EX_VARIABLETHREAD instead of EX_
VARIABLEARCTHREAD)
Canned Cycle output:
Single Path Canned Cycle (G76)
• EX_CANNEDTHREAD
Multiple Path Canned cycle (G92)
• EX_CANNEDTHREADSTART
• EX_CANNEDTHREADBODY
• EX_CANNEDTHREADEND
OFF (G32) and lead variation = 0
• EX_CONSTANTTHREAD
OFF (G32) and lead variation not 0
• EX_VARIABLETHREAD
• EX_VARIABLEARCTHREAD
Flow of examples:
1) Single Path Canned Cycle
EX_CYCLESTART
EX_RAPID X=60 Z=10
EX_STARTPOINT X=60 Z=10
EX_RAPID X=44 Z=10 Entry mode (optional)
EX_LINEAR X=40 Z=5 Lead-in (Feed)
EX_FIRSTTHREADPOINT X=40 Z=5
EX_CANNEDTHREAD X=30 Z=-20 Thread Final Depth
EX_RAPID X=60 Z=-20 Exit mode (optional)
EX_RAPID X=60 Z=5 Exit mode (optional)
EX_CYCLEEND
2) Multiple Path Canned cycle
EX_CYCLESTART
EX_RAPID X=60 Z=10

EX_FIRSTTHREADPOINT X=40 Z=5
EX_CANNEDTHREADSTART X=36 Z=-20 Thread First Depth
EX_CANNEDTHREADBODY X=33 Z=-20
EX_CANNEDTHREADBODY X=31 Z=-20
EX_CANNEDTHREADBODY X=30.4 Z=-20
EX_CANNEDTHREADBODY X=30 Z=-20 Thread Final Depth
EX_CANNEDTHREADEND
EX_CYCLEEND
3) Canned cycle OFF
EX_CYCLESTART
EX_RAPID X=60 Z=10
EX_CONSTANTTHREAD X=36 Z=-20 (EX_VARIABLETHREAD if lead not constant)
EX_RAPID X=44 Z=-20 Lead-Out
EX_RAPID X=44 Z=5
EX_CONSTANTTHREAD X=31 Z=-20
EX_RAPID X=44 Z=5
EX_LINEAR X=30.4 Z=5 Lead-in (Feed)
EX_CONSTANTTHREAD X=30.4 Z=-20
EX_RAPID X=44 Z=5
EX_CONSTANTTHREAD X=30 Z=-20
EX_RAPID X=44 Z=5
EX_CYCLEEND
With CANNEDCYCLE, the thread starting point and the thread ending include extensions.

SolidTurn Cutoff
Keywords EX _ TOOLCANCEL
Examples: EX _ MAINEND
EX _ ENDCODE
EX_CUTOFFTSTART
Notes
EX_CUTOFFEND
• The flow of examples is the same with and without
Symbolic Codes: canned cycle.
PARTCHUTECODE • Between Rough and Finish pass, it outputs an EX_
CHUTECLOSED TECHNOLOGYCHANGE if the SPINDLESPEED or
the FEEDRATE has changed.
CHUTEOPEN
CHUTESPINDLECODE
CHUTETOMAIN
CHUTETOMID
CHUTETOSUB
Flow of examples:
EX _ BEFORECYCLE
EX _ xxxxTOOLCHANGE
EX _ CONSTANTSURFACE
EX _ SETWORKCOOR
EX _ CUTOFFSTART(LatheCycle) or EX _
CYCLESTART
EX _ CYCLESTART is output if EX _ CUTOFFSTART
hasn’t been defined in the post.
EX _ RAPID(LatheCycle)
EX _ STARTPOINT(LatheCycle)
EX _ LINEAR(LatheCycle)
…
EX _ CUTOFFEND(LatheCycle) ) or EX _
CYCLEEND
EX _ CYCLEEND is output if EX _ CUTOFFEND
hasn’t been defined in the post.
SolidTurn B-Axis Contouring

Examples: Postprocessor example:
EX_RAPID : Linear rapid motion (B angle might change) EX_LINEAR : G01 X Y Z B F
EX_LINEAR: Linear feed motion (B angle might change) B is the BAXIS Formatable code.
EX_CIRCLEZX: Circular motion with constant tool
orientation
NC output example:
G01 X10. Z-5.0 B20
X,Z,B are the axis position at the end of the movement.

Rotary Face Milling - Polar Interpolation
Rotary Face Milling Operation with Polar interpolation set Useful Keywords:
to YES.
FACEINTERPOLATEON: G Code associated to polar
Tool positions are output in rectangular coordinate system interpolation ON
(X Y), instead of XC. XY work system rotates to the start
FACEINTERPOLATEOFF: G Code associated to polar
C position of the operation. The start point is always at
interpolation ON
Y=0.
YABSOLUTE: Formatable for Y axis coordinates
Commonly the Y direction is output in NC code with
the keyword Y or with the keyword C (but this is still a YRAPID: Formatable code that outputs the same value as
distance) YABSOLUTE
Using YRAPID, you can declare a second symbol
to output Y coordinates.
Examples:
EX_FACEON : Polar interpolation is ON from this
example
EX_FACEOFF : Polar interpolation is OFF after this
example
EX_FACESEG : Polar interpolated Linear move
EX_FACEARC : Polar interpolated Circular move
EX_FACE_RAPID : Polar interpolated Rapid move
EX_FACE_COMPENSATION : Polar interpolated
Compensation ON move
EX_FACE_COMP_OFF : Polar interpolated Compensation
OFF move
Wrap Milling - Cylindrical Interpolation

Wrap Milling Operation with Polar interpolation set to YES
For cutting on cylinder circumference.
Programming is made assuming a plane by developing the cylinder circumference into the plane.
Even if programming is made assuming a plane, ESPRIT outputs the position with ZABSOLUTE(distance) and
AAXIS(angle).

Using cylindrical interpolation can shorten the program length because ESPRIT outputs the circular motions in the
cylindrical plane.
Without cylindrical interpolation, circular motions in the cylindrical plane are approximated by small linear moves (quality
varies with the tolerance of the operation page).
Useful Keywords:
SIDEINTERPOLATEON: Code associated to cylindrical interpolation ON
SIDEINTERPOLATEOFF: Code associated to cylindrical interpolation OFF
WORKINGDIAMETER: Formatable code to output the working diameter
AAXIS: Formatable code for the C axis
Examples:
EX_SIDEON : Cylindrical interpolation is ON from this example
EX_SIDEOFF : Cylindrical interpolation is OFF after this example
EX_SIDE_RAPID : Rapid with Cylindrical interpolation ON
EX_SIDE_SEG: Linear move with Cylindrical interpolation ON
EX_SIDEARC: Arc with Cylindrical interpolation ON
EX_SIDE_COMPENSATION: Compensation move with Cylindrical interpolation ON
EX_SIDE_COMP_OFF: Compensation OFF move with Cylindrical interpolation ON
Note:
Some machines might accept programming with Y and Z coordinates and Y and Z are the position in the cylinder
circumference plane.
To output these 2 distances instead of a distance and an angle, you need to calculate Y in the postprocessor (G16
Cylindrical plane with some FANUC controls).
Arrays
To access the clcode for operation/tools which are ahead, it is necessary to create an array.
Post examples which are used in setting up the arrays are:
EX_CYCLEDEFINITION – this post example is called once at the beginning of the NC program for every machining
operation (cycle). This allows for certain information regarding each operation to be initialized at the start of
the program. For example, machine registers such as for the offset for each operation could be set using EX_
CYCLEDEFINITION

EX_TOOLDEFINITION – this post example is called once at the beginning of the NC program for every tool used in the
program
EX_TOOLDEFINITION2 – this post example is called once at the beginning of the NC program for each operation, but
unlike EX_CYCLEDEFINITION, EX_TOOLDEFINITION2 is for tool information related to each operation
The difference between EX_TOOLDEFINITION and EX_TOOLDEFINITION2 is that EX_TOOLDEFINITION is
called only once for each tool. EX_TOOLDEFINITION2 is called for each operation. So if more than one operation
is using the same tool, that tool information will be repeated by each of those EX_TOOLDEFINITION2. But using
EX_TOOLDEFINITION2, however, you could know exactly how many operations were using that tool and by using it in
conjunction with EX_CYCLEDEFITION you can associate certain tool information with specific information from each
operation using that tool.
In a MillTurn type of environment, sometimes it is necessary to call the tool in certain fashion if it is a turning tool, and
in different fashion if it is a milling tool. In the following sample, we’ll setup an array inside EX_TOOLDEFINITION2 to
access the type of tool for current cycle and type of tool for next toolchange cycle.
VARIABLE : ToolStyle(1..999) IsMillTool(1..99) IsLatheTool(1..999)
EX _ TOOLDEFINITION2 : ToolStyle(nextclfile(101))=(nextclfile(110))
: IF (((nextclfile(110)>=1) && (nextclfile(110)<=14)) || (nextclfile(110)=20) \\
||(nextclfile(110)=25))
: IsMillTool(nextclfile(101))=(1) ENDIF
: IF (((nextclfile(110)>=15) && (nextclfile(110)<=19)) || ((nextclfile(110)>=21)\\
&& nextclfile(110)<=24)))
: IsLatheTool(nextclfile(101))=(1) ENDIF
Notice that array variables must be defined in this format:
array _ name(lower _ index..upper _ index).
Now that the array has been setup and values have been stored, based on what the array returns on toolchange, we
know whether current tool is turning or milling type, and whether next tool is turning or milling type.
DEFINE ToolTypePresent
: IF (IsMillTool(PresentTool)=1) “(THIS IS A MILLING TOOL)” ENDIF
: IF (IsLatheTool(PresentTool)=1) “(THIS IS A TURNING TOOL)” ENDIF
ENDDEFINE
DEFINE ToolTypeNext
: IF (NextTool>0)
: IF (IsMillTool(NextTool)=1) “(NEXT TOOL IS MILLING TOOL)” ENDIF
: IF (IsLatheTool(NextTool)=1) “(NEXT TOOL IS TURNING TOOL)” ENDIF
: ENDIF
ENDDEFINE
DEFINE TC : BLANKLINE
$ToolTypePresent
$ToolTypeNext
ENDDEFINE
EX _ FIRSTTTOOLCHANGE :
$TC
EX _ OTHERTOOLCHANGE :
$TC
EX _ LASTTOOLCHANGE :
$TC

Wire EDM
SolidWire® Essentials
Get your hands on the newest SolidWire product developments and functionality. This popular class is always a winner
with practical hands-on examples that let you test drive the latest innovations to SolidWire functionality. Attend the
SolidWire Essentials class first and then advance your knowledge further by attending the other SolidWire classes
available throughout the conference.

9 9 How to use the new multiple cut-off “Bridge” function
9 9 How to use the enhanced Advanced Operation Sorting, updated with additional functionality
9 9 How to use the new internal corner rounding option
9 9 How to update associated features when an imported CAD model is updated

Multiple Cut-off Function
Multiple cut-offs, commonly referred to as “bridges,” are necessary when
a punch or slug (in case of a die), may be too heavy or cumbersome to Multiple Cut-off At-A-Glance
be extracted without trouble. By selecting the multiple cut-off locations • Add any number of cut-off
correctly, stress can be effectively released and the punch or slug can be locations to an existing draft
extracted without trouble. feature
Through this new option, multiple cut-off locations are linked to “Punch”, • Additional cut-offs can be placed
“Die” or “Open” features. “Multiple Cut-off” works on both Draft Conic on Draft Conic or Ruled features
and Ruled features. SolidWire technology has been updated to recognize the • Two new cut-off commands have
multiple cut-off locations on the feature and will apply the same cut-off length been added to the Edit Feature
to all cut-off locations. toolbar
• Add Extra Cut-off (Bridges) lets
you manually add any number of
break points through the selection
of thread locations
• Remove Extra Cut-off lets you
manually remove break points
through the selection of an
existing entry location that has a
corresponding break point
Accessing the Multiple Cut-off function Adding break points

Two new commands have The Remove Extra Cut-off Additional break points the feature based on the
been added to the Edit command lets you remove are created by clicking location of the selected
Features toolbar: existing break points the Add Extra Cut-off thread location.
• Add Extra Cut-off created with the Add command and selecting The number of break
• Remove Extra Cut-off Extra Cut-off command. the draft conic or ruled points will be consistent
feature you want to with the number of thread
The Add Extra Cut-off modify, then selecting
command is used to create locations selected.
existing thread points.
additional break points on
a feature. The break point will be
created perpendicular to
198 SolidWire® Essentials

Removing break points Controlling the length of the cut-off
Removing a break point selecting an existing bridge The length of an additional be identical to the one
is easily accomplished by thread point. cut-off is controlled on created on the technology
clicking the Remove Extra the technology page. All page.
Cut-off command and then additional cut-offs will
Example
1 Place a draft feature on the part 2 Create extra break points on the feature
Use the Draft Feature On the Edit Features selected thread location.
Recognition command to toolbar, click Add Extra This is where the wire will
create a draft feature on Cut-off . enter the feature.
the part. Select the desired draft Continue selecting any
Since this punch is a closed feature. other thread locations for
feature, the feature is Select the thread location the chosen feature.
created with one start where the wire will re- When you are finished,
point and one thread thread and enter the part. select another command
point. or press the Esc key.
Notice that a “bridge”
symbol is added to the
feature, normal to the

3 Remove a break point from the feature 4 Viewing the feature in the Property Browser
On the Edit Features You can continue selecting When you select the Select the forward/
toolbar, click Remove any other thread locations feature with break points, backward scroll buttons
Extra Cut-off . for the chosen feature. its break point start to toggle through the
Select an existing bridge When you are finished, locations and thread bridge locations.
thread location. select another command locations are visible in the
or press the Esc key. Property Browser.
5 Setting the length of the cut-off

The length you enter on the technology page for Primary
Distance (and, optionally, Secondary Distance) is applied
to all the break points on the feature. The length of each
cut-off is identical.

Advanced Operation Sorting
Advanced Operation Sorting
At-A-Glance
• Updated with additional
functionality, particularly to handle
the multiple cut-off function
• New “Sort By” option [Rough]
[Skim][Cut-off]
• New “Split Skim Cuts” option that
provides sorting by each skim cut
New Sort By option

The new “[Rough][Skim] cuts first to relieve the
[Cut-off]” option sorts stress from the material,
all rough operations first, and then do all the skim
then all skims, and then all cuts before performing the
cut-off operations. cut-off.
This option gives users the
ability to do all the rough
New Split Skim Cuts option Other dialog design changes

The new “Split Skim Cuts” All Rough cuts are You’ll also notice that the Order” option has been
option is valuable for performed first, then “Insert Position” options moved and renamed
users who cut material each individual Skim cut, are now placed on a drop- “Alternate Direction”.
that quickly corrodes in followed by or preceeded down list instead of being This option alternates the
the tank by reducing the by the Cut-off depending listed as radio buttons. direction of each cut when
amount of time that each on the “Sort By” strategy Also, the previous operations are reordered.
cut is subjected to the selected. “Reverse Second Cut
dielectric fluid.

Example of Sort By option [Rough][Skim][Cut-off]
Profile 1 Profile 2 Profile 3
1R, 1S1, 1S2, 1S3, 1S4, 1C 2R,2S1, 2S2,2S3, 2S4, 2C 3R, 3S1, 3S2, 3S3, 3S4, 3C
Before Sort After Sort
Operations Operations
1-R 1-R
1-S1 2-R
1-S2 3-R
1-S3 1-S1
1-S4 1-S2
1-C 1-S3
2-R 1-S4
2-S1 2-S1
2-S2 2-S2
2-S3 2-S3
2-S4 2-S4
2-C 3-S1
3-R 3-S2
3-S1 3-S3
3-S2 3-S4
3-S3 1-C
3-S4 2-C
3-C 3-C

Example of Split Skim Cuts
Profile 1 Profile 2 Profile 3
1R, 1S1, 1S2, 1S3, 1S4, 1C 2R,2S1, 2S2,2S3, 2S4, 2C 3R, 3S1, 3S2, 3S3, 3S4, 3C
Before Sort After Sort
Operations Operations
1-R 1-R
1-S1 2-R
1-S2 3-R
1-S3 3-S1
1-S4 2-S1
1-C 1-S1
2-R 1-S2
2-S1 2-S2
2-S2 3-S2
2-S3 3-S3
2-S4 2-S3
2-C 1-S3
3-R 1-S4
3-S1 2-S4
3-S2 3-S4
3-S3 3-C
3-S4 2-C
3-C 1-C
This option will do the Rough cut on Profile 1 then Profile 2 then Profile 3. This process reverses and repeats for the 1st ,
2nd, 3rd and 4th skim cuts and the cut-offs.

Internal Corner Rounding
There are a couple of good reasons why the new Internal Corner Rounding
technology is important: Internal Corner Rounding
• Individuals who have an older machine that does not have a corner At-A-Glance
rounding function. In this case, the CAM software needs to overcome this • Provides a way to modify sharp
deficiency. The user requires an easy way for the CAM system to create internal corners for each cut
radii at all internal corners. This internal radius is required on all cutting • Replaces the CW rad and CCW
passes and the radius value is defined by a static value that gets added to rad settings that were previously
the offset amount for each given cutting pass. removed from the technology
• Most, if not all, wire EDM machines can NOT do a corner slowdown on pages
tapered parts. The user must rely on the CAM software to do this for • New settings available on the
them. Cut-Off tab of 2-axis and 4-axis
Contour pages and the Advanced
When Internal Corner Rounding is enabled, all internal non-tangential corners tab of the Pocket page
will be modified by filleting the corner by the offset amount plus an addition
to the offset. • This new option is available for all
machine types except AgieVision
Accessing the Internal Corner Rounding function The “Addition to offset” value
The new Internal Corner Users have the ability to When Internal Corner For example, if the Offset
Rounding function has enable the function and Rounding is enabled, for the Rough cut is set
been added to the Cut- enter a static value that internal non-tangent to 0.147 and “Addition to
Off tab of the 2-axis and will be added to the Offset corners are rounded by offset” is set to 0.005, the
4-axis Contouring pages amount for each given any Offset value defined radius of the fillet applied
and to the Advanced tab cutting pass. for the Rough cut and each to all internal corners on
of the Pocketing pages for Skim cut plus the value the Rough cut will be is
all machine types except entered in “Addition to 0.152.
AgieVision. offset”.

Example of Internal Corner Rounding
The offsets for the Rough and three Skim cuts are set as shown below:
When Internal Corner Rounding is enabled and “Addition to offset” is set to 0.005, the internal corners are rounded
using the sum of the Offset + Addition to offset.

Associativity
Associativity can be defined as the recognition of a part and its subsequent
downstream activities. When the part model changes, it is recognized and the Associativity At-A-Glance
downstream activities from the original part are associated to the changed • Provides a way to update
part. associated features when an
imported CAD model has
In ESPRIT 2009, associativity is maintained on the feature and is currently
changed
limited to solid bodies and faces and the selected absolute reference
collection. Thus, this type of associativity is only intended to address the • Maintains association between
subset of problems best described as engineering changes. Engineering the CAD model features and the
finished tool path
changes are changes where a face(s) in the absolute reference changes, the
collection doesn’t change. Example of a typical engineering change is a radius • This is particularly useful when an
is enlarged/reduced or a hole is repositioned or even a pocket is moved or engineering change has been made
increased/decreased. In each case the collection of faces must never change, to the original CAD model
and can only be modified. (Note: When the ESPRIT FX Add-In can be
utilized, the user will have fewer restrictions. See “Associativity and ESPRIT
FX” as described later.)
When a part model that was used as the basis for an ESPRIT programmed
part is changed a notification is sent to the user informing them that the part
model has changed. The user then has the option to ignore the change or
reload the part model. If the part model is reloaded, feature recognition will
be rerun on the same faces.
Check Reference File Status File Status

A new menu entry has the import location of the Current – The CAD is located in the same
been added under the file. File has the same name, absolute path as the
ESPRIT File menu. This The status of the file is located in the same originally imported file
entry displays a listing of displays one of three absolute path (the exact and it has a different time
all the CAD files that were possible states: file path address) as the stamp.
imported into the ESPRIT originally imported file and Missing – The CAD File
file. 1. Current it has the same exact time cannot be located by its
Status of the CAD Files 2. Modified stamp. name and/or its absolute
is determined by the date 3. Missing Modified – The CAD path.
and name property and File has the same name,

Modified Status Missing Status
The CAD files that have the reference file the The CAD files that reference and timestamp
the same absolute path timestamp of the updated can no longer be found will be recorded when
and a different timestamp reference file is recorded through the absolute it completes the load
are displayed as Modified. in the ESPRIT file and the path are displayed as process. The solid body
With a Modified status solid body in the ESPRIT Missing. With a Missing in the ESPRIT file is then
the user has the option file is then replaced with Status the user has the replaced with the new
to update the reference the updated reference file. option to reload the referenced file.
file in ESPRIT by selecting reference file by selecting
the Update button. If the the Restore Link button.
user chooses to update The new file’s absolute
Command Buttons
Update - Changes the originally referenced CAD file Be careful with the Update and Restore Link commands,
in ESPRIT with a modified CAD file. Immediately upon a user may use these options to entirely replace the solid
selection of the Update button the reference CAD file will body with a fundamentally different part model, and the
be loaded into ESPRIT. All downstream activities will then results can be unpredictable and not specified.
be carried out on this model. (I.E. Feature Recognition Delete - Allows the user to remove the link between
will rerun on the Absolute Reference, and the operations ESPRIT and the referenced CAD file. Upon selection
recalculated on these features.) The absolute path and of the Delete button all selected listed references and
timestamp of the updated reference files will be recorded geometric entities will also be removed from the ESPRIT
when they are loaded into ESPRIT. work area.
Restore Link - Allows the user to browse to a location
of a file that they wish to use instead of the original
reference. The intention of the Restore Link option is to
relocate a reference file that has been moved to another
location, or to find the reference file that was saved under
a different name.

Example
Place the Draft Feature and Toolpath onto the part model (Note: in this example only features were placed for clarity
and less clutter).

a) The Die dimensions and location are changed.
b) The Hole sizes and location are changed.
Open Check Reference File Status. The status has changed to Modified. Select Update.
The feature gets updated. Note that the absolute references do not change between the two models. (the face id
numbers are the same)

Associativity and ESPRIT FX™
This is a preferred way to using associativity in ESPRIT 2009, because there is more control, flexibility and reliability.
When using the ESPRIT FX CAD Feature Tree, the user is still limited to solid bodies and faces, and the absolute
reference collection; however the absolute reference collection is now mapped to a specific CAD feature. This mean
that the absolute collection associated to the appropriate CAD Feature can change and associativity will be maintained
through the CAD Feature.
The Check Reference File Status can be viewed and accessed through the CAD Feature manager. The icon preceding the
imported Solid model shows the current status.
Current- A check mark is placed on the specific solid modeler icon used. (In this example it is SolidWorks)
Modified
Missing
By right-clicking on the imported solid model name in the CAD Feature manager, the Update, Restore and Delete can be
accessed.
Additionally, the user has the ability for ESPRIT to automatically check the status of the solid model. When check, this
option is active and the time is enter in hour, minutes and second as when ESPRIT goes to check its status.

Example
Place the Draft Feature and Toolpath onto the part model.

a) The Cut Opening dimensions are changed.
b) Filleted corners are ADDED to the 4 inside corners.
Click on the solid model name and select Update Cad File.
The feature gets updated. (Note: the absolute reference changes between the two models. The face id numbers are
different). However, associativity is maintained because the CAD Feature that is used to create the Draft Feature is the
same,

SolidWire Advanced Draft Feature
Recognition
The Draft Feature Recognition is a very powerful tool for Esprit Wire EDM. This document will show the different ways
to use the DFR

9 9 How to automatically generate feature start and thread points
9 9 Important options in the Draft Feature Recognition dialog
9 9 How to create a draft feature from 2D geometry and add a gradual taper
9 9 How to use the Property Browser to modify draft features
9 9 How to create draft features from 3D geometry
9 9 How to create draft features from existing chains
9 9 How to automatically select the faces of solids using the Grouping Properties command
9 9 How to create draft features on complex solid models

Overview
One of the big advantages of using Draft Features rather than chains is that they give the ability to control the Thread
Point and Start Point of an EDM operation.
Thread Point and Start Point Definitions

A Start Point is a point on the profile.
For a Die or Holes, the lead-in/out point must be inside the profile. Otherwise, the point will be ignored.
For a Punch, the lead-in/out point must be outside the profile. Otherwise, the point will be ignored.
Automatically creating Thread and Start points in Draft Feature

Recognition
Before clicking on the Draft Feature Recognition button, the contour (wireframe or solid faces) and the points need to be
selected.
There are 3 main scenarios:
• The Thread and Start Point already exist
• Only the Thread Point exists
• No points exist
212 SolidWire Advanced Draft Feature Recognition

Scenario 1: The Thread and Start Point already exist
When both the Thread Point and the Start Point exist, Draft Feature Recognition will simply use those points:
Scenario 2: Only the Thread Point exists

When only the Thread Point exists, Draft Feature Recognition will automatically create the Start Point based on the rule
you selected in the Draft Feature Recognition Page:

When the Approach Type is set to Normal, the Start Point is created at CLOSEST point normal to the Thread Point:
When the Approach Type is set to Middle, the Start Point is the CLOSEST middle point from the Thread Point:
When the Approach Type is set to End Point, the Start Point is the CLOSEST end point from the Thread Point:
When the Approach Type is set to Single Direction, the Start Point is created according to the specified angle:
When the Approach Type is set to Both Directions, the Start Point is the CLOSEST point from the Thread Point at the
specified angle:

Scenario 3: No points exist
When no point exists, the Start Point is created at the middle of the longest element:
The Thread Point will be created NORMAL to the longest element, at the distance specified on the Rules tab:
Summary
The 3 scenarios can be simplified as follows:

Important Options
The following options are important to understand when creating draft features:
• Combine Element
• Driving Profile
• Auto Match Lines
Combine Elements
When this option is set to Yes, Draft Feature Recognition will combine two or more feature elements into a single arc or
segment feature element.
Example: The two segments below can be combined as one single segment.
This option is important when doing advanced conic. Pivot Taper changes are only allowed between elements. When
Combine Element is set to No, it conserves the amount of element.
When Combine Element is set to Yes, only one segment remains, the code will be shorter but no Pivot can be created
here.

Driving Profile
For land and taper and Ruled features, the driving profile is set automatically. Otherwise you can set the priority on
where to create the driving profile.
• Optimum: If Bottom failed then Top.
• Top: The primary profile is created on the upper profile (UV Plane)
• Bottom: The primary profile is created on the lower profile (XY Plane)
Notice that you can manually set the heights of the XY and UV planes. For instance, if “Driving Profile” is set to Bottom,
it will be created on the XY plane. Now if XY is higher than UV, then of course the driving profile will be at the top. This
allows the user to control the position of the Driving Profile without even having to open the Rules Tab.
Example:

Auto Match Lines
This option is used for 4-axis features only when working with geometry and chains. Specify whether to create match
lines automatically.
• None: Use the selected wireframe elements or surface connection lines only.
• One to One: Automatically create match lines between the upper and lower profiles. One to one matching is used to
create linear match lines between each element in the upper profile and each element in the lower profile.
Example 1
The top and bottom profiles are broken into segments but they have the same length.

When Auto Match Lines is set to None, no matchline will be added. The wire will move linearly between them.
When Auto Match Line is set to One to One, the matchlines are added in order to connect each element from the top
and bottom profile.
Example 2
Here the top and bottom profile don’t have the same length.

We only have the extremity matchlines:
When Auto Match Line is set to None, no matchline will be added. The wire will move linearly between them, the part
would be incorrect:
When Auto Match Line is set to One to One, the matchlines are added in order to connect each element from the top
and bottom profile. This cut is correct.

Lesson 1: Create a feature from 2D geometry
We saw that creating an EDM feature from geometry and managing the start
and thread points was really easy but it can also be used to generate advanced Lesson Summary
conic profiles. In this lesson you will:
There are 2 ways to add/edit the taper value of a feature sub-element: • Add a gradual taper to a feature
• The Taper Change command using the Taper Change command
• The Property Browser • Learn how to use the Property
Browser to change taper, corner
styles, and depths
1 Create a feature 2 Enable sub-element selection

Create a feature from a hexagon. Make sure SUB-ELEMENTS mode is on.
3 Select a feature sub-element

Do a left click on the first element of the feature. The segment will highlight first.
This is not what we are interested. Right-click again and the feature highlights.
Right-click again to select the feature sub-element.

4 Use the Taper Change command to change the taper of the selected sub-element
On the Edit Features toolbar, click Taper Change.
Let’s type 0 for Starting Taper and 4 for the Ending Taper and click OK.
A gradual move has been added on the first element.
5 Select multiple sub-elements

It is also possible to apply taper on multiple sub elements.
Click Undo to remove the taper you just added.
Using the method described previously, select the first element.
While holding the Ctrl key, select the last element.
Now while holding the Shift and Control key select an element between the start and end.
6 Change the taper of multiple sub-elements

Open the Taper Change page and use the same values as before.
The taper gradually changes from 0 to 4 along the selection in the direction of the feature.

Using the Property Browser
The taper attribute is also visible in the property browser once the feature is selected.
Under “Machining”, Draft gives the value of the taper applied on the feature. The attribute is Blank when the taper is not
constant all along the feature.
The taper information for each sub-element can be obtained in the “Sub-element” section.

If the taper is set at the Draft level, the Starting Angle and Ending angle will automatically be set to this value: the taper
remains constant on this sub element.
When Starting Angle and End Angle are different, Draft becomes blank: the taper changes gradually along the sub
element.
Note: The changes directly take affect after the edition.
Edit Corner Mode

The same way we edited the Taper in the property browser, we can set the corner mode.
Under “Machining”, “Corner Radius Mode” and “Sharp Corner Mode” set the mode for the whole feature.
“Corner Radius Mode” can be set to:

• Conical
• Isometric

“Sharp Corner Mode” can be set to:
• Sharp
• Blend
Under the “Sub Element” section, the mode can be set specifically for each feature sub-element. Program Radius is
available in this section only:
Edit Heights
The heights can be edited in the property browser for 2 axis features.
The driving profile remains unchanged. The “Depth” corresponds to the vector from the secondary plane to the driving
profile: a negative depth show that the driving profile is at the bottom.

The same way, a Land Depth can be set for Land & Taper.

Lesson 2: Create features from 3D geometry
In order to use 3D Geometry to create Draft feature:
The top and bottom profiles have to be in the XY and UV planes. The plane heights cannot be changed when working
with 3D geometry.
At least 1 match line must exist.

Note : For 2 axis, if the number of elements is different on the top and bottom profile, additional match lines will be
required.
Example with a pivot taper change:
The feature recognition needs information on how to connect the top and bottom profile. The match lines that define the
pivot must then be selected:

Lesson 3: Create features from chains
Creating a feature using a chain works just like a 2D geometry. The chain start
point and the direction don’t matter, only the geometry does. Lesson Summary
For example, the two following chains will produce the same draft feature. In this lesson you will:
• Update all the chains in an old file
to draft features
1 Select chain features and thread points

Select all the chains in the document.
While holding the Ctrl Key, select all the points of the document. Use the “Point” filter:

2 Create a draft conic feature
Click on the Draft Feature Recognition button.
Set the part type to Die and the plane heights to 0.5.
Click OK.

Lesson 4: Create a feature from chains + match
lines
Creating a Feature with two chains and matchlines requires the chains to have same direction, same start point and as
many as matchline as possible.
This is a very powerful tool because the planes height can be edited and the chains don’t have to be planar.
The following picture shows the errors to avoid.
The following picture shows a correct selection:

Lesson 5: Using propagation to select solid faces
The Grouping Properties command on the Edit toolbar makes it easier to
intelligently select and deselect faces on solid models. Lesson Summary
This command offers a higher level of control over the automatic selection In this lesson you will:
and deselection of solid faces. Now, when the Shift key is held down during • Learn about the options in
the selection process, multiple solid faces can be selected automatically based Grouping Properties
on the selection of the following face elements: • Swap faces
• A single edge • Create a feature on a part with
• A face loop non-continuous faces
• A face • Use chains to obtain a draft
feature
In the following example, all the outer faces are selected in one click. Then an
EDM draft conic feature can be created simply and easily. • Create a feature on a part with a
non-continous taper region
Using the Grouping Properties command

When you click the Grouping Properties icon ( ), a dialog displays that lets you set your preferences when different
sub-elements are selected in the work area. These preferences stay in effect until you change them. You do not need to
open the dialog each time you want to group face elements.
Pressing the Shift key automatically enables the preferred grouping properties during the selection process. You must
hold down the Shift key during the entire time elements are being selected.
To the right of each option is a properties icon . Not all options have properties you can set. In that case, the icon is
grayed. Clicking the properties icon will display a dialog where you can set properties that are only applicable for that
particular option.

Using propagation in wire EDM
First of all make sure the grouping of sub-element is enabled:
The most common options used in wire EDM are:

• Edge with “Opposite Edge”
• Loop with Adjacent Outside
• Face with Vertical Faces.
• Swap
Edge
Opposite Edge: This option can only be used on faces that consist of four non-tangent edges. The face sharing the
selected edge is grouped along with the next face that shares the opposite edge.
Each face that shares an opposite edge is then propagated until all faces sharing opposite edges are added to the group.

This type of propagation is generally used when trying to select the land only or the taper only of a land and taper:
Loop
The Adjacent outside loop propagation is usually the best way to select Die and Punch.
A selected loop’s edges can be shared with other edges and their corresponding loops. Adjacent Outside selects the
connected (adjacent) and shared (outside) edges and their corresponding loops. This set of associated faces is what is
grouped.
The shared edges and their corresponding loops are then used to process the group faces. This collection of a loop’s
associated faces is what actually is being placed in the group.

Face
Vertical Faces: The face selected is grouped and if the next face that shares a common edge is vertical, it is then added
to the group. This process continues until all vertical faces that share a common edge are added to the group. The work
plane set in ESPRIT is used to determine if a face is vertical.
Maximum Tilt Angle: This setting defines the range of what represents vertical. This option can be very useful for wire
EDM programmers who only want to group faces that can be machined based on certain machining UV angle limits.
Wire EDM Walls Only: This option is available to avoid grouping faces that cannot be cut with a wire EDM machine. A
test is performed to decide which faces cannot be machined. A vector is extended normal to the top and bottom edge of
a face and a point is placed by an offset amount. A line is then created through the two points and, if this line intersects
the solid, then that face is discarded from the group.

Wire EDM Walls Only — enabled
Wire EDM Walls Only — disabled
Swap
The Swap Option simply swaps the selection: what was grouped becomes ungrouped and what was ungrouped becomes
grouped. This option can be used both for solid and geometry.
In this file for instance you want to select everything but the top and bottom face.

1 Select two faces 2 Swap the faces
Select the top and bottom faces. Make sure the propagation is set to “Faces” and press
Ctrl+W.
Now all the faces except the top and bottom faces are
selected.
Example 1
Feature recognition will fail here because of the red face that obviously cannot be cut in EDM.
The work around here is to get rid of the area that causes
problem. It can be done at the CAD level by splitting the red
face.
Another solution is to split the solid inside ESPRIT using the
Part Profile command.
This tool will split the solid in the XY plane.

1 Move the XY plane to the top of the gear tooth
First we need to move the XY plane to the top of the Select the arc at the top of the tooth.
tooth.
Click on the work plane button or press F10.
Although there are several ways to move the work plane,
here we are going to use “Work Plane From Geometry”.
2 Split the solid

Click on the Part Profile button.
Select the solid and use Cross Section with Split Solid.
Click OK. The solid is now split.

3 Create a draft feature
You can now use the feature recognition on the solid of Correct the UV plane height in the Feature Recognition
the bottom. page.
Select the faces using face propagation. Click OK.

Example 2
This file fails because the fillets in the corner where badly created in the CAD system. We cannot use the solid here. The
work around is to use chains to obtain the feature.
1 Smash the solid into wireframe 2 Eliminate the geometry you don’t need
Select the solid and press Ctrl+C. Mask the solid and delete all the geometry except for
Set Transformation Type to Smash. the geometry shown above.
Select Wireframe.
Click OK.

3 Create chains 4 Replace match lines
Create a chain on the top profile and on the bottom Some of the match lines are arcs! You need to replace
profile (make sure they go in the same direction and them with segments.
have the same start).
5 Create the draft feature

Select the 2 chains and the match lines.
Open the DFR tech page.
Set the plane heights and click OK.

Example 3
The Draft Feature Recognition will recognize Land & Tapers only if there is a continuous “line” that separates the Land
and the Taper.
The following shape will not work because the Taper Region (in Blue) in interrupted.
1 Create a feature on the taper region only

Use Draft Feature Recognition on the Taper region using the plane height of this region only.

2 Translate the feature
Select the feature and translate it to the bottom of the solid.
3 Adjust the feature height

Adjust the height of the feature using the Depth property in the Property Browser.
4 Adjust the land depth

Adjust the Land Depth property in the Property Browser.

SolidWire for Agie
The technology pages for the Agie 123 and AgieVision have undergone a complete transformation bringing them to
parity with all the other wire EDM technology in ESPRIT. Now Agie customers can take advantage of all the enhanced
technology and advantages in ESPRIT Wire EDM, such as Draft Feature Recognition for both geometry and solids, an
underlying API, ease of use and a new expert system for AgieVision and AgieVision V controls with the addition of several
new and crucial settings being added.

9 9 How the new AgieVision EXPERT system works for both the AgieVision Control and the AgieVision V control
9 9 The new additions to the AgieVision technology pages
9 9 The new additions to the Agie123 technology pages

AgieVision Expert System
ESPRIT contains an integrated EXPERT system that will generate the proper
cut technology for the AgieVision and AgieVision V control. AgieVision Expert System At-
A-Glance
• Select and output values
recommended by the
manufacturer
• Choice of two databases: Master
(manufacturer recommendations)
and User (customizable by the
user)
• Two controls: VISION and
VISION 5 each with a unique
dialog and settings
Launching the AgieVision EXPERT System Selecting the AgieVision Control

Launch the Expert System, which lets the user select The layout of the Expert System dialog changes based
and output values recommended by the manufacturer. on the control type selected.
When the AgieVision control is selected, the dialog box
is configured with the appropriate settings to program
this control. Several new settings have been added to
this dialog box.
246 SolidWire for Agie

Technology Data Type
For the AgieVision control, the user does not specify
the number of cuts, power settings, offset or feed rate
information. Instead, the desired technologies are defined
When New is selected the five quality parameters
inside the AGIEVISION control and the quality of a
selection options will be available, allowing the user to
machining is made by choosing five parameters:
define the required quality. A quality target name can also
Ra as the roughness Ra (μm) be entered and this name along with the selected quality
Tkm, as the tolerance Tkm (μm) parameters can be saved and stored in the EXPERT
System to be called up again for future programming.
Te as the corner deviation TE (μm)
High Speed
High Quality When Existing is selected the five quality parameters
When these setting are selected and outputted in the selection options will be disabled allowing the user to
NC code, the AgieVision control then recommends a list select from the list of saved quality target named. Once a
of quality cutting conditions in order of closet matching quality target name is selected, the five quality parameters
first. associated to the quality target name is displayed.
The following are new settings added to the AgieVision
Expert system to help the user manage the quality cutting
conditions: When User is selected the five quality parameters
selection options are blank and disabled. The user enters
a User Technology name that matches an existing one on
the machine control.
Managing Quality Targets

The AgieVision EXPERT System now provides a way for the user to manage the list of existing quality target names.
By selecting the edit button next to Manage Quality Target, an Edit Quality Target dialogue box is launched, allowing
the user to review, and delete any previously saved quality target names.

User Custom Database and Edit Parameters
The Expert System has two databases: a default (Master) database and a User Custom Database. You can select data
from either database.
• The Default Database (Master) contains manufacturer-recommended data that cannot be changed.
• The User Custom Database lets the user control the list of selection options for Workpiece Material and Wire
Material.
Select any item in the listed box and then select the back ward arrow, This item is now moved to the available box.
Only the items that are in the listed box will appear in the pull down menu. At any time the user can move an item
from the available box to the listed box by selecting the forward arrow.
Selecting the AgieVision V Control

The layout of the Expert System dialog changes based on the control type selected.
When the AgieVision V control is selected, the dialog box is configured with the appropriate settings to program this
control. Additionally, the user must select the specific machine type being used.

The AgieVision V Control
This AgieVision V expert system is principally different from the AgieVision in two ways:
• The EXPERT system reads machine specific data file that are supplied by the manufacture .
• The user chooses from a list of eight quality parameters instead of five.
As a result, the user can now view the number of cuts , offset , and feed rate information based on the selection of the
quality parameters.

Offset Wire Path
Offset Wire Path has been added to the Agie EXPERT System which will now give the user a way to have ESPRIT
calculated the offset values for each cut.
*Note - When programming the AgieVision control, the EXPERT System has no way of knowing the number of cuts
or offset values. Thus, when Offset Wire Path is set to yes, the Expert system will EXPAND and display an additional
dialogue box allowing the user to enter the number of cuts and the exact offset amount associated to each cut.

New additions to the AgieVision technology pages
Part Setup Contouring

Security Plane – Enter the distance between the Contour → Separation – When executing the cutoff
upper plane of the piece and the upper wire guide the machine uses reduced power settings to prevent
during erosion. With the AGIECUT CLASSIC the wire breaks. This would define the point for the
distance must be set to 0 machine to power up to main cut settings in the cutoff.
Return Plane – Enter the distance between the upper This will accept either positive or negative settings.
plane of the piece and the upper wire guide during A positive number will travel that far along the form
positioning inside the work piece. before powering up. A negative number will power up
on the lead in line. I would recommend always using
a positive number in this field or a short circuit will
probably be created.
Entry → Contour - When starting a machining the
machine will start with softer entry technology to
prevent wire breaks. This defines the point for the
machine to power up to full settings. This will accept
either positive or negative numbers. A positive number
will travel that far along the form before powering up.
A negative number will power up on the lead in line. It
is recommended that a negative number be used in this
field.
Increment of Entries – Enter the distance the entry
point will be shifted incrementally for each trim cut.
Contour → Exit - When reaching the end of a contour,
the machine will change to softer exit technology to
prevent wire breaks. This defines the point for the
machine to power down to softer settings. This will
accept either positive or negative number. A positive
number will travel to that distance from the end of the
form before powering down. A negative number will
power down on the lead off line. This is used only in
the main cut in a forward direction of cut. Any number
smaller than the holding tab will not be reached.

New Agie123 technology
The old Agie Technology pages as well the post processor have been completely redesigned for Esprit 2009. Agie users
are now able to take advantage of the technologies and draft features introduced three years earlier.
Forward and Reverse Registers

The new pages introduce the Forward & Reverse Registers concept. The users are now able to handle easily reversed
cuts by setting the D and P registers for forward and reverse passes.
In order for the machine to offset the toolpath on the left, a negative offset must be entered. Set the offset value, the
Forward D register and Reverse D register.
When the machine needs to offset on the right the Forward Register is output, otherwise the Reverse register is
output.
Sorting Machining Strategies

The passes can now be sorted. The Rough and Skim You are now allowed to choose between Rough-Skim,
passes used to be the same entity: Night Die and Punch Strategies.
In Esprit 2009 you are now able to manipulate each

pass, edit them or sort them.

Offset Side Support for Draft Features
The offset side no longer has to be set by the user. The Draft Features can now be used. Data such as the
operation Type—Die, Punch, Open Left and Open height, the taper values, corner modes or slug opening,
Right—will determine it automatically. are taken directly from the features to the technology
pages:
Land and Tapers Offset Type

Agie can now perform Land & Tapers. You can now choose whether the offset is performed
by the machine or by ESPRIT.
When the machine is in charge of the offset, all internal

sharp corner will be wrong. Use the New Internal
Corner Rounding to solve this problem.
Cut-offs Rotate Entry Point Strategy

The new cut-off strategy allows Primary, Secondary & “Rotate Entry Point Strategy” allows the user to choose
Slug Stop codes. whether to alternate the start point on die profiles that
have multiple skim cuts. When multiple wire paths are
used to cut a profile, an undesirable entrance line may
be produced when the same entry point is used for all
cuts. To produce a smooth finish all around the profile,
the following strategies will rotate the entry point at
the beginning of each cut.

SolidWire for Charmilles
The Charmilles Technology Manager now lets you create, delete, rename or edit technology files. It is needed specifically
for the ESPRIT user who does NOT have CT Expert installed on their offline programming computer. Nevertheless, a
user that has CT Expert installed will greatly benefit from this technology also.

9 9 How to create a technology file
9 9 How to delete a file
9 9 How to rename a file
9 9 How to edit a file
9 9 How to use the new Charmilles Wizard

Lesson 1: Create a Charmilles technology file
The Charmilles Technology Manager lets the user generate a technology file name along with storing the number of cuts,
the power, feedrate and offset information associated to each cut, and the effective part height. The technology file name
is then added to the list of previously stored technology file names. The user then has the ability to select this file from
the Technology File pull down box; ESPRIT will read this file and then populate the technology fields with the previously
stored parameters.
1 Open the Technology Manager

Fill in the number of cuts and the associated Power, Feedrate, and Offset fields that are needed.
Then click the Technology Manager button.
2 Save the current settings as a Technology File

Give the Technology File a name a click Save.
The Charmilles Technology Manager will store the information based on the machine type and unit used in the
following directory:
C:\Program Files\D.P.Technology\ESPRIT\Data\Technology\ machine type \ctxpusi\ unit
The New Technology data are added to the Technology File combo Box.
256 SolidWire for Charmilles

Lesson 2: Delete a technology file
1 Delete a technology file

On the technology page, select the Technology File to delete and click on the Technology Manager button.
Click the Delete button
Lesson 3: Rename a technology file
1 Rename a technology file

On the technology page, select the Technology File to rename and click on the Technology Manager button.
Rename the file and click Save.

Lesson 4: Edit a technology file
1 Edit a technology file

On the technology page, select the Technology File to edit and click on the Technology Manager button.
Select the Show/Hide Details check box.
2 Change the settings and save

Make your modification and click the Save button.

Charmilles Wizard
The EDM Wizard is a prototype project which will give a user an easier way to program a part. The wizard interface
focuses on the “ease of use” concept by two aspects:
• A New Graphic User Interface has been developed with a step by step approach.
• Intelligent default have also been defined and set for each step
The EDM Wizard is a step-by-step approach which guides a user through a five step approach.
1. Define the Part Setup: the user will define the specification of his part such as the program number and /or start
position
2. Define the Simulation Stock: the user will define the stock to be used by the simulation based on a block definition,
feature extrusion or a solid
3. Create Features: the user will create all the features which need to be machined.
4. Create Processes: the user will create technology/processes for each defined feature.
5. Simulate: the user will control the created processes on the Toolpath Simulator using the entire machine environment.
The Charmilles Wizard will be available for:
• Charmilles Millenium
The Wizard Interface Layout Step 1 - Define the Part Setup

Part Setup lets you enter a program number and can
The navigation buttons allow the user to move define the initial position of the wire. After Part Setup
from one step to the other. is completed, a marker displays the start position of the
wire in the work area.
Navigation status
The navigation status shows the user the step he is
currently working on, the next and the previous step
An arrow indicates the current step
A check mark indicates completed steps. and help
button.
A dot indicates steps to be completed.

Step 2 - Define the Simulation Stock Step 3 - Create Features
The simulation stock definition is the second step of the The creation of the features is the third step of the
wizard. wizard. In this step the user creates the features by
In this step the user will define one stock to be used for selecting the machining elements (faces, geometry)
the simulation. by group (Punch, Die, Hole, etc…). Once the dialog
is validated, the wizard will go through the selection
The user has three methods to create a stock: items, and create the feature for each group with the
• From a block current settings.
• From an extrusion The wizard will sort the existing feature by group and
• From an existing solid in the workspace (This option show them in the wizard feature tree.
is only available when a solid is in the workspace.)
Step 3 - Create Features (continued) Step 3 - Create Features (continued)

By default the Feature Manager contains five main Wizard Technology Mode
nodes that represent the five main feature types: The Feature Recognition settings are set by default by
• Die ( ) the wizard based on the feature type. However there
• Punch ( ) are a few settings that require user input for each
• Open Right ( ) selection
• Open Left ( ) Die/Punch Selection
• Hole ( ) When the user is creating a Die/Punch selection, the
Each node will contain the existing features and the user will have to define the Lead-In/Out once the
newly created selection. To create a new feature, the selection in the document is done.
user selects the type of machining to accomplish by Automatic Lead-In/Out Point
selecting one of the five nodes. Then, the user will ask
the wizard to add a new selection using the add button
( ). The user can now select the faces of the solid in
the workspace.
The user can define the Lead-In/Out Point to
As soon as the user selects the add button, the icon automatically let the Feature Recognition determine the
of the add button become an “update” button ( best lead-In/Out point for the current selection
). When the user is done with the selection, they will
select this icon in order to validate the selection. Manual Selection of the Lead-In/Out Point
The user can define the Lead-In/Out Point by manually

selecting a point or a circle in to workspace after the
selection is finished.

Open Left/Right Selection Planes Height
When the user is creating an Open Left or Open Right The calculation of the plane height of the feature will
selection, the user will have to define the Lead-In and depends on the type of the element of the selection
the Lead-Out point once the selection in the workspace The selection contains at least one face
is done.
If the selection contains at least one face, the wizard
Automatic Lead-In/Out Point will compute the height of the feature based on
the minimum and the maximum height of the solid
(Bounding box of the solid).
The selection contains only 3D geometry
automatically let the Feature Recognition determine the When the selection contains only 3D geometry
best lead-In/Out point for the current selection (different Z value across the selection), the Feature
Recognition will automatically compute the height of
Manual Selection of the Lead-In/Out Point the feature based on the minimum and the maximum Z
value of the selection
When the selection contains only 2D planar geometry
(same Z value across the selection), the Wizard will
allow the user to change the height of the feature in the
Plane Height dialog.
Step 4 - Create Processes

The creation of processes is the fourth step in the
wizard. In this step, the user creates the processes to
be applied on the created feature(s).
The processes are created directly in the tree when the
user is creating a new technology on a feature.
When the document contains existing technology, the
wizard will show them in the wizard tree.
The Wizard only shows the parent technology; the
wizard does not show the Rough, Skim and Cut-Off
operations.

Step 5 - Simulation and NC Code (continued)
The user can navigate through the toolpath simulation
using the simulation navigation toolbar.
Each button on the toolbar performs an action on the

simulation.
Stop Button: This action will stop the simulator
and will restore the files to its normal state.
Pause Button: This action will pause the simulator
Play Button: This action will start or restart the
simulator
One Step Button: This action will force the
simulator to move step by step each time the user
clicks this button.
Multiple Step Button: This action will force the
simulator to move by a specified step amount each
time the user clicks this button. (The multistep
value is defined under the parameter option on the
Simulator toolbar in ESPRIT)
Slug Removal Button: This action displays the slug
removal for each cut. By default the slug removal
option of the simulator is turned on. As each
simulated operation is completed, the slug stock is
added to the list in the Slug Removal dialog. You
can select a stock condition in the list and choose
to remove it, move it up, or move it down.
Simulation Speed Slider: When the user
moves the slider value; the simulation speed
changes. If the selector is at the furthered
right, the simulator is running at the normal
speed.
Step 5 - Simulation and NC Code

Simulation
The simulation of the operations is the fifth and final step
of the wizard. In this step, the user will be able to simulate
the toolpath created with the wizard.
The simulation will use the machine environment that was
previously defined by the wizard with step one. The most
used simulation commands are available
Creation of the NC Code
When the user reaches the simulation step, the wizard
will automatically generate the NC Code into the “NC
code Files” (available in Tools/Options/File Locations)
folder using the name of the current file to set the name
of the NC Code. The EDM factory approved post
processor is used as the default post and is located in the
following directory:
\Program Files\D.P.Technology\ESPRIT\Data\Wizard\EDM\
EDMWizardPost.asc

SolidWire for Sodick
There have been a couple of additions in ESPRIT that are unique to the Sodick technology. First of all, ESPRIT now
contains an integrated ESPRIT cutting condition data reader that will generate the proper cut technology for all four
Sodick Linear Controls (LP, LQ33W, LQ and LN). Secondly, a new introductory, trial wizard is being introduced. You will
get a chance to test drive this new wizard and provide feedback as to its usefulness.

9 9 How the ESPRIT cutting condition data reader works
9 9 How to add a new machine type by importing the appropriate Sodick .dat files into the User Custom Database
9 9 How to use the new Sodick Wizard

ESPRIT cutting condition data reader
ESPRIT contains an integrated Cutting Condition Data Reader that will generate the proper cut technology for all four
Sodick Linear Controls:
• LP
• LQ33W
• LQ
• LN
1 Launch the Cutting Condition Data Reader

Launch the Expert System, Cutting Condition Data
Reader, which automatically loads values recommended by
the manufacturer.
264 SolidWire for Sodick

2 Select the type of control
Select the control type based on the machine control you are using. The data selection and NC code format are based
on this selection.
Sample of Condition Header for LN1, LQ1W or LQ33W:
( ON OFF IP HRP MAO SV V SF C PIK CTRL WK WT WS WP)
C000 = 012 013 2215 000 240 040 8 0080 0 000 0000 025 160 130 045
C001 = 014 013 2215 000 244 020 8 0080 0 000 0000 025 160 130 055
Sample of Condition Header for LQ1WS, LQ33WS or LP::

( ON OFF IP HRP MAO SV V SF C PIK CTRL WK WT WS WP PC SK)
C000 = 012 013 2215 000 240 +040.0 8.0 0080 0 000 0000 025 160 130 045 0000 00
C001 = 014 013 2215 000 244 +020.0 8.0 0080 0 000 0000 025 160 130 055 0000 00
3 The LQ1WS, LQ33WS and LP Precision Selection Options

The Sodick Conditional Search data display has change when using LQ1WS, LQ33WS and LP type of controls. You can
now perform a condition selection based on Precision and Predicted Cut Speed.
1. Select the machining Roughness and Precision range, which will display the available Surface finishes and number of
cuts options.
2. Select the number of cuts from the available options.
3. Select the Precision number and corresponding Average Speed, Surface Finish and Number of Cuts. These
parameters become highlighted in YELLOW when selected. (Additionally, when the cursor is hovered above the
Precision number the kind of condition pattern is then displayed.

4 Show Machine Condition Data option
When this box is checked, the detailed Cut Condition Data is displayed. The user can use this option to view the data
or edit a specific field, and thus modifying the condition header file being displayed in the NC code.
( ON OFF IP HRP MAO SV V SF C PIK CTRL WK WT WS WP PC SK)
C000 = 012 013 2215 000 240 +040.0 8.0 0080 0 000 0000 025 160 080 040 0000 00
C001 = 013 013 2215 000 243 +020.0 7.0 0080 0 000 0000 025 160 130 055 0000 00
C002 = 001 013 2215 000 000 +031.0 5.0 1017 0 000 0000 025 200 100 140 0000 60
C903 = 000 001 1015 000 128 +180.0 8.0 0260 0 009 0000 025 200 100 040 0000 61

Adding a new machine type
If a certain machine type is unavailable in the ESPRIT Default Database (Master), you have the ability to add a new
machine type in the User Custom Database by importing the appropriate Sodick.dat files into ESPRIT.
Steps to import Sodick.dat files into the ESPRIT User Custom Database:
1 Copy the Database Files from the Sodick Machine (LN1W Example)
Bring a 1.44Mb floppy disk to the control. Follow the prompt “Insert floppy disk in the drive and all
Press “Setting” and “Disk”. files will be deleted”.
Press “Data Backup”. Click “OK”.
Click on “Sodick Database” and “Corner Control” so that Data backup begins.
a check mark appears in those boxes. Remove the Backup disk from the floppy drive when
Click “NEXT”. completed message appears.
Click “OK”.

2 Copying and Importing database files into the ESPRIT programming computer
Once you have created the backup disk at the machine, Go back to the floppy for the second file and open the
you need to copy 4 or 5 files depending on the machine folder 0009.
control (5 files for the LP and LQ33w and 4 files for the Copy the following file to a temp folder on the ESPRIT
LQ and LN) from the disk onto the ESPRIT programming Computer.
computer. Copy the database files from the machine into a
TEMP folder on the computer. • Aic.dat
Open the floppy disk with Windows Explorer.
Open the folder 0006.
Copy the following 3 files to a temp folder on the ESPRIT
Computer:
• Cond_cond_s.dat
• Menu_Cond_s.dat
• Msg_Cond_s.dat

3 Importing the database files into the ESPRIT User Custom Database
Set Databases to User Custom Database (Step 1) The Import Button will become available and depress it.
Select the specific control type (Step 2) (Step 7)
• LN1W / LQ1W NOTE: The steps are the same for the LP and LQ33W
control. However 5 files are required instead of 4 files.
• LQ33W / LP
Launch the Import/Edit Machine Database button (Step 3)
Select Import Database from Data Files and select OK
(Step 4)
Select the browse button and browse to the TEMP
folder file location where the .dat files where copied and
selected each of the specified .dat file (Step 5)
Enter a Name (Step 6)

Sodick Wizard
The EDM Wizard is a prototype project which will give a user an easier way to program a part. The wizard interface
focuses on the “ease of use” concept by two aspects:
• A New Graphic User Interface has been developed with a step by step approach.
• Intelligent default have also been defined and set for each step
The EDM Wizard is a step-by-step approach which guides a user through a five step approach.
1. Define the Part Setup: the user will define the specification of his part such as the program number and /or start
position
2. Define the Simulation Stock: the user will define the stock to be used by the simulation based on a block definition,
feature extrusion or a solid
3. Create Features: the user will create all the features which need to be machined.
4. Create Processes: the user will create technology/processes for each defined feature.
5. Simulate: the user will control the created processes on the Toolpath Simulator using the entire machine environment.
The Wizard Interface Layout Step 1 - Define the Part Setup

Part Setup lets you enter a program number and can
The navigation buttons allow the user to move define the initial position of the wire. After Part Setup
from one step to the other. is completed, a marker displays the start position of the
wire in the work area.
Navigation status
The navigation status shows the step the user is
currently working on, the next and the previous step
An arrow indicates the current step
A check mark indicates completed steps. and help
button.
A dot indicates steps to be completed.

Step 2 - Define the Simulation Stock Step 3 - Create Features
The simulation stock definition is the second step of the The creation of the features is the third step of the
wizard. wizard. In this step the user creates the features by
In this step the user will define one stock to be used for selecting the machining elements (faces, geometry)
the simulation. by group (Punch, Die, Hole, etc…). Once the dialog
is validated, the wizard will go through the selection
The user has three methods to create a stock: items, and create the feature for each group with the
• From a block current settings.
• From an extrusion The wizard will sort the existing feature by group and
• From an existing solid in the workspace (This option show them in the wizard feature tree.
is only available when a solid is in the workspace.)

By default the Feature Manager contains five main Wizard Technology Mode
nodes that represent the five main feature types: The Feature Recognition settings are set by default by
• Die ( ) the wizard based on the feature type. However there
• Punch ( ) are a few settings that require user input for each
• Open Right ( ) selection
• Open Left ( ) Die/Punch Selection
• Hole ( ) When the user is creating a Die/Punch selection, the
Each node will contain the existing features and the user will have to define the Lead-In/Out once the
newly created selection. To create a new feature, the selection in the document is done.
user selects the type of machining to accomplish by Automatic Lead-In/Out Point
selecting one of the five nodes. Then, the user will ask
the wizard to add a new selection using the add button
( ). The user can now select the faces of the solid in
the workspace.
As soon as the user selects the add button, the icon automatically let the Feature Recognition determine the
of the add button become an “update” button ( best lead-In/Out point for the current selection
). When the user is done with the selection, they will
select this icon in order to validate the selection. Manual Selection of the Lead-In/Out Point


Open Left/Right Selection Planes Height
When the user is creating an Open Left or Open Right The calculation of the plane height of the feature will
selection, the user will have to define the Lead-In and depends on the type of the element of the selection
the Lead-Out point once the selection in the workspace The selection contains at least one face
is done.
If the selection contains at least one face, the wizard
Automatic Lead-In/Out Point will compute the height of the feature based on
the minimum and the maximum height of the solid
(Bounding box of the solid).
automatically let the Feature Recognition determine the When the selection contains only 3D geometry
best lead-In/Out point for the current selection (different Z value across the selection), the Feature
Recognition will automatically compute the height of
Manual Selection of the Lead-In/Out Point the feature based on the minimum and the maximum Z
value of the selection
When the selection contains only 2D planar geometry
(same Z value across the selection), the Wizard will
allow the user to change the height of the feature in the
Plane Height dialog.
Step 4 - Create Processes

The creation of processes is the fourth step in the
wizard. In this step, the user creates the processes to
be applied on the created feature(s).
The processes are created directly in the tree when the
user is creating a new technology on a feature.
When the document contains existing technology, the
wizard will show them in the wizard tree.
The Wizard only shows the parent technology; the
wizard does not show the Rough, Skim and Cut-Off
operations.

Step 5 - Simulation and NC Code
Simulation
The simulation of the operations is the fifth and final step of the
wizard. In this step, the user will be able to simulate the toolpath
created with the wizard.
The simulation will use the machine environment that was
previously defined by the wizard with step one. The most used
simulation commands are available
Creation of the NC Code
When the user reaches the simulation step, the wizard will
automatically generate the NC Code into the “NC code Files”
(available in Tools/Options/File Locations) folder using the name
of the current file to set the name of the NC Code. The EDM
factory approved post processor is used as the default post and is
located in the following g directory:
\Program Files\D.P.Technology\ESPRIT\Data\Wizard\EDM\
EDMWizardPost.asc

Step 5 - Simulation and NC Code (continued)
The user can navigate through the toolpath simulation using the
simulation navigation toolbar.
Each button on the toolbar performs an action on the simulation.

Stop Button: This action will stop the simulator and will
restore the files to its normal state.
Pause Button: This action will pause the simulator
Play Button: This action will start or restart the simulator
One Step Button: This action will force the simulator to move
step by step each time the user clicks this button.
Multiple Step Button: This action will force the simulator to
move by a specified step amount each time the user clicks this
button. (The multistep value is defined under the parameter
option on the Simulator toolbar in ESPRIT)
Slug Removal Button: This action displays the slug removal
for each cut. By default the slug removal option of the
simulator is turned on. As each simulated operation is
completed, the slug stock is added to the list in the Slug
Removal dialog. You can select a stock condition in the list
and choose to remove it, move it up, or move it down.
Simulation Speed Slider: When the user moves the
slider value; the simulation speed changes. If the
selector is at the furthered right, the simulator is
running at the normal speed.

Post Processor SolidWire
All the EDM Posts have been rewritten for Esprit 2008 in order to:
• simplify the post programming by using a more symbolic approach to describe functionality
• simplify the post programming by using an object oriented approach to emphasize code re-usability
• achieve a better level of readability
• achieve a better level of maintainability
• achieve a better level of flexibility

The New Format
In the new posts, all the logic is inside the DEFINE Section. The EXAMPLES are simply calling a sequence of DEFINES/
FUNCTIONS. The names of the DEFINES show the action being performed.
Example: here is the EX_CYCLESTART from the FANUC Post:
Readability
Let’s compare the cyclestart from the Mistubishi 2008 and 2007 posts:
276 Post Processor SolidWire

This is the whole EX_CYCLESTART from the 2008 post.
These are 40 of the 166 lines of the EX_CYCLESTART from the 2007 post. The new post is obviously easier to read.
In the new posts, the SetFlagsCycle define “gives a name” to the CLFILE codes. Each CLFILE Code corresponds to a
parameter in the technology page. For instance nextclfile(178) gives the Workpiece bottom height.
The old posts were sometimes hard to read because the logic was simply using the CLFILE Codes:
Example:
: IF { nextclfile{297} = nextclfile{178}}
: RefPlane_To_SecondaryPlane={abs{nextclfile{179}}}
: ELSE
:…
This test would now be written as follow:
: IF { Referenceplane=WorkPieceBottom}
: RefPlane_To_SecondaryPlane={abs{WorkpieceThickness}}
: ELSE
:…

Maintenance
The new post format is also easier to maintain. Let’s imagine a post customization where the order of the code needs to
be changed. For instance the G92 must be output after the Power settings:
This is where the G92 is output.
This is where the Power is output.

In this example the only thing to do is to copy paste the $Activate_Coordinate_System after $Output_Power_Master_
Code:
Now let’s say the $Output_Initial_Cutting_Condition has been modified for a special type of work. DP now updates the
post from the post library. What you need to do update your post without losing your customization is to simply copy/
paste your customized DEFINE into the new post!
Writing a new Post

Writing new posts becomes also easier. All the EDM machines are using the same logic but the output may differs. For
instance the DEFINES Cut_Wire_As_Needed, Move_To_Thread_Point, Thread_Wire, Thread_Wire etc… will always
exist for all the kind of machines.
New Variables
All the new posts are using common variables. For instance the operation type, taper, registers etc. are checked or are
being calculated at the beginning of the EX_CYCLESTART. A list of variables is then set. The status of the taper, register
etc... can be checked at anytime during the post by using these variables.
Here is a list of the most used variables:
is_EDM2_CONTOUR 1 when the cut is a 2 axis contour
0 when it’s a pocket a manual cycle or a 4 axis contour


is_CUT_OFF 1 when the pass is a Cut-Off
0 when the pass is not a Cut-Off

isTAPERcut 1 when the pass is a 2 axis contour with taper
0 the pass is either not a 2 axis or has no taper

CUT_NUMBER 0 -> Rough
1 -> Skim 1
2 -> Skim 2
3 -> Skim 3
…
9 -> Skim 9

WorkpieceThickness Gives the Thickness of the part
Referenceplane Gives the Height of the reference plane
WorkPieceBottom Gives the Height of the Bottom of the part
WorkPieceTop Gives the Height of the Top of the part
RefPlane_To_SecondaryPlane Gives the Vector from the reference plane to the secondary
Cut_Height Gives the actual height of the cut (useful when doing land & Taper)

Unit_Variable Gives the unit conversion when switching between Inch and Metric

CYCLE_COUNT 0 for the very first operation of the program. Incremented for each Operation
Example: If we wanted to know if the current pass is a 2 axis skim cutoff, here is the logic we would use:
IF{ is_EDM2_CONTOUR=0 && CUT_NUMBER>0 && is_CUT_OFF=1}
Another Type of variables are set under the DEFINE Initialize_Global_Variables. These variables are actually switches
that allow changing the post behavior. Some people want something the other want the opposite. These variables allow to
make thoses changes without having to modify the code inside the post.
Example:
: USE_TRANSITION_MODE={1} ## SET THIS TO ZERO IF YOU WANT SYSTEMATIC RAPID MOVES
BETWEEN CYCLES
: OUTPUT_SEQUENCE_NUMBER={0} ## SET THIS TO ONE IF YOU WANT THE “Nxxx”
SEQUENCE_NUMBER

ESPRIT Mold™
ESPRIT Mold 3-Axis Essentials

This session offers practical hands-on examples of the latest functionality and product enhancements in 3-axis machining.

9 9 How to define and use a surface to cover an area you don’t want to machine
9 9 How to use the CLEAN machining strategy
9 9 How to use the REMAC machining strategy
9 9 How to avoid tool holder collisions by transforming 3-axis tool path into 5-axis with AUTOTILT
9 9 How to use color to define different allowances on surfaces

Lesson 1: Define and use a covering surface
There are times when you want a roughing operation to mill over an area that
will be machined later. ESPRIT Mold lets you use one or more surfaces to Lesson Summary
cover an area you do not want the tool to enter. In this lesson, you will:
• Extract two curves from the
model onto a new layer
• Create a loft surface from the two
curves
• Use the lofted surface as a cover
in a roughing operation
• Use a different allowance in XY
with respect to the Z direction
1 Import the model and the tools and create the stock
Open EM V10. Select the C10 tool.
Import the file: model1.igs Create the stock as a “Box” using the default maximal
Import the tools library: tools_model1 dimensions.
2 Create a new layer for the curves

On the “Layers” toolbar, select the “Layers” icon. This sets the “curves” layer as the working layer, so that,
Select “New_Layer_3” and rename it to “curves”. in the future, you will be able to isolate the items on that
layer.
Click on the column to the left of the layer “curves”.
282 ESPRIT Mold 3-Axis Essentials

3 Extract a curve at the side of the slot
On the “Curves definition” toolbar, click “Chain contour”.
Select the contour as shown.
4 Confirm the selection of the contour

Now the system displays a question mark “?” because you Confirm by left clicking the contour to be extracted to
can select, by right-clicking, the surface from which you curve.
want to extract the curve.
In this case, the result is identical whether you extract
the contour from the upper planar surface or from the
vertical shaped surface.

5 Extract a curve on the opposite side of the slot
Repeat the same steps to extract the opposite curve.
If the two curves have an opposite direction, you must
invert one of them by selecting the icon “Reverse a curve”
on the “Curves tools” toolbar.
6 Create a loft surface from the two curves

Create a new layer and name it “Cover_surf”. Select the 2 curves and then right click 3 times (once to
Activate the new layer to make it the working layer. end of selection, another time to confirm the surface
previewed, and the last right-click to exit the loft
On the “Surfaces definition” toolbar, click “Surface by function).
selection curves (loft)”.

7 Rough the part
Select “3 axis machining” and then “ROUGHING” This check assures that the tool reaches the bottom
On the 2nd page, enter 2 mm for the height of cut and plane.
check “Automatically add interleaving cut over planes”.
8 Set the horizontal allowance to 0

On the 5th page, set to 0 the “Horizontal areas
allowance” (the “Vertical areas allowance” is set to 0.5 by
default).

9 Add the loft surface
On the 11th page, add the loft surface.
Adding this surface in this section prevents the tool from
entering inside the slot shape.
10 Calculate the tool path

Click Finish.
The toolpath is soon calculated and you can simulate it. If
you calculate the stock now you will notice, zooming in on
a corner, that we get a 0.5 on the wall and no allowance
on the bottom plane

Lesson 2: Mill between two curves (CLEAN)
CLEAN is a very efficient finishing strategy. It works by fitting the toolpaths
between 2 curves. In our example we will take advantage of the 2 curves Lesson Summary
already defined for the loft surface. In this lesson, you will:
• Create a CLEAN operation
between two curves
• Change the direction of the
tool path from tangent to cross-
tangent
1 Create a CLEAN operation

Select the tool S4, ball tip of 4 mm diameter. Select the strategy “Milling between two curves
Click “New 3 axis machining”. CLEAN”, the last in the list.
On the 2nd page, select “Pick” and select the 2 curves.

Click Finish and soon you get this toolpath.

3 Change the direction of the tool path
By default the toolpath evolves along the direction of the To make the direction of the tool path perpendicular
curves. to the curves, go to the second page of the tool path
definition and change “Tangent direction” to “Cross”.
4 Calculate the cross tool path

When you click Finish, you get this toolpath.

Lesson 3: Re-machine the part to finish the edges
The edge radius inside the slot is 1 mm. Our last finishing with the ball-tip tool
of 4 mm diameter has left some extra material upon it. Lesson Summary
• Create a REMAC operation to
remove the material left by the
previous tool
• View the collision between the
part and the tool holder
You will use a smaller tool with a 2 mm diameter to finish the slot. You will
also encounter a problem with the shape of the tool holder as it collides with
the part during machining.
The next lesson will show you how to correct the problem.
1 Create a REMAC operation

Select the tool S2, ball-tip 2 mm diameter. Its tool holder Set “Reference Tool” to S4 (the tool used in the previous
represents the conical shape that such small tools usually CLEAN finishing operation).
have. Set ZMIN so that the edge external to the plug will not be
In “3 axis machining” select the strategy “Bitangency Rest- machined.
Material re-machining REMAC”
On the 2nd page, set the “Cuts Distance” to 0.3.

2 Set the behavior of the remachining operation
On the 3rd page, check “Mixed behavior”
Uncheck the “Corners remaching with ZMILL mode”.
In the “Planes zones remachining section”, check “Clean”.
3 Calculate the tool path 4 View the tool holder collision

Click “Finish”. When the calculation (i.e. the conical part of the
finishes, ESPRIT Mold tool itself) will collide with
informs you, both on the the part.
graphic and in the Control Here is highlighted a point
Panel, that, for this where there is a collision.
machining, the tool holder

Lesson 4: Avoid collisions with AUTOTILT
If you have a 5 axis machine, you can transform this 3-axis colliding toolpath
into 5-axis tool path with no collisions. This a 5-axis functionality but, as it Lesson Summary
starts from a holder colliding in a 3-axis tool path, we will take the advantage In this lesson, you will:
of showing it during this 3-axis session.
• Convert 3-axis tool path with
collisions to 5-axis tool path
without collisions
1 Adjust the 3-axis tool path with a 5-axis AUTOTILT operation

Click “New 5 axis machining”. Click Next.
In the 5 axis machining list, select the AUTOTILT.
2 Select the 3-axis operation to transform

The “Original machining” shows which machining
operation will be transformed. The default is the last
machining operation defined, so this is OK.

3 Calculate the 5-axis tool path
Click “Finish” and you will get the new 5-axis toolpath, where all collisions are avoided.
You can also see the tool tilting to avoid collisions in realistic simulation with the Machine_BC.

Lesson 5: Use color to define different allowances
Let’s suppose you need to completely machine the slot shape and the upper
plane, but along the slot shape is needed an allowance of 0.1 mm while the Lesson Summary
upper plane must be finished to net shape. In this lesson, you will:
EM V10 presents a new functionality that lets you assign surfaces to different • Change the color of the surfaces
groups using their color. That way, different allowances can be considered inside the slot to blue
within the same operation. • Create a MILL operation
Once you’ve added surfaces to a group, that group is available for other • Add the blue surfaces to a group
operations. and define the stock allowance for
the group
Let’s test this new feature within the “Parallel Plane Milling” MILL strategy.
• Calculate the tool path using the
default allowance of 0 for the
planar surfaces and the defined
allowance for the surfaces in the
group
1 Change the color of the slot surfaces

Use the color utility to change the color of the surfaces that form the slot to blue.
2 Create a MILL operation

In the “3 axis machining” dialog, select “Parallel planes Milling MILL” and the tool S4, ball-tip 4 mm diameter.

3 Set the XY step distance
On the 2nd page, set the XY step to 0.2 mm
4 Set the vertical and horizontal allowance

On the 6th page, select “Add/Remove” and pick the 2 When you confirm with OK, a new group (Group1) for
surfaces forming the slot shape. allowance is created. This group, with its characteristic
Set the “Vertical areas allowance” to 0.1 and the allowance, will be available for any new machining to be
“Horizontal areas allowance” to 0.1 mm defined in the future (into this same session).

5 Select the surfaces to be machined
On the 9th page, click “Add/Remove” and select the 4 surfaces to be machined, 2 for the slot and 2 for the upper
plane.

Click “Finish” and you get this toolpath.
7 Calculate the stock

Calculating the stock, we get a 0 mm allowance on the upper plane and 0.1 mm on the slot surfaces, which is what we
expect.

ESPRIT Mold 3+2 Essentials
9 9 How to define a reference system APL
9 9 How to use an APL as Working Plane
9 9 How to rotate the tool-axis respect to an APL direction
9 9 How the links between machinings are applied
9 9 How to change the links
9 9 How does the “no bridge” link work

Lesson 1: APL
1 Import the model and the tools
Open EM V10 Import the tools library: tools_3+2
Import the file: Select the C10 tool
Piramid_ESPRIT.igs
2 Create the stock

Define a line segment on the edge of the pyramid.
Create the stock as a “Revolution” using the line.
Getting the stock as shown:
3 Create the first Rough

Select 3 axis machinings
Select ROUGHING and give the name “ROUGH_FROM_
TOP_C10” to the operation.
In the 2nd page put -32 to ZMIN, to completely pass the
minimal Z of the model with the toolpath.

4 Calculate the tool path 5 Load a new tool
Click Finish. Make a tool-change and load the tool C6, end mill
diameter 6 mm, which we will use from now on.
6 Define an APL using 3 points

On this part we will need to machine each side of the pyramid inclining the tool axis normal to every side. To get this
inclination we will refer to the Z axis of a reference system that into EM is called “APL”.
In the APL toolbar select the first icon, APL from 3 points:
Select Snap on model modality:

On the side with the “E” letter select in order the 3 points shown:
and get the APL having its Z axis normal to the “E” face:
298 ESPRIT Mold 3+2 Essentials

7 Define a second APL using 2 points and an angle
As you can know getting the geometrical information for this APL, its Z axis is inclined of 43.898 degrees with respect
to the absolute X axis. We will use this information to use the second possibility in the definition of an APL, 2 points
giving the new origin and X axis direction and one angle:
Let’s apply this definition on the “S” face:
and we get APL2 as shown:

8 Define a third APL normal to a face
Let’s use for the “P” face a third mode to define the apl:
Select any point in the “P” face.

Select the “Normal to face” in the bottom menu:
Moving the cursor on the model faces the system shows you the isoparametric curves passing through that point; the
direction of the Z axis of the APL that will be defined will assume the direction of the normal to the picked face in its
picked point:
So we get the APL3 as shown:
As you can see this time the X and Y axis don’t assume a particular orientation put this is not important for our
purpose that it is only to orient the tool-axis along the Z direction.

9 Use the APL to define a Working Plane
When we design some geometrical entity like a curve, this entity is defined in the XY plane of the absolute reference
system. If the entity must be defined over another plane rather then the XY we must define a Working Plane WP. Any
APL can be used as WP through the selecting the icon and then the APL:
For example let’s set the WP on APL2 to build a curve by points in the center of letter “S” shape:
Of course when picking the points on the “S” upper plane we must have selected the “snap on model” and the graphic
must show “Mod” (the point is on the model surface) for every picked point.
To reset the WP select the icon:
Let’s repeat the same procedure to create a Polyline on the “P”:

Lesson 2: 3+2 Machining
1 Inclinate the tool axis on the Z direction of an APL
In the APL toolbar select the “Tool axis rotation by APL” icon:
Pick the APL1 as shown:
And the result is:
Note that when the tool axis is rotated on an APL that APL becomes the WP.
When the tool axis is inclined the stock remain as it is: this is a great advantage for the operator who can go on with
multiple machinings on different tool-axis without taking care of the evolution of the stock and never producing “air
cutting”.

2 3+2 Machining: rough around the “E”
A 3+2 machining is a regular 2ax or 3ax machining done with the tool-axis inclined. Let’s start machining the “E” as we
are already oriented for it.
Select 3 axis machining.
Select ROUGHING and verify you have the C6 tool
In the second page pick a point on the model to give the ZMIN as shown:
In the 6th page set the tolerance to 0.01 and the allowance to 0:
Press FINISH and you get:
And the result in terms of stock is:

3 Face milling the “E”
To face milling upon the “E” letter we will change the tool to C10. For a tool change we suggest (it’s not mandatory
and it depends on your machines capabilities) to reset the tool axis direction to the vertical one before changing the
tool, using the icon:
This will correspond to a A0C0 / B0C0 in terms of G-code

Select the C10 tool:
Again rotate the tool-axis on APL1

As APL1 becomes the new WP design a rectangle referring to the “E” edges as shown:
Select 2 axis machinings and the “Face Milling” in the operation list:

3 Face milling the “E” (continued)
Name the operation as FACE_E

In the second page select the “automatic” mode and the rectangular curve:
In the 4th page select the Z level for the machining picking a point on target just on the “E” upper plane:

Press FINISH and you get the toolpath as shown:
And the “E” side is completely finished (except of course the radius 3 mm inside the corners due to the tool radius) as
you can verify through the stock:

4 Mill the “S”
We will now repeat the complete procedure on the “S” side.
• Reset the tool-axis
• Change the tool and take C6 again
• Rotate on APL2 (reference system built for “S” side)
• Rough on the “S” side selecting the ZMIN on the bottom of the face and setting allowance to 0.
And you get this toolpath:
And this result in terms of stock:
Now we will use a different strategy to face the “S” taking advantage from the central curve we defined before.
• Reset the tool-axis inclination
• Change tool and take the C10
• Inclinate again on APL2
In 3 axis machinings select “Contouring profiles on model CONT”
In the 2nd page select the curve done over the “S”:

In the 4th page select the Compensation to None to get the tool center on the curve itself:
Press Finish and you get this result in terms of toolpath and stock:

5 Rough the “P” and repeat the Face milling from “S” to mill “P”
We will now repeat the complete procedure on the “P” side.
• Change the tool and take C6 again
• Rotate on APL3 (reference system built for “P” side)
• Rough the lateral exceeding material for “P” through a ROUGHING
• Change the tool and take C10
• Rotate on APL3
We will now show how it is possible to repeat an existing machining, the CONT done on the “S”, with a different tool-
axis direction to apply it on the “P”.
In the workspace right-click on the operation “FACE_S_C10” and select “New…” in the pop-up menu:
When you create an operation through the “New…” mode, the system maintains all the parameters of the
starting operation but it adopts the tool and the tool-axis active at the moment. So in this case the tool
that appears in the first page is C10 because we previou`sly made the tool change and the machining will be done in the
direction of APL3 (normal to “P” face) because we have already rotated the tool-axis on this direction.
So in this first page we only have to give the appropriate name to the operation: FACE_P_C10:
In the second page there is the reference to the curve to be machine. We must Remove CURV1 which is the one over
the “S”:

And pick CURV2, the one over the “P”:
Then you just press Finish and the face-milling of the “P” is executed correctly as all the technological parameters are
maintained. The results in terms of stock shows:

Lesson 3: Links between machinings
The operation tree in the workspace now shows:
Moreover than the machinings this structure also contains all those movements that, for any couple of subsequent
machinings, bring the tool from the last point of the previous operation to the first point of the successive operation.
Also there are links from the virtual point where we suppose the (first) tool starts the session 0,0,QUOSIC (parameter
176) and the first point of the first machining, and from the last point of the last operation to a clearance final point.
Because the sequence of the operations can be changed moving them in the tree by the mouse, this links cannot be
cabled, but they are calculated just in time for every simulation or post.
In EM we consider 2 different kind of links:
1) 3 axis link when both the operations linked are 3 or 2 axis
2) 5 axis link when one of the 2 operations linked is 3+2 or 5 axis
We consider the starting and ending status to be 3 axis.
The 5 axis link is considered to be executed with RTCP always activated on the machine.
How to simulate the links

To simulate a link previous to an operation you must simulate that operation (drag & drop the operation into the graphic
screen) and then press the icon “Simulate previous” at the bottom right of the screen:
Then I suggest to simulate the link block by block:
Similarly to simulate the link next to the operation, when simulating that operation, press “Simulate next”:
If for example we simulate the link between the first and second operation we get:

How to change the links
The links can change in function of the machine cinematic. For a head-on-head machine they will be different respect to
a table-on-table. So, before changing the links, we must select the real machine where we are going to operate. In our
example: NC Machine → Select Machine and select the Machine_table-on-table.
The links between machinings are configured in the menu page: Utilities → Options → Setup → Links between
machinings:
Where you can see that the selected machine is indicated because the list and priority you will choose will remain saved
through the system registers.
With “New” you can add a new kind of link into the list. Then through the “Up” and “Down” bottoms you can modify
the priority of a link inside the list.
The link “no bridge”

This link only creates a detach along the tool-axis direction of the previous operation and then an approach on the tool-
axis direction of the next operation; no other movements are foreseen except these two: it is up to the post processor,
through its special section “no bridge”, to add particular positioning if needed.

The detach/approach length can be set in the page:
That you can find into all the operations 2, 3 and 5 axis.
We suggest to use this kind of link for table-on-table machines particularly when they are small, because often the
additional movements executed with RTCP cause out of range of the linear axis.

ESPRIT Mold 5-Axis Composite
Machining
The new Composite cycle provides the maximum flexibility by allowing the user to select from a wide range of machining
patterns and, likewise, a wide range of tool axis direction rules. The variety of choices gives the user the creativity to
compose any complex 5-axis function with few limitations.
Composite milling is based on the idea that any multi-axis machining function, no matter how complex, is composed of
four main steps:
1. Select the area to be machined.
2. Define the appropriate method for machining the selected area.
3. Decide the tool axis orientation as the tool moves through the defined toolpath.
4. Define how the tool will perform all auxiliary movements such as approaches, retracts, links between cuts, and so on.
This also includes the selection of the appropriate behavior to use if the tool cannot reach any of the selected areas to
machine.

9 9 How to define roughing and finishing operations for a turbine blade using a Composite 5-axis operation

Lesson 1: Roughing
1 Import the model and the tools
Lesson Summary
Open ESPRIT Mold V10.
Import the file:
• Define the initial stock
turbin_blade.igs
• Define two APLs
Import the tools library
tools_x_blade.ttb • Rotate the tool axis
Select the BULLNOSE20 tool. • Rough the two sides of the
impeller blade
2 Rotate the imported geometry 3 Define the initial stock

Select the following menu items: Right-click on “Rough undefined” and select “Define
Edit > Model > Rotate 3 axis. start rough”.
Specify 90 degrees around Y-axis and click OK. On the Box tab, use the default measurements.
Click OK.

4 Define two APLs 5 Rotate the tool axis
You need to define 2 APLs, one for each face of the Rotate the tool axis by selecting the APL on the convex
blade, perpendicular to the surface. face of the blade.
6 Define the roughing operation for the convex surfaces of the blade
Open the 3-axis machining dialog and select ROUGHING.
316 ESPRIT Mold 5-Axis Composite Machining

7 Modify the height of each cut
With respect to the defaults, only modify the ‘Height of each cut’ to 1 mm.
8 Specify a limit
Specify a limit. The type is ‘Curve from target contours’.
This option will activate the picking of faces on the model.

9 Select faces on the model and the limit curve
Pick the three faces of the convex face of the blade.
Then select the just defined curve.
Right-click to return to the dialog.
10 Calculate the toolpath

In the ‘Options on given limits’ section, select the ‘Touching border’ option.
Click Finish.

11 Create a roughing operation for the concave surfaces of the blade
Again, open the 3-axis machining dialog and select ROUGHING.
You will repeat the ROUGHING machining on the other side of the blade.
12 Change the limits for the concave face

The only difference in the procedure is that because the face is Concave, in the ‘Options on given limits’ section,
instead of ‘Touching border’ option, you have to select ‘On border’.

Pick the concave face.
Right-click to return to the dialog.
Click Finish.

Lesson 2: Semi-finishing with the Composite cycle
Lesson Summary
• Create a Composite cycle using
a bull nose tool and the Planes
Intersection curve pattern
• Set the tool orientation
perpendicular to the surface with
a lead angle of 10 degrees
• Lock an axis to create a 4-axis
operation
1 Semi-finish with a bull nose tool

From the 5ax machining dialog, select COMPOSITE machining, then NEXT.
2 Select the surfaces to machined

Click Add/Remove. Click Right twice; one time to deactivate the selection
Using the Selection Box, select all the surfaces of the box, and the second to return to the Composite dialog.
blades.

3 Verify the machining side
Select the ‘Check/Reverse machining side’ button. In this example, no external side of surfaces are displayed
When you click the ‘Check/Reverse the machining side’ in gray. Usually, you have to click each gray surface to
button, the selected surfaces will display in green for reverse it so that the orientation of every surfaces aligns
the side to be machined and gray for the internal side, according to the rest of the surface set.
according to the personal Colors Setting choiches. Right-click to return to the Composite dialog, then click
Next.
4 Choose the curve pattern

Select Planes Intersection (parallel) as type of Curve Pattern, click the ON option in the ‘Machining mode of curve
points section’, then click Next.

5 Pick the start point for the set of parallel planes
In the dialog, click Pick in the ‘Start point’ section: then pick the point shown on the blade surface.
6 Pick the end point

Then click ‘Pick End point’ in the same dialog.
Again, pick the point shown on the blade surface.

7 Define the orientation for the parallel planes
In the dialog, select ‘Perpendicular to Z axis’ in the Planes Orientation section.
Specify 3 mm for the Step (DPASS): this will be the stepover increment during the machining
8 Set the tool path strategy

In the Next dialog, Toolpath Strategy, select One Way “One Way (Original sequence)” means that the tool will
(Original Sequence) and disable the ‘Attach/Connection move through the interpolated curves while respecting
point moving’ button. the order of the original interpolation.
This page allows to specify how the tool will move
between curves of calculated pattern:

9 Set the tool axis direction strategy
From te Next dialog, select ‘Normal to Drive or machined surface’.
Click Next to proceed to the ‘Tool Axis Option dialog.
10 Define the tool axis orientation

Here, specify in the order: 90 degrees as fixed angle respect to the Z axis direction
10 degrees for the Lead Angle: this is necessary to ensure : this will cause a 4-axis machining, with a blocked rotary
a sufficient forward slope to avoid gouging during the axis (Turning-style operation)
machining of the concave side of the blade Click Next.

11 Define the stock allowance
In the ‘Numerical Control’ dialog, change the Allowance Then, stop to the ‘Rapid Links to apply’ dialog:
(SVR) value to 0,1 mm.
Jump over the next two dialogs, Links to apply and
Approaches to apply, as the defaults are suitable for this
application.
12 Define the rapid links

Clicking New, add to the priority list the ‘Radial around Z axis’ and the ‘No straightening’ links.

13 Remove rapid links you don’t need
Then, remove all the preexisting default links: Rapid, Rapid straightening above, Out of model box an Lateral
straightening no Z negative.
14 Calculate the Composite tool path

Ignore all the remaining dialogs and click Finish.

Lesson 3: Finishing with the Composite cycle
Lesson Summary
• Create a Composite cycle using
a ball mill and the Isoparametric
curve pattern
• Set the tool orientation
perpendicular to the surface with
a lead angle of 10 degrees
• Lock an axis to create a 4-axis
operation
1 Finish with a ball mill

Select the tool named FS5 from the tool library.
2 Define the Composite cycle

From the 5ax machining dialog, select COMPOSITE have to select, in addition, also the surfaces of the two
machining, then NEXT. fillets between the blade and side.
Again, using the selection box, select all the surfaces of The operation is similar, using the selection box
the blade. With respect to the previous operation, you

3 Verify the machining side
Verify visually that the selection is complete and that no Again, all the selected surfaces appear in green, so it is not
further surfaces have been selected. necessary to reverse any surface.
Right-click to return to the Composite dialog, then click
the ‘Check/Reverse machining side’ button.
4 Define the curve pattern

Click Next, and in the following dialog page, select Isoparametric pattern type, leaving the default (TOUCH) for the
Machining mode of curve points.

5 Define the direction of the curve pattern
Click next, and in the following dialog, select a surface as the Leading surface, then specify the desired Cuts distance
and the direction, that on this case is the Tangent direction
6 Define the tool path strategy

In the Next page, Toolpath strategy, leave all the defaults, then click Next.

7 Define the orientation of the tool axis
In the following page, Tool Axis direction strategy, select ‘Normal to Drive or machined surface.
Click Next.
8 Define the tool axis options

In the following page, Tool Axis options, specify a Lead suitable for this application. Then, stop to the ‘Rapid Links
Angle of 10 degrees, and a Fixed angle of 90 degrees with to apply’ dialog.
respect to the Z axis.
Jump over the next three dialogs, Numerical Control,
Links to apply and Approaches to apply, as the defaults are

9 Define the rapid links
Again, add the new links Radial around Z and ‘no straightening’ and remove all the preexisting links.

Click Finish to start the machining calculation.

ESPRIT Mold 5-Axis Impeller, Port
Machining
9 9 How to define a 5-axis roughing operation oriented to impeller roughing
9 9 How to define Composite 5-axis operations oriented to port and intake machining

Lesson 1: Rough an impeller
1 Import the model
Open EM V10 (set operations in mm and restart EMold)
Import the file: Impeller_Split.igs
2 Define the initial stock

The Impeller Roughing (Roughimp) function is based on the actual shape of the stock, so it is necessary to define an
initial stock.
We want to use the Stock definition by Revolution of a curve: let’s define a curve of the external profile of the impeller,
to create a stock like that could be obtained by a turning operation.
Extract a curve from a side face of a blade of the impeller:
Explode the curve to get four different edges:
Note that sometimes, depending on the default tolerances used, you can get more than 4 curves, and it could be
necessary to chain together some of the so obtained curves.
334 ESPRIT Mold 5-Axis Impeller, Port Machining

Now, add some linear curves to complete the external profile of the impeller:
To be able to ‘snap’ the model contours, be sure that the Model button in the Snap Bar is enabled:
Now, chain the just defined curve pieces to compose the external profile:
Now right-click on ‘Rough undefined’ in the root of the Workspace tree, then click ‘Define start rough’ in the
pop-up menu. The Initial Stock definition dialog will appear.

Select the ‘Revolution’ label, then pick the just defined curve and click OK :
3 Prepare the edge curves for the ROUGHIMP function

Extract curves from the internal faces of a pair of the main blades, and from the both sides of the splitter:
Then, explode all these curves in their corner points:

Delete all the transversal segments of the exploded curves, leaving only the main edges:
Then chain the eventual fragmented curves and reorient it from the external diameter toward the inside:
NOTE : General rule to prepare the curves

The Impeller Roughing function is based on a geometric construction that uses only the two pair of curves as input
information. This means that the shape of the extracted curves is important. You should not have problems extracting
the two pair of curves from the blades surfaces. The only rule to accomplish this is to avoid hooks at the beginning and
the end of the curves, as shown in the following example:

4 Define the Roughimp operation
Import the tools library tools_x_Impeller.ttb
Select the BULLNOSE6 tool
From the 5 axis operation dialog, select Roughimp:
The next dialog allows the selection of the curves that mark the limits of the volume of material to be removed.
Curves of main blades : you have to pick 4 curves, representing the internal edges of two main blades. The
sequence to pick the two pair of curves is the following:

Curves of splitter (when existing): in this example the impeller is a Splitter-type, because an additional shorter
blade is present between the main blades. In this case you will get a better toolpath if you specify two additional pairs
of curves, extracted from the lateral surfaces of the Splitter-blade, and ordered in the following sequence:
Click Next, getting the following dialog:

Here, only verify that the specified Pass height (this is the deep increment to progressively remove the material
between blades) is 3 mm, then click Next.
Select Isoparametric, then click Next.
Just set the Cuts distance to 1 mm, then click Next.

In the Toolpath strategy select ‘Optimized (Inversion allowed)’ this will produce a zig-zag toolpath.
Then just click Finish to start the toolpath calculation:

This is the result on the rest material updated:

Lesson 2: Composite for port machining
1 Import the model
Open EM V10 (set operations in mm and restart EMold)
Import the file: Port_twin.igs
Import the tools library: tools_x_Piping.ttb
Select the FS10 tool.
2 Define the pipe axis

Using the new function Point for pipe axis, define a sequence of points internal to the right pipe of the twin port. If
you see the normal pointing toward the external of the pipe, check the ‘Reverse direction’ option in the Property bar:
When finished, disable the Shading view of the Model and enable the ‘Contour’ view:
Using the ‘Curve by points’ function, collect the just defined points to generate a 3D curve:

Extend the defined curve of 30 mm at each extremity, using the ‘Extends a curve’ function of the Curve Tools toolbar:

3 Define the Composite operation
Select the COMPOSITE operation from the Technology 5 axis dialog, then click Next:
In the Surface selection dialog: click Add/Remove button:
Using the ‘Selection box’ function, select the complete model:

Then click right twice, the first time to disable the selection box, the second to return to the Composite dialog.
Then select the ‘Check/Reverse machining side’ button:
When you click the ‘Check/Reverse the machining side’ button, the selected surfaces will display in green for the side
to be machined and grey for the internal side, according to the personal Colors Setting choices:
In this example we want to machine the internal surface, so we have to click all the surfaces that appears in green, to
reverse it:

Then click Right to return to the composite dialog and click Next:
This is the page to select the type of curve pattern: This step lets you decide which type of machining pattern you want
to use to cover the area to be machined.
Select ‘Planes intersection (perpendicular to curve) : this pattern is generated by intersecting the selected
surfaces with a set of planes, perpendicular point by point to a specified 3D curve. This pattern is ideal for the
machining of pipe-like shapes, with the planes positioned along the curve axis of the pipe.
Leave Touch (the default) as Machining mode of curve point, then click Next:

Pick the axis curve just defined, then click in the order the Start Point and the End point on the curve. The position of
the clicked point is not critical: it is enough that the point are slightly ‘outside’ the pipe, to be sure to do not loose any
intersection with the surfaces.
Specify 1 mm as Step: this will be the stepover value for the machining toolpath.
Click Next.
Select ‘One Way (original sequence)’ as Toolpath strategy, then click Next.

Select ‘Through point’ : this means that during the machining, the tool axis will be forced to pass through a specified
fixed point. Click Next.
First, click as Thru point, the initial point of the extended curve, then select ‘Internal toolpath (female)’ as we want
to machine the internal surface of the pipe.
All the following pages of the dialog can be ignored, as the default are suitable for our application, so click Finish :
The red part of the toolpath is due to the final Toolholder Collision
Check: there is an evident collision in the final part of the toolpath. So
we have to reduce the toolpath to eliminate the unreachable part of
the surfaces.

4 Modify the Composite operation to prevent a toolholder collision
Select the just calculated Composite machining in the Workspace tree, then open the leaf clicking on the ‘plus’ sign and
click Right on the Parameters to open the pop-up menu, then click on ‘Modify parameters’ :
The Composite dialog will be re-opened: click Next until you reach the following page:
The point to be modified is the End point, so click Pick to that point. You will get a windows like this:
Answer Yes to synchronize the Machining (considered as an Object) with the actual Geometry.
Then click the End point along the curve, to stop the calculated toolpath before the toolholder collision:

Then click Finish to restart the machining calculation:
5 Machine the opposite side

To complete the pipe machining, select a new Composite operation, and in the ‘Selection surfaces’ pages, instead of
the complete model, select only the right channel of the twin port:
Right-click and verify the correct orientation of the selected surfaces:

Click Next and again select the pattern type ‘Plane intersection (perpendicular to curve)’, picking the same curve and
the following Start/End points:
Then select Oneway (original sequence) in the next page;

Again choose ‘Through Point’ as rule for the Tool axis direction, and pick the following point:
Then click Finish to start toolpath calculation:

As you can see from the picture, there is an unreachable zone, because in ‘shadow’ respect to the selected fixed point.
To get a complete machining it is necessary a different strategy for the Tool Axis rule.
6 Create a Composite Through Curve

Define an APL on the CURVE, in the proximity of the mouth of the pipe:
Make it the Working Plane, then extract a curve from the target model in the following way:

Then reduce the internal curve applying an offset of 6 mm:
Finally, Move the curve, always with respect to the same working plane, by 20 mm along Z and 10 mm along X:
Now, Modify Parameters of the last Composite operation: go forward (clicking Next) in the dialog pages until you
reach the Toolaxis direction stategy page: here, change the rule from ‘Through point’ to ‘Through curve’ :

Click Next, and in the following page, click the ‘Pick curve’ button: again, you will get the message ‘To select elements
from current geometry, local geometry must be dropped. Continue?’ answer Yes.
Pick the curve, and change the ‘Selection of point on curve’ option from the default (Minimum distance) to ‘Plane
Intersection’ and ‘Internal Cutting’. Then, click Finish:

As shown by the picture, the tool axis is constrained to pass through the curve, but it has more ‘freedom’ to reach the
interior of the pipe: this is the toolpath of both Composite machinings defined in this example. The picture evidences
that the interior of the pipe is completely machined.
In a similar way you can define the axis curve and the Composite machining for the other side of the twin port.
In the following picture, the results of the real machining realized on a resin block:

ESPRIT Mold Post Processor and
Machine Configuration
9 9 About the EM Post architecture and where the files are located
9 9 How to run the post-processor
9 9 How to use AutonPost to create and modify a post project
9 9 How to insert the RTCP activation
9 9 How to create a Post having exploded cycles
9 9 How to create a post using Rotated Reference Systems
9 9 How to create a machine configuration
9 9 About the Alternative Solution and the related parameters
9 9 How to get continuous rotation of C when its numerical values range is limited between 0-360

Lesson 1: Post-Processor Architecture
The post-processor scheme
Location of the files

The processor file Auton.exe is located (depending on the Operating System language) usually into:
C:\Program Files\ESPRIT Mold 10.0\
CLFile.apt is temporary file that is created when the post is launched. It is located into:
XP C:\Program Files\ESPRIT Mold 10.0\ tmp\
VISTA C:\Users\username\ AppData\Local\ ESPRIT Mold 10.0\tmp\
The post-processor file AutonPost.exe is located into:

C:\Program Files\ESPRIT Mold 10.0\ AutonPost\
The post-processor project is an .xml file that characterize the behavior of AutonPost in order to obtain the
requested G-code. It is located into:
XP C:\Program Files\ESPRIT Mold 10.0\ AutonPost\AutonPostLibs\
VISTA C:\Users\username\ AppData\Local\ ESPRIT Mold 10.0\AutonPost\AutonPostLibs\
Installing EM a default project file DefaultLibrary.xml is loaded into this folder. It can be use as a reference to create
further projects.
The G-code (or NC output file) is located wherever the operator set to place it inside EM. To uniform our working
session I suggest to create into your PC the folder:
C:\toolpaths\
and we will use it for our training sessions.
358 ESPRIT Mold Post Processor and Machine Configuration

Lesson 2: How to run the Post-Processor
Run the post from inside EM
The operator can start the post execution from inside EM simply selecting the icon “Start Post-Processor” in the
Technology toolbar:
Then a “Post Processor” window opens where in the left section it is possible to select/unselect the operations to be
posted and the right section is for the selection of the post project, i.e. of the .xml file in \AutonPostLibs folder:
As soon as you press Start the G-code is produced and opened into a Notepad window.
As you see when you run the post from inside EM, AutonPost.exe is completely transparent (i.e. the user doesn’t see that
it is recalled).
Run the post to create or modify a post project .xml

AutonPost.exe can also be used to create or modify pp projects.
• Go in the folder where DefaultLibrary.xml is located
• Create a copy of it
• Rename it TEST.xml
• Open EM V10
• Select the machine “machine_table-on-table”
• Open the project inclinate_holes.atc
• Deactivate the operation DRILL_10_MM
• Post using the project TEST: you will get a general ISO G-code
• Go into C:\Program Files\ESPRIT Mold 10.0\ AutonPost\ and run AutonPost.exe
• Open the file TEST.xml:

The path for TEST.xml is in this case for a PC with VISTA.
Run the post (same icon that inside EM) and open CLFile.apt, as showed in the following image:
And you get the G-code as follows:

Lesson 3: Configuration of a 3+2 Post-Processor
Use of RTCP
The program we have just obtained wouldn’t work on the machine and you would see the tool going elsewhere respect
its supposed working area. This because the tool-axis of the operation posted is inclined (3+2 machining) and the machine
needs in such case the activation of a special function called RTCP (Rotation Tool Center Point) that compensate the
position of the linear axis in function of the rotation of the rotary axis.
From the machine operator point of view, the program only needs to write the coordinates X,Y,Z of the tip of the
tool, referred to the absolute reference system, and the rotation values BC (in our case). Then the RTCP
function (when available and activated) will take care of producing the correct positioning of the tool with
respect to the part, considering the machine kinematic, the tool length, and other things.
The RTCP function change in different CNC in the form and the rules for its activation.
Let’s introduce into our TEST.xml an RTCP activation in the FANUC style. After the tool change T1M06 we need to
program the block G43.4H1
Inside AutonPost, is the section “File Structure” select “Tool Change”:

In the section “After First Tool Change” type G43.4
With the cursor in the same area right-click and this pop-up menu appears:
Select “Insert Register and/or Function”

This new pop-up menu appears:

Select the line “RegisterToolLengthCompensation” and press Insert
You get inside the window the string: G43.4”RegisterToolLengthCompensation”
Copy the complete string and paste it in the bottom area “After Other Tool Change”
Press “Apply to all tools”
Press OK
Save the project, clicking on the diskette icon
Run the post, selecting again CLFile.apt, as already explained and you get:
And this program would work in our table-on-table machine with CNC in FANUC style.
The RTCP function works as well for 5 axis continuous machinings.

Exploded cycles
Go back to EM V10.
Deactivate the operation ROUGH_POCKET_C10
Activate the operation DRILL_10_MM, which is a drill cycle on 4 points inside the pocket, to be executed with the tool-
axis inclined.
Run the post TEST_3+2
You get the following error:
The fact is that TEST.xml derives from a generic post. Usually on CNCs is not possible to use the canned cycles G81,
G82, G83 …. out of the XY plane without defining rotated reference system. One simple way to overcome this problem
is to explode the cycle, i.e. to program all the interpolation instruction G00, G01 and the coordinates instead of the cycle.
Let’s consider the following cycle:
G81 R2 Z-10 F100
X10 Y20
G80
This code corresponds to the exploded:
G00 X10 Y20
G00 Z2
G01 Z-10 F100
G00 Z2
Let’s see how to get this result in our post:
• Go in the folder where TEST.xml is located
• Copy into this folder the file Cycle_Explosion_scheme.xml
• Create a copy of TEST.xml
• Rename it TEST_exploded_cycles.xml
• Go back to AutonPost and open TEST_exploded_cycles.xml
• From the upper menu select Scheme → Import → Import Cycle Explosion Configuration
• Answer “yes” to the warning question

• Select the file Cycle_Explosion_scheme.xml and open it
• Select Cycle → Coordinates and check the box for Fixed cycle explosion as shown:

• Press OK
• Save the project
Run the post, always opening CLFile.apt, and you get:
Of course the G43.4H2 line, RTCP activation, is mandatory for the correct execution of this program.
This solution can satisfy those users drilling just a few holes into molds. Instead those user making lot of holes on their 5
axis machine will complain that using this code they will not be able to adjust the cycle (for example enlarging the depth of
the drilling) directly on the CNC.

Use of rotated reference plane
For those users requesting an output in terms of cycles G81, G82 the code must include appropriate commands to define
rotated reference systems RS and the tool-tip coordinates must be then referred to these RS.
Let’s suppose to adopt the FANUC command to create a rotated RS. The format for such command is:
G68.2 X x0 Y y0 Z z0 I a J b K c
Where x0, y0, z0 are the coordinates of the origin of the new RS and a, b, c are the Euler’s angles that determinate the
orientation of the new RS respect to the absolute one.
The RS created transparently inside EM has its origin coinciding with the origin of the absolute system, that means x0=0,
y0=0, Z0=0, and its Z axis direction is parallel to the direction of the Z axis of the APL picked to get the tool-axis
inclination. The X and Y of the RS are automatically defined by EM (usually they are not parallel respect to the X and Y
direction of the APL).
It’s useful to describe the difference between Euler’s and Spatial angles.
The Euler’s angles are applied in this way: from the absolute system AS rotate the system of a degrees around the X axis.
Through this rotation you get a new direction for Y axis that we indicate with Y’ (and also of course a new direction for
the Z axis Z’). Now rotate again the system of b degrees around Y’ and you get a newer direction for the Z axis that we
call Z’’. Rotate the system of c degrees around Z’’ and eventually you get the position of the RS.
Inside AutonPost the Euler’s angles values are stored inside the registers:
RegisterEuleroDegreeAngleAxis1
Euler’s angles are for example adopted from the CNC producers FANUC, SELCA
The Spatial angles are applied in this way: from the absolute system AS rotate the system of a degrees around the X axis.
Then rotate the system of b degrees around the Y axis of the AS. Then rotate again of c degrees around Z of the AS.
Inside AutonPost the Spatial angles values are stored inside the registers:
RegisterRotationAxis1
Spatial angles are for example adopted from the CNC producer HEIDENHAIN
Let’s see how to introduce the RS inside the TEST post:
• Make a copy of TEST.xml and rename it TEST_3+2.xml
• Go back to AutonPost
• Open TEST_3+2.xml
• Go back to the section “File Structure” → “Tool Change” and eliminate the RTCP activation G43.4”RegisterToolLength
Compensation” from both the 2 sections “After First Tool Change” and “After Other Tool Change” so that this 2 areas
become empty.
• Press “Apply to all tools”
• Press OK
• Save
• Machining Parameters → Technological Parameters

• Check the option “Use rotation matrix” and “All indexed machining”; this will transform the coordinate values in
function of the RS.
• OK
• Save
• File Structure → Machining Change
Current Machining → 3 axis
In the Next Machining → 3+2 Axis section insert the following types and registers (use the technique of the right-click
already explained):
G00”RegisterAngle1””RegisterAngle2”
G68.2X0Y0Z0”RegisterEuleroDegreeAngleAxis1””RegisterEuleroDegreeAngleAxis2””RegisterE
uleroDegreeAngleAxis3”
The page will appear as shown:

• Press Ok
• Save
• File Structure → Program End
• Fill both the 2 sections “End other NC output” and “End last NC output” with the following lines:
G69
G00G28G91Z0
B0C0
M30
Where G69 cancels the RS, G00G28G91Z0 move the Z axis on the maximum height available on the machine, B0C0
move the rotary axis to their 0 position:

• OK
• Save
• Run the post and you get the result:
Note that this output is only FANUC style not precisely fixed for a special FANUC model.
You can also go back to EM, activate and post both the 2 machining obtaining a code complete of milling and drilling
through cycles having all the coordinates referred to the RS.

Lesson 4: Machine configuration
The machine-tool description
For EM the machine-tool is represented through a folder containing an .xml file and an .stl representation of each
component, usually the basis and the 5 axis, so globally 6 .stl files.
The machine configuration is completely independent from the post processor: it is important do not confuse the xml
file for the machine with the xml file of the post.
The machine configuration is in charge to transform the tool-axis direction programmed in EM 3+2 and 5 axis operations
into the real axis rotations of the machine.
The xml file

The .xml file contains the cinematic description of the machine. It’s very important to describe the kinematic chain
programming the axis sections as they really concatenate one on the other. For example in the Machine_head-on-
head we have one kinematic-chain composed by the basis (table) on which moves the X axis (the portal), on which
moves Y (traverse), on which moves Z (column), on which rotates C, on which rotates B (spindle).
In the Machine_table-on-table instead we have two kinematic-chains moving on the basis. One is composed by Y
axis on which moves the Z axis . The other cinematic-chain is composed by X axis on which rotates B (tilting table), on
which rotates C (rotary ntable).

The stl files
In each axis section is recalled an stl file representing the solid model of that axis. If you have the 3D model of machine
in your CAD system you must align the axis of the machine congruently with the X, Y and Z of the absolute reference
system. For example, for a mill-turning machine, the spindle axis should coincide with the Z axis of the reference system.
The rotary axis must be positioned on their 0 position.
We suggest to position the origin of the absolute reference system in the center of the table where the part is placed.
The stl solids must be as we say “water proof”, i.e. there must not be open borders in it. This condition is usually
respected if you are extracting the stl from a solid modeler CAD system.
The alternative solution in 3+2

• Open EM V10
• Open the EM project inclined_holes.atc
• Select the machine “Machine_head-on-head”
• Enter the 5 axis realistic simulation
• Go into NC Machine → Machine Parameters and put the DeltaStockZ value to 400. This means that we consider the
part lifted 400 mm from the plane of the table.

• Go to Utilities → Realistic Simulator → Show Machine Coords and you will get a window showing the axis coordinates.
We will be particularly interested into the rotary axis coordinates B and C.
• Activate the simulation going on Toolpath on the top in the workplace, right-click, select “Animation” in the pop-up
menu, press play block by block in the button simulation bar since the tool inclinate, and you get a positioning into
C0B45
Note the “-“ designed in the visible side of the C axis, to distinguish this side from the opposite where a “+” has been
designed.
In this machine B has a symmetrical behavior, i.e. it can rotate +/- 150.
In this case for the requested tool-axis direction we can have 2 couples of angles, i.e. 2 solutions, B45C0 and B-45C180
To switch to the other possible solution B-45C180:
• Open the “+” in the tree for the operation ROUGH_POCKET_C10
• Right-click on “Alternative solution OFF”

• Select “Enable alternative solution” and the operation switch to “Alternative solution ON”
• Simulate again, and you get:
The primary solution calculated from EM, i.e. the one having “Alternative solution OFF”, is the one with
B>0
The alternative solution in 5 axis

• Open EM V10
• Open the EM project sphere.atc: it is a simple 5 axis contouring on a spherical model
• Select the machine “Machine_head-on-head”

• Enter the 5 axis realistic simulation
• Simulate the toolpath block by block
You can see that the operation starts from the position B14.24C0. Going toward the top the B value decrees toward 0.
When the tool reach the top of the sphere the C axis makes a 180 degrees revolution going in the position C-180 (that is
the same of C180 anyway):

Then, in the proceeding of the simulation, B goes again on positive values, always incrementing them.
This happens because, with the actual configuration for the machine parameters, the system always privilege the solution
(between the 2 available) for which the primary axis (B in our case) goes on positive values.
This big 180° revolution of the C axis with the tool-tip in touch with the part should be avoid because, a minimal bad
tuning of the TCP, would produce a mark on the part and also because the tool movement should be stopped in its
feeding on to wait the completing of the C180 rotation, creating a technological problem.
To avoid this behavior:
• Go into NC Machine → Machine Parameters and give to Epsilon the value 0.1:
• OK
• Simulate again
Now you can see that when the tool reaches the top B starts going with negative values; so the system automatically
switches to the alternative solution, avoiding the C revolution.
When we increase the Epsilon value the system can recognize the tool axis verticality. Physically we consider the tool-
axis vertical when the both the Vx and Vy components of the tool-axis versor are < Epsilon.

This because the toolpath goes on discrete points that never coincide precisely with the tool-axis versor 0,0,1
There is also another condition that must occur for the automatic switch to the alternative solution: the rotation that
would involved the secondary rotation axis C, dC, must be grater than DeltaAngDegree (one of the “NC Machine
parameters”)
For example in our case dC = 180 > 45 so the switch is applied.
If we want to force the system to never switch to the alternative solution we must set DeltaAngDegree to
0
The set of DeltaAngDegree = 0 is mandatory in these 2 cases:
1) When the primary axis A/B range is a asymmetrical for every kind of machine kinematic, like for example when it
is -30 / +120
2) When the primary axis A/B rotates around a 45° inclined axis
Continuous rotation of C
• Open EM V10
• Select the machine “machine_table-on-table”
• Open the project C_continuous_rotation.atc
• Go into 5 axis realistic simulation
• Show the machine coordinates
• Start the simulation
You will see the C axis rotating continuously reaching at the end the position C3622, corresponding to more then 10
rounds.
If we post the operation using the post TEST we will find of course the C axis assuming values from 0 to 3622.
Now let’s suppose that in our CNC machine C must be programmed only into the range 0-360 and that to get a
continuous rotation in the same direction in the case of a situation like this:
C359
C1
We should program:
C359
M94
C1
where M94 works as a reset, so that for the CNC that position would be C-1 instead of C359

To get this output we must operate both into the machine xml and into the post.
• Make a copy of the folder machine_table-on-table and rename it machine_table-on-table_360
• Enter inside this folder and rename the file Machine_table-on-table.xml into Machine_table-on-table_360.xml
• Make a copy of the post project TEST.xml and rename it TEST_M94.xml
• Open with Notepad (or any other file editor) the file machine_table-on-table.xml inside the folder machine_table-on-
table_360
• Change the section name on the second line as shown:
<Name>Machine_table-on-table_360</Name>
• Go to the end of the file and between the lines:
</KinematicChain>
</NCMachine>
insert the following section:
<Parameters>
<ResetInRiposiz> NO _ Z </ResetInRiposiz>
</Parameters>
So that the complete end of the file is:
</KinematicChain>
<Parameters>
<ResetInRiposiz> NO _ Z </ResetInRiposiz>
</Parameters>
</NCMachine>
This section make the table not to revolve back when its range limit is reached
Now go up to the section of the C axis that start with the lines:
<Axis>
<Name>C</Name>
And go just few lines below in the section describing the range of C :
<Min>-20000</Min>
<Max>+20000</Max>
and change it into:
<Min>0</Min>
<Max>360</Max>
So that the range of the C axis is limited inside 0 and 360 degrees
• Save the file and exit
• In EM go to NC Machine → Select Machine an select the machine machine_table-on-table_360
Note that every time you edit the .xml file of the machine, to let EM apply the modifications done, you
have to select again the .xml file of the machine.
• Run the realistic simulation. Now you can see that the C axis, although it rotates continuously like before, but its value
always arrives till 360 and restarts from 0.
• Run AutonPost
• Open the post project TEST_M94.xml
• Go on Functions
• Select the line FunctionRotationTable and set the fields as shown:

• Being selected on FunctionRotationTable press Queue
• The window for the queue definition opens:
• On the right, on the “Usable data” field select “Register/Function”

• In the below list select “FunctionRotationTable” and press “Insert”. The “FunctionRotationTable” goes in the queue, the
central area. This means that when reading CLFile.apt the system will find the instruction ROTABLE the content of this
Function (M94) will be written in the code.
• Press OK in the “Function queue” window

• Press OK in the Functions window
• Save
• Run the post
• Scrolling towards C360 you will find the sequence:
X-12.695Y-1.908Z16.405B-30C358.045
X-12.466Y-1.85
X-12.262Y-1.765
X-12.081Y-1.654
X-11.905Y-1.508
X-11.753Y-1.337
X-11.627Y-1.145
X-11.535Y-0.937
X-11.475Y-0.716
X-11.449Y-0.522
X-11.446Y-0.391
X-11.454Y-0.083Z16.404B-30C359.586
M94
X-11.45Y0.012Z16.4B-29.998C-0.015
X-11.45Y0.236Z16.405B-29.999C1.182
X-11.444Y0.512Z16.404B-29.999C2.561
X-11.423Y0.825Z16.405B-29.999C4.129
where the M94 is correctly applied.

ESPRIT KnowledgeBase™
KnowledgeBase Launchpad, Part 1:
The Art of Automation
An automated CAM system is designed to do one thing: make your job faster and easier.
True “push button” automation in ESPRIT means that, with only a few mouse clicks, a user can produce one or more
machining operations. The number of clicks required to produce the NC code depends on the level of automation you
decide to build into the system. A certain amount of user interaction is still required to direct ESPRIT in what task to
perform.
For each click, ESPRIT takes only a few seconds to perform a task that usually takes several minutes for a person to do.
But ESPRIT does not define the task on its own. You need to provide ESPRIT with a set of instructions that tell it what
you want it to do.
You can start by automating one or two simple tasks and then add more automation as you become more comfortable
with the technology.

9 9 The benefits of automation
9 9 How to decide what to automate
9 9 How to develop a plan for automation
9 9 The nuts and bolts of automation in ESPRIT

Why automate?
As talented machinists and programmers leave the field and fewer workers enter it, the importance of capturing the
knowledge of skilled workers is critical to moving a business forward.
Companies spend a lot of money training a worker to become a good CNC programmer. The costs include years of
training on machines, computer hardware, software, workholding techniques, and best machining practices plus salary,
benefits, utilities, insurance, and more. The knowledge is embedded in the worker, not the company, so when that
employee leaves either for retirement or for another job the worker carries those costs and that knowledge out the
door.
To retain the best machining knowledge, a company must be able to capture and store it in a way that other machinists
and trainees can use. The ESPRIT KnowledgeBase allows a company to put manufacturing process data that has been
optimized over the years onto a computer, where it can be shared and utilized by anyone in the company with permission
to access that information.
Storing knowledge within ESPRIT lets the computer perform repetitive tasks, allowing highly skilled workers to spend
more time improving manufacturing processes. Sophisticated CAM automation gives any manufacturer the advantage of
allocating its valuable human resources to strategic endeavors that enhance the competitiveness of the entire business.
Why automate?
• Re-use tried and true machining techniques
• Prevent human errors
• Save time
• Utilize skilled workers for more important tasks
• Get new employees up to speed quickly
• Update all machining processes automatically when a process has been improved
Deciding what to automate

It is not practical to automate everything.
• First, a task has to lend itself to automation by being repeatable. That means that you can break the task down into a
series of steps that have little variation. For example, using the same machine setup over and over or identifying similar
hole patterns.
• Second, you have to decide if a task is worth the time and effort to automate. Tasks that are performed often, take a
lot of time, or are prone to human error are prime candidates for automation.
The more difficult a task is, the more time it will take to automate. Also, tasks that require skilled human intervention are
also difficult to automate.
A common rule is that the first 80% of tasks identified for automation will require only 20% of your time, while the last
20% of tasks will take 80% of the time needed to automate.
You have to decide whether that last 10-20% is worth the time involved to automate or whether you should simply assign
those tasks to your most skilled people.
TASKS
Easy Difficult
80% 20%
380 KnowledgeBase Launchpad, Part 1: The Art of Automation

Tasks can be categorized into 4 zones by their importance to the company and how urgent they are. Categorizing tasks
by zone can help you decide where to assign your automation resources.
Urgent Not Urgent
Important I II
Not Important III IV
Zone 1: These are important tasks that pop up suddenly and must be completed quickly. You don’t have time to
automate these tasks. However, if the same task keeps appearing in this zone you need to look at the underlying cause
and work on a resolution to move the task into Zone 2.
Zone 2: These tasks are important to your company and usually involve the day-to-day running of the company. Tasks in
this zone make ideal candidates for automation because they provide longterm payback from your automation efforts.
Zone 3: These tasks must get done quickly but are not important enough to be worth the time spent on automation.
Zone 4: You should never automate a task that is both unimportant and not urgent. In fact, you should analyze these
tasks to see if you need to do them at all. For example, if paperwork is being generated that will be filed away somewhere
and seldom reviewed, it would be better to simply keep a backup of the electronic copy.
Deciding how to automate: The Plan

Before you automate, you need a plan. You also need to gather a team
of employees who have the hands-on experience to make sure your
plan will work. It’s the underlying knowledge of your skilled employees
that will help you get the most from automation.
You will need to document and improve your current processes before
you can start automation. Otherwise, you are simply automating the
inefficient processes you currently have instead of achieving the best
possible productivity.
You will definitely encounter resistance to change. It’s human nature to
be wary of the unknown, especially if you think your job is in jeopardy.
This is where your team will be especially useful. These are the people
who will be working and communicating with everyone during the
improvement process.
Here are some tips on how to avoid resistance to change:
• State your goals clearly and definitively. A goal could be to eliminate
back orders, improve delivery times by x number of days, improve
quality by x%, reduce setups by x minutes, and so on. Make your
goals as concrete as possible.
• Explain the direct benefits to the company, such as more repeat
orders, delivering orders faster than the competition, delivering
better quality than the competition, higher output with the same
amount of work.
• Explain the direct benefits to the employees such as better training,
less stress, more opportunities to learn new skills, value place on
their input.
If employees or managers feel their jobs are threatened, you will have
little success.

Storing your shop information
Automation starts with a database that stores and organizes information about conditions in the shop and how your
company machines its parts. The purpose of the database is to create a virtual replica of all the cutting tools, raw
material, and CNC machines that actually exist on the shop floor. Even more important, the database stores proven
machining parameters and processes so the CAM system can make the best choices when a program is created.
The KnowledgeBase Manager
The KnowledgeBase Manager is your link to every type of manager in the KnowledgeBase. These include:
• Cutting Tool Manager: Set up and store your commonly used cutting tools
• Speed Feeds Manager: Set up and store your commonly used part materials, cutting tool materials, types of cut, spindle
speeds and feed rates.
• Default Technology Manager: Set up and store default technology settings for the cutting cycles you use most often
• Process Technology Manager: Set up your own part types and create the machining processes to cut those parts
Caution!!! Do not modify the pre-loaded data provided by ESPRIT. This data is overwritten each time ESPRIT is
installed. Copy the pre-loaded data to your own data groups and then modify it to match your own shop floor.
Once data is set up in the system, it can be shared and programmers can begin using it immediately. When you start a
new document, the first task is to open KnowledgBase Document Setup so you can the tell the system something about
the job at hand, such as the type of part being machined, the material being machined, and which machining preferences
to use.

This gives the system enough information to retrieve the correct
data from the database and automatically fill in machining
parameters as operations are created.
A simple task like setting up shop floor data in a database lets the
CAM system:
• Automatically select the correct cutting tools based on the
part material and type of operation
• Automatically calculate appropriate spindle speeds and feed
rates based on the part material, tool material, depth of cut,
and tool diameter
• Automatically select user-defined machining preferences
SolidWire Expert System

Most EDM machine types in ESPRIT are accompanied by an expert system database that stores cut data recommended by
the machine tool manufacturer.
The Expert System has two databases: a default (Master) database and a User Custom Database. You can select data
from either database. The Default Database contains manufacturer-recommended data that cannot be changed. The
User Custom Database lets you add, edit, delete, and completely customize data in the database by adding or deleting a
machine model, wire specification, workpiece material, and more.
Note: Charmilles machines have their own CT-Expert System.

Store your cutting tool information
The Cutting Tool Manager lets you create tool groups and the tools that are stored in each group. Depending on the
types of tools you use, you could create a tool group for each machine, for certain types of machining (high-speed or
standard), for unit of measure (inch and metric), or any combination that makes it easy for you to find and select tools.
If you want to use the pre-loaded tools, create your own tool group and then simply select the tools you need and
copy them to your new group.
To add a tool to the database, select the Tool Group you want to update and then right-click and select Add. The
interface for creating turning or milling tools is exactly the same interface you find in ESPRIT.
Use your cutting tool data in ESPRIT

After you set up your Tool Groups and define the tools in them, you can use them in ESPRIT and they will be the same
from one job to another.
• On any technology page that uses a tool, you can click on the database icon to open the Cutting Tools Manager from
within ESPRIT. Select the tool you want and click OK to add the tool to your operation.
• In the Tool Manager, click the KnowledgeBase button and select Cutting Tool Manager. You can either drag and drop

tools from the KnowledgeBase to the Tool Manager one by one or you can select several tools and then click “Add
Selected Tools To ESPRIT”.
Store your feed and speed data

The Speed Feeds Manager stores all the information you need to automatically calculate the ideal speeds and feeds for
your machining operations.
Information is grouped in a “Standard”. Each standard contains information about part materials (class and condition),
types of cut, cutting tool material, and speed/feed data. You can copy any of the data from one standard to another.
Just right-click on a material class, material condition, type of cut, or tool material and select Copy Current to copy
only the selection or select Copy All to copy all the data in that field.
Important: If you have the CutData standard installed, you are not allowed to copy and paste the data to another
standard.
After you define your materials and types of cut, you can define your speed/feed data based on any combination of part
material, tool material, and type of cut.

To add your own speed/feed data, right-click in the Speed Feed Data grid and select Add New. You can then enter
information about the tool diameter, the cut depth, speed, and feed rate.
You can also review your Speed Feed Data in a graphical display. Right-click in the grid and select Graph Data. You can
view the information in the graph by unit (inch or millimeter), Z Cut Depth, or Tool Diameter. When you hover the
cursor over a point in the graph, you can edit the data.
Use your speed/feed data in ESPRIT

After you set up your Standard and the speed/feed data inside the standard, you can use it in ESPRIT to automatically
calculate acceptable speeds and feed rates based on the actual tool and technnology settings when you create a new
machining operation.
First, open KnowledgeBase Document Setup and select your Speed Feed standard and a material from the standard.

Then, when you open a technology page, make sure “Use Feed and Speed KB” is set to Yes and select a Type of Cut.
When you select a cutting tool, ESPRIT will load the appropriate speeds and feeds from the KnowledgeBase.

Store your machining preferences
The Default Technology Manager stores your machining preferences in Default Groups. Each group can only store the
machining defaults for one of each type of technology (Facing, Pocketing, Contouring,...) but you can create as many
default groups as you like.
If you want to use the pre-loaded defaults, create your own default group and then simply select the technologies you
want and copy them to your new group.
To add technology to your Default Group, simply right-click in the grid and select Add to add a single technology or
select Add All to add all the technology available in ESPRIT. The technology pages in the Default Technology Manager
are exactly the same as the technology pages you see in ESPRIT.
Use your default technology in ESPRIT

After you set up your default technology, you can use it in ESPRIT to automatically load data into the technology
pages when you create a new machining operation. Open KnowledgeBase Document Setup and select your Default
Technology Group. When you open a technology page in ESPRIT, you will see your own default settings.

Store information about the parts you machine
The Process Technology Manager stores information about the types of parts you machine and the processes you use
to machine them.
Each Part Type contains a list of Feature Types. Each Feature Type can be further defined with keys (for example, a
pocket feature can be defined as small, medium, or large). A unique machining process can then be associated with
each combination of Part Type/Feature Type/Key.
Note: Creating your own types of features requires an advanced understanding of the KnowledgeBase and is not
covered in this class.
If you want to use the pre-loaded feature types and their associated processes, create your own Part Type and then
simply select the types of features you will use with that type of part and copy them to your Part Type.
You can then update the processes with your own machining defaults.
Use your part type data in ESPRIT

After you set up your Part Types and define the features and processes in them, you can use them in ESPRIT to
automatically recognize features and their linked machining processes.
Open KnowledgeBase Document Setup and select a Part Type. As you create features in ESPRIT, they will be
recognized and you can apply the associated process.

Advanced automation techniques
Although this class is an introduction to automation, there are other advanced techniques that will help you fully
automate ESPRIT.
Express yourself with expressions

On any technology page, you can right-click over a field and then click Edit Properties. You can type a mathematical
expression or a Visual Basic expression. These expressions can be entered to simplify the programming or even automate
processes.
To help you build the VB expressions, you can use the Expression Builder.
The Expression Builder provides lists of variables

and common functions used to build expressions
on technology pages and in the KnowledgeBase.
Use expressions to calculate settings for machining
operations, set defaults, or define specific feature
types. Build expressions by selecting variables and
commands in the Expression Builder dialog or
simply type the expression.
Expressions have access to the full power of VBA
including sub-routines, functions, access to VB and
C++, and the complete ESPRIT API.
Get to know your API

To truly customize ESPRIT to fit your shop, you should have an understanding of the Application Programming Interface
(API). You can then create custom programs to automate almost any repetitive task.
The purpose of the ESPRIT API is to provide an interface for programming ESPRIT applications. Applications written using
the ESPRIT API come in the form of macros and add-ins. Macros are individual programs that a user runs similar to the
way they run other commands on the menus and toolbars in ESPRIT. Add-ins typically provide a larger system of related
commands.
API stands for Application Programming Interface. Programming is at the center of it. The more an API user knows about
computer programming and programming languages, and likewise the more they know about programming ESPRIT from
the interface, the better they will be able to exploit the ESPRIT API. ESPRIT API applications can be small or large in
scale. Sometimes productivity can be gained by just taking a few minutes to write a macro that saves a couple of mouse
clicks each day. In other cases a company might devote weeks or months to the development of automatic add-ins in
order to realize large reductions in part programming time further down the road.
The bottom line is increasing productivity, and the ESPRIT API is a powerful tool that provides tremendous potential.

KnowledgeBase Launchpad, Part 2:
Automation in Action
9 9 How to add automation for each step of the feature recognition/machining process
9 9 How to use more advanced API functionalities for the automation of turning features
9 9 How to use the GetToolByDiameter function to pick a tool from the database based on the Tool Diameter, Tool
Type and Tool ID

Lesson 1: Adding Automation
In this example, we will load a 2D drawing (dwg file) in ESPRIT and, for each step of the recognition/machining process,
we will see how to add automation.
Define the manual process

Before starting with any automation, it’s very important to analyze all the processes the user has to do manually. We will
then treat one by one the process to see how we can improve them.
Step 1: Prepare the document
99 Import the 2D Drawing
99 Define the Machine Setup
Step 2: Create Features
99 Run Hole Feature Recognition
99 Define the Features Depth and other “3D Properties” (counterbore, countersink)
Step 3: Create Operations
99 Define Tools
99 Define Processes
Step 4: Simulation
99 Define the Simulation Stock
When loading the 2D drawing file in ESPRIT, the file is loaded in a blank document (using the default unit and machining
mode). The next step is to define the machine setup based on the machine you will use to machine the document.
392 KnowledgeBase Launchpad, Part 2: Automation in Action

Prepare the Document
You need to identify all the manual steps you have to do for a specific task, then you can analyze them and see how you
want to add automation and if it is actually worth it.
Identify the potential issues
• When dealing with multiple machining modes, you may have to change the current machining mode
• If you are working with multiple system unit (inch and metric) you may have to change the current unit
Identify what has to be done several times
• Every time you are creating a new document, you need to define a machine setup
Building automation with a template
In ESPRIT, there is an easy way to make the document consistent with the system unit and the machining mode using a
template. If you define a template with a predefined unit and machine mode, when merging a CAD file, you will ensure
the consistency of your document.
Note: Make sure you have “Show Template Dialog” checked in the Options Dialog.
The template document can also contain solids, geometry, as well as the machine setup. Therefore if you define your
template with a predefined machine setup, you will not have to do it every time.
Automation does not always require Visual Basic or the KnowledgeBase, sometimes you only need to use all the
functionalities of ESPRIT.

Create Features
Creating the features on a 2D drawing is not straight forward because the Feature Recognition in ESPRIT is made for
solids; however the Hole Feature Recognition is also working on 2D but it will not be able to define the depth of the
feature ptop.
In this document, we are trying to recognize the following holes:
Hole feature recognition on a 2D drawing

When the option “Manual Selection” is unchecked, the Hole Feature Recognition will look at all “Holes” in the
document and recognize them.
The Hole Feature Recognition in ESPRIT will always group the holes by size, and in this file, some holes of different
type (Tapped and Simple Hole) are given the same type.
Since ESPRIT requires one ptop per process, we will have to “manually” separate those ptops.

Automate Hole Feature Recognition with color
Since we do not have any solid model, the Hole Feature Recognition cannot define the depth of the feature
automatically. This has to be done manually.
The goal of any automation is to reduce the number of actions that the user has to do manually.
Based on the previous step, you can see that the major issue is to automate the Hole Feature Recognition. However, in
this file, there is currently no way to distinguish a “simple hole” from a “Tapped Hole”.
When dealing with a 2D drawing file, the “easiest” way is to find a convention between the CAD and the CAM to
characterize the type of the hole. One way of doing it is to get a color convention for each type of hole. For example:
This way, using the API, we will first sort the holes by color and run the Hole Feature Recognition on each group to
extract the ptop. Using this type of automation, we will avoid having to manually recreate the “incorrect” ptops.
The second advantage of this method is, since we are using the API, we will have more control on the created ptop to
add more properties:
• Default depth
• Customized Name for the Ptop, etc…
Creating a VBA application to automate the Hole Feature Recognition
In order to use the API, we will have to use the VBA to create a simple application to reproduce the steps we are
doing manually:
1. Group the holes by color.
2. Run Hole Feature Recognition on the groups.
3. Define the depth of the feature.
4. Change the Name of the ptop according to the feature for a better comprehension.

Hole Feature Recognition — Automation in Action
The first step is to change the color of the holes in the CAD Software according to the color convention, then merge
the file in the created template.
Once you run the created macro, the ptop will be sorted, renamed, assigned a color based on the circle color, and set
to a default depth.
This way, in one click, you will have ptops that will be a lot easier to use for the machining process.
Create Operations
The type of the operation to be applied on the feature depends of the feature type:
• Tapped M Process
⇒⇒ Spot, Drill, Tap
• Tapped Tr Process
⇒⇒ Spot/Drilling/Tap
• Simple Hole Process
⇒⇒ Drilling
For each operation, the user needs to create the proper tool based on the feature diameter and the technology type.
In order to automate your processes, ESPRIT offers you two choices:

1) Save Processes on your local computer
99 Advantage: Consistency,
88 Inconvenient: You cannot use a rule to pick automatically a tool based on the feature from the Cutting Tool
Manager; you need to choose the right process for each feature
2) Save Processes in the KnowledgeBase Manager
99 Advantage: Consistency. The KnowledgeBase will automatically apply the process based on the feature type with
full access to the Cutting Tool Manager from the process.
88 Inconvenient: It is more work to first build the rules in the KnowledgeBase Manager
Because of its flexibility, we will use the KnowledgeBase Manager to build the automation for the processes.
The first step is to create a new Part Type that will contain all our feature types and processes.
When the part type is fully done, every time you have a DWG file you want to automate, you will be able to load and
use the same part type to apply the same processes.
Create a new Part Type

Based on the Hole Feature Recognition macro, we know that the document contains three different feature types
(ptops): Tapped M, Tapped Tr, Simple Hole.
According to the color convention, we can define the following rules:
If the feature is green then it’s a “Simple Hole” feature.
99 “IsFeatureColor(Feature, VbGreen)”
If the feature is red then it’s a “Tapped M” feature.
99 IsFeatureColor(Feature, VbRed)
If the feature is yellow then it’s a “Tapped Tr” feature.
99 IsFeatureColor(Feature, VbYellow)
We need to create three new feature types in the KnowledgeBase.
Then we need to set the properties for each Feature Type to automatically recognize a hole by its color.

For each feature type, we need to create a new process in the KnowledgeBase Manager:
Simulation
In order to simulate the file correctly, the user will have to create a new stock. Currently in this part, the stock will be
defined by the outermost closed boundary.
This process can be automated by running a Feature Recognition on the geometry to extract the largest feature as the
boundary, then using the API to define the stock automatically. Since this function is not that easy to write and this
manipulation has to be done only one time per document, it may not be efficient to spend more time on it.
Using the automation process on a different part

The main goal of the automation is not to automate the process on a part but on a family of parts. Let’s apply out
automation process on a similar part.

Lesson 2: Turning Feature Recognition
The next automation example uses more advanced API functionalities in order to do the automation of the “Turning
Feature Recognition”.
The automation here will cover the Feature Recognition, the Stock Definition and the Processes using the
KnowledgeBase.
Manual Feature Recognition

Usually, when creating a turning program, the easiest way to create the features is to use the Turning Profile function
and, based on the created geometry, make the chain features one by one.
You will now have to select the different portions of the profile you want to turn into features.

Feature Recognition — Unleash the API!
The creation of the features is a very repetitive process and the method of creating the features is always the same:
The macro will analyze the geometry and then split it into six zones to make features out of it.
When the Feature Recognition has found all the features, it will then extract all the remaining undercut features
(grooves).
Feature Recognition — Add Machining Properties

Since the Feature Recognition is done through the API, the macro will add machining properties to each feature based
on the type of the feature:
• Left or Right Side (Sub Spindle or Main Spindle in this machine)
• Type of Work (Face, OD or ID)
• Type of the Profile (Main or Sub)
Since those properties will be added to the feature, the KnowledgeBase will be able to use them to find the right
processes.
The name of the feature will also be changed for a better visibility in the Feature Manager.
The Name of the Feature is preceded by a number that allows the Feature Manager to sort the Feature by “Machining
Priority”.

Set up the automation in the KnowledgeBase Manager
Once the features are created, the next step of the automation is to define all the required components of the
KnowledgeBase:
• Create the Feature Types in the Part/Features/Process Technology Manager
• Define the Tools in the Cutting Tool Manager
• Create the Processes in the Part/Features/Process Technology Manager
Turning Feature Recognition — Automation in Action

Step 1: Run the Turning Feature Recognition on the part using the Macro on the target solid. When the option
“Create Stock” is set to “Yes” the macro will also define a “Bar” Stock in the Machine Setup based on the shape of the
solid.
Step 2: Create the Processes on the Main Spindle: Select the features starting with “Right” from top to bottom (the
order of the selection will be the machining order).

Turning Feature Recognition — Automation in Action (continued)
Step3: The remaining operations will be done on the Sub Spindle; therefore we need to add a part transfer before
creating the Processes on the Sub Spindle.
When the Pickup and Release operations are created, we need to add synchronization between the turrets:
Step 4: Select the remaining feature and apply the process from the KnowledgeBase.

Turning Feature Recognition against the Stock
The Turning Feature Recognition macro has been enhanced in ESPRIT 2009 to support existing stock (all types of
stock). The macro will automatically compare the target to the existing stock to create only the needed feature.
When running the macro, the option “Create Stock” should be turned off since we are using an existing macro.
Turning Feature Recognition on geometry

The Turning Feature Recognition macro has been enhanced in ESPRIT 2009 to support closed profiles that define the
“Target” as input in the case where you do not have a solid for the target.

Lesson 3: Get a Tool from the Cutting Tool
Manager
In ESPRIT 2008, if you wanted to load a tool from the Cutting Tool Manager in a Process Step, you will have only two
choices:
• Call the tool directly from its Name using the function “GetToolByID(“TooID”)”
• Find the tool in the Cutting Tool database using the function GetToolByDiameter()
The GetToolByDiameter function is a generic function that will allow you to pick a tool from the database based on the Tool
Diameter, Tool Type and Tool ID.
This function still exists in ESPRIT 2009, but there are now new functions to load tools from Cutting Tool Manager
specific to each tool type.
GetDrillTool Function
The GetDrillTool function is a KnowledgeBase Function available in the KBMVBModule class that will allow you to select
a Drill tool based on parameters specific to a drill tool.
Visual Basic Definition
Public Function GetDrillTool(LowerToolDiameter As Double, _
Optional UpperToolDiameter As Double = 0, _
Optional sFilter As String = “”, _
Optional MinimumFluteLength As Double = 0, _
Optional MinimumToolLength As Double = 0, _
Optional BottomAngle As Double = -1, _
Optional ToolGroup As String = “”) As String

Input Definition
The function GetDrillTool will automatically find a Drill Tool based on the following specific parameters:
Example: the Cutting Tool Database contains the following drilling tools:
If you want a tool of diameter of 10 (+/-0.2) with a minimum flute length of 65, you will use the following VB Code:
GetDrillTool(9.8, 10.2, “DRILL D%”, 65) will return “DRILL D10.1 F70 TA118 TL70”.
GetThreadMill Tool Function

The GetThreadMillTool function is a KnowledgeBase Function available in the KBMVBModule class that will allow you to
select a Thread tool based on parameters specific to a thread tool.
Visual Basic Definition
Public Function GetThreadMillTool(ToolDiameter As Double, _
Pitch As Double, _
Optional sFilter As String = “”, _
Optional MinimumThreadLength As Double = 0, _
Optional MinimumToolLength As Double = 0, _
Optional TaperAngle As Double = -1, _
Optional ToolGroup As String = “”) As String

Input Definition
The function GetThreadMillTool will automatically find a Thread Tool based on the following specific parameters:
Example: the Cutting Tool Database contains the following thread tools:
If the user wants a Thread Mill with a Diameter of 10 of the type “ THREAD MILL R Dxx” with a pitch of 1 and a flute
length at least 18:
GetThreadMillTool(10, 1, “THREAD MILL D%”, 18) will return “ THREAD MILL D10x1 TH20 TL60 TA0”
Generic GetTool Functions

The new GetTools functions are in the module “KBMUtilities.bas”. All the functions are actually built around a generic
function “SearchToolByConditions” that takes a list of conditions (CLCode, Tool Type, etc…); therefore it will be easy
to build your own GetToolDrill Function for example.
There are three types of conditions: Condition by Range, Exact Condition, and Regular Condition
“Condition by Range”
Example: the Tool Diameter (ClCode 103) needs to be in between two close values:
⇒⇒ Minimum Value ≤ Tool Diameter ≤ Maximum Value
⇒⇒ Tool Diameter ±Value

“Exact Condition”
Example: the Pitch (ClCode 1856) needs to be an exact value:
⇒⇒ Pitch=1.25
“Regular Condition”
Example: the Flute Length must be greater than a value:
⇒⇒ Flute Length ≥ 25
When all the conditions are setup, the last step is to query the tool based on the previous condition to the generic
function SearchToolByConditions.

Cutting Tool Management
During this session, you will see how to use the Cutting Tool Manager and the Feeds and Speed in ESPRIT.

9 9 How to manage your tools in the Cutting Tool Manager
9 9 How to search for a tool in the Cutting Tool Manager
9 9 How to take advantage of the new Tool Manager to manage your tool database
9 9 How to make your own Speed Feeds database
9 9 How ESPRIT computes the Speed Feeds

Cutting Tool Manager
In ESPRIT 2008, the Cutting Tool Manager has been rewritten in the KnowledgeBase. Along with the new interface, the
Cutting Tool Manager has been fully integrated in ESPRIT (access from the operation page, better integration in the Tool
Manager in ESPRIT 2009).
Why use the Cutting Tool Manager?

When creating an operation in ESPRIT you need to have an existing tool in the document. There are multiple ways to get
the tools in ESPRIT:
• Create the tools every time you need one
99 There is no restriction when you create the tool
88 You need to make sure that the created tool does actually exist in your shop
88 No consistency since you may enter a different parameter the next time you will create the “same tool”
• Load the tools an existing library stored on the computer/network
99 Assuming the library is up to date, the tools exist in the shop
99 Consistency, all users are using the same library
88 Managing a “File Library” is not easy: to update a specific tool, the library needs to be loaded in ESPRIT, modified
and resaved. The security of the library (read/write access) has to be done by the operation system; no easy backup
system
• Load the tools from the Cutting Tool Manager (local/remote database)
99 Assuming the database is up to date, the tools exist in the shop
99 Consistency, all users are using the same database
99 The update of the tools in the database is done directly in the Cutting Tool Manager (you do not have to run
ESPRIT)
99 The Security (access), backup of the database is done in the KnowledgeBase Manager
In ESPRIT 2009, you can access the tools from three different places:
• ESPRIT KnowledgeBase Manager
• Tool Manager
• Operation Pages
Cutting Tool Manager in the KnowledgeBase Manager

Since ESPRIT 2008, the KnowledgeBase Manager is an external application made to manage the database. The Cutting
Tool Manager in the KnowledgeBase Manager is the place to manage your tool database. When sharing the database with
other users, only one person at a time should access the KnowledgeBase Manager.
410 Cutting Tool Management

Creating Tool Groups
In the Cutting Tool Manager, you have a way to create groups of tools to allow you to manage your tool library. For
example, you can use the tool groups to sort the tools by Machine Type.
Share a tool across Tool Groups

Since the Cutting Tool Manager is based on a database, you can share a tool across different tool groups. For example,
if you are using a tool group as the machine type, you may have a tool shared by multiple machines.
Set the tool group(s) of a tool

To share a tool with another tool group, select the tool, right-click and select “Add to groups”.
In the dialog “Tool Group Membership” select the other tool group the selected tool will be shared with.

Use the Comment field to get an extra group
The KnowledgeBase does not allow the user to create a new “group” to sort your tools into sub-groups, for example:
The Machine Type can be “represented” by the Tool Group, but the sub-group “Type of Tool” does not exist in the
database.
If you are not using the Comment field, you could use it as a “Custom Sub Group”. You will have to make sure the
strings “Rough Tools” or “Finish Tools” are correctly entered for each tool.
When the Comments are entered correctly, you can use the “Group By” ( ) functionality of the KnowledgeBase
Manager to show the tools sorted by the Machine Type (Tool Group) and Cutting Style (Comment)
Add a tool from the Cutting Tool Manager (in the KnowledgeBase Manager) to ESPRIT
The KnowledgeBase Manager has been “separated from ESPRIT” in ESPRIT 2008, therefore, the Cutting Tool Manager
of the KnowledgeBase Manager does not have the “Add Selected Tools to ESPRIT” button like in ESPRIT 2007 or in
the Cutting Tool Manager of the Tool tab.
However, since the Tool Manager in ESPRIT supports the drag and drop, you can select tools in the Cutting Tool
Manager and drag and drop the selection in the active tool tab.

Searching for tools in the Cutting Tool Manager
When dealing with thousands of tool, the biggest issue you may encounter is to find a tool! The Cutting Tool Manager has
couple functions to narrow the search down.
Let’s try an example: “Find all Ball Mill Tools with a diameter in between 5 and 10 mm, with a flute length that is at least
35 mm”
1 Show all tools in the database

Since the tool group has no unit, we cannot sort the tools by tool group because the statement does not specify the
tool group. Set the Tool Filter to “Any” to show all tools in the Cutting Tool Manager
2 Show only ball mill tools

We are looking for a Ball Mill, so we can define the Tool Style filter to “Ball Mill” in order to see only the Ball Mill
Tools.
3 Narrow the search to a range of tool diameters

Now we will narrow the search by keeping only the tools with a diameter in between 5 and 10 mm using the custom
filter of the Tool Diameter.
In the Custom Dialog, create the tool diameter criteria “5 ≤ Tool Diameter ≤ 10”
4 Filter by flute length

The last condition is to have a flute length greater or equal to 35.
If there are still a lot of tools remaining, use the custom filter on the Flute Length to keep only the valid tool.
Otherwise, just use the sort descending/ascending on the flute length to sort the remaining tools.

If you are looking for multiple tool styles with a condition of Tool Diameter, etc… you cannot filter based on the tool
style like in the previous example. In this case, use group by “Tool Style” to see all the tools (grouped by Tool Style) with
the previous condition:
Note that when the filter is “blue” ( ), a filter is applied on the selection; to “reset” the filter, select all in the filter list.
Accessing the Cutting Tool Manager from the Operation Page

In ESPRIT 2008, all the operation pages have been enhanced to support the loading of a tool directly from the Cutting
Tool Manager without creating the tool in ESPRIT.
When clicking on the button ( ) on the right of the Tool ID, ESPRIT will load a simplified version of the Cutting Tool
Manager of the KnowledgeBase Manager.

Group, Sort, Find Tools
The Cutting Tool Manager of the operation dialog has the same Sorting/Filtering functionality as the one of the
KnowledgeBase Manager (except “Show All Tools”).
Limitations...
This simplified version of the Cutting Tool Manager is made to be a “selection tool” not a manager application; therefore
you will not be able to:
• Add/Remove/Edit Tool Groups
• Add/Remove/Edit Tools
Note: You can also select only one tool at the time.
Accessing the Cutting Tool Manager from the Tool Manager

In ESPRIT 2009, you can access the Cutting Tool Manager at any time from the tool tab from the menu KnowledgeBase/
Cutting Tool Manager.
When loaded, you will have access to the full version of the Cutting Tool Manager but this time, since it’s loaded from
ESPRIT, the Cutting Tool Manager will have the “Add Selected Tools to ESPRIT” functionality available.
Functionalities
This version of the Cutting Tool Manager has all the functionalities of the KnowledgeBase Manager. If you want to add
one or more tools, select the tool in the grid then, click on the button “Add Selected Tools to ESPRIT”.

Managing tools from the Tool Manager
In ESPRIT 2009, the tool manager has been rewritten to have a better integration of the KnowledgeBase in ESPRIT.
KnowledgeBase Status of the tools

In ESPRIT 2008, when a tool was in the document, it was not easy to know whether or not the tool came from the
database or was created in the document.
In ESPRIT 2009, the new tool manager displays the status of the tool within the database using icons in the tool grid:
Note: The status of the tool is not “live”, if a user is adding/removing a tool while working in the current document,
the tool tab will not refresh the status of the tool until you reopen the file or manually refresh the manager.
Delete a tool from the database

When a tool comes from the database, you can delete the tool of the database (if you have the privilege access in the
database) directly from the tool manager without using the Cutting Tool Manager.
Delete a tool association with the database

When a tool comes from the database, you can break the link between the tool and the database: the tool will remain
in the database but the tool in the document will became “unique” to the document; this way when refreshing the tool
from the KnowledgeBase, this tool will remain the same.

Refresh tool(s) from the database
When the tools in the document come from the database, you have a way to synchronize your tools with the database.
From the Tool Manager, you can either refresh all the tools or only the selected tool.
When refreshing a tool from the database, ESPRIT will override the current tool in the document by the one from the
KnowledgeBase.
Update the database with current tool

When refreshing from the database, the tool in the current document will be “replaced” by the one in the database.
However, if you want to update the tool in the database by the one you’ve modified in the document, you need to use
the command “Update Tool In Database”.

Save an ESPRIT tool in the database
If you have created a tool in the document (or just loaded in), the Tool Manager allows you to save the tool(s) directly
into the Cutting Tool Manager without even opening the KnowledgeBase Manager.
When in the “add tool” dialog, you can select the tool group where you want to store your tool, or even create a new
one.
Note: You will notice that after tool is saved in the Cutting Tool Manager, its KnowledgeBase status will be updated (
).
Conflict Management
If you are trying to load or paste a tool that have an existing “Tool ID” or “Database ID” in the document, the Tool
Manager will prompt the user to manage the conflict.
The dialog will be prompt for each tool conflict (unless specify otherwise – see “do this for all conflicts”)
• Replace Tool “Name of the Tool”: the tool in the document will be replaced by the tool you are copying.
• Do Not Replace “Name of the Tool”: no action, it will skip the current tool
• Create a New Tool Renamed “Name of the tool (1)”: the tool will be copied in the tool under a different name.
• Do this for all conflicts options: specify to the Tool Manager to use the selected option for all other conflicts
(only in the current copy action)
• Skip Button: no action, it will skip the current tool
Note: The dialog does not show up when creating a new tool. If the name already exists, it will be named with the
extension (1), (2), etc…

Speed Feeds Manager
Use the Speeds Feeds Manager to define default cutting speeds and feedrates for milling and turning operations based on
any combination of part material, tool material, and type of cut. When an operation is created, ESPRIT will combine the
Speeds Feeds Standard selected in KnowledgeBase Document Settings with the actual tool and technology settings on the
operation page to provide acceptable cutting speeds and feedrates.
Why use the Speed Feeds Manager?

When creating an operation in ESPRIT you need to define speed and feeds. There are multiple ways to define the Speed
and Feeds in ESPRIT:
• Set the Speed Feeds Manually for each operation
99 You will have the full control of the Speed and Feeds values
88 You need to look at the Speed Feeds table of your tool vendor for each operation
88 No consistency since you may enter a different parameter the next time you will define the Speed and Feeds.
• Get the Speed Feeds from the Speed Feeds Manager (local/remote database)
99 Consistency, all users are using the same database
99 Assuming the database is set correctly and up to date, you will reduce the Speed Feeds errors when entering the
values
99 When the setting of the operation is set to “Use Speed Feed KB=Yes”, the computation of the Speed Feed is
automatically done by ESPRIT.
99 The Security (access), backup of the database is done in the KnowledgeBase Manager
88 The database needs to be defined at first.
Speed Feeds Manager in the KnowledgeBase Manager

The Speed Feeds Manager in the KnowledgeBase Manager is the place to manage your Speed Feeds database. When
sharing the database with other users, only one person at the time should access the KnowledgeBase Manager.

Creating a new standard
You can use the existing standard “Cut Data” of ESPRIT, but this is “generic” database with a multiple material,
condition, type of cut and Material condition you may not use.
In order to have an efficient Speed Feeds database, it’s recommended to create your own Cutting Standard with your
own material, type of cut, etc…
Since you can use only one standard per document, if you want to create multiple standards, you have to choose wisely
what you will put in the standard; the easiest way is to have only standard for your company.
Creating materials
The definition of the materials is split in two categories: “Part Material Class” and “Part Material Condition”.
The “Part Material Class” is the name of the Material you are cutting, for example “Steel”.
The “Part Material Condition” corresponds usually to the Hardness of metal, of the way the metal is produced (die
case, wrought, forged, etc…), for example “HRC 20-32”
Note: the fewer combinations between Material Class/Condition you have, the easier it will be to define your database.
When you have no conditions for the material, just enter “None” as a material Condition.
Creating a Type of Cut

The Type of Cut is a designation of the way the tool will cut the material, for example: Side Milling, Slotting, Drilling,
Plunging, threading, etc…for example, Side Milling.
The type of cut is independent from the Material Class; you do not have to define a Type of Cut for each Material
Class/Condition.

Type of Cut in ESPRIT
The Type of Cut is a setting you will have to define often in each document. When using the Speed Feeds Manager in
ESPRIT, you will need to set the Type of Cut on every operation (unless it’s already stored in the default), therefore the
less Type of Cut you have, the easier it will be on the daily basis.
For example, when using the Cut Data database that contains a lot of different Type of Cut, you will have to select the
right type of cut among 20 items.
If you minimize the database to the only Type of Cut you need, the selection (as well as the creation of the Speed
Feeds) will be easier.
Note: the Type of Cut is independent of the type of operation; therefore you may see the type of cut.
Creating tool material

The Tool Material corresponds to the material of the tool such as HSS, Carbide, etc… for example “TiAN Coated”; it
could be also use to define the tool vendor name, for example “KENNAMETAL – TiCN Series”.
The Tool Material is valid only in the selected Standard.
Tool material in the Cutting Tool Manager

When creating a tool in the Cutting Tool Manager, you can specify the Material of the Tool. However, since the Cutting
Tool Manager “does not know” what will be the standard of the document, the Cutting Tool Manager will show the
list of all existing Tool Material across all standards. Therefore, if you define you tool material with a name that already
exists in the database; it will not be easy to select the right material for the tool.

Tool material in ESPRIT
The Tool Material is available in the document from the Tool dialog. ESPRIT will list all the available Tool Materials
of the current standard in the technology page. Since the document allows you to pick only one Standard, it’s very
important to load tools created in the selected standard, if not, ESPRIT will automatically pick the first available Tool
Material in the current standard and you may end up with invalid Speed Feeds.
Note: when the Tool Material is the same Name across multiple Standards, and you did not select the right one in the
Cutting Tool Manager, you may not notice the issue until you get the incorrect feed speed. It’s very important to use
distinguished name for the Tool Material and minimize the number of Standard.
Get the Speed Feeds in the operation page

When the Standard and Tool Material are correct and valid (existing data in the Speed Feeds Manager), you will be able
to get your Speed Feeds directly from the database in the operation dialog.
The Speed Feeds Manager does return only the XY Feedrate value, the Z Feedrate is computed by ESPRIT as a
percentage of the XY Feedrate.
The “Z Feedrate Factor Percent” is per document, it will be applied to all operations within the document. If you
change it afterward, you will have to rebuild the operation in order to recalculate the new Z Feedrate.

Creating Speed Feeds Data
When using the Speed Feeds Manager, after defining the material condition, type of cut and tool material, you will have
to define some Speed Feeds data in order to get Speed Feeds in the operation.
The data need to be defined for each combination of Material/Type of Cut/Tool Material because each combination
may give you a different value.
You can enter as many “Speed Feed” references you want for any unit. The created data will be displayed in a grid
visible based on the Material/Type of Cut/Tool Material combination.
Note: The values are not converted automatically in inch when created in metric and vice versa.
You will need at least one data to get a Speed Feed value and at least two to get an interpolated Speed Feed value
when the Tool Diameter/Cut Depth does not exist in the database.

Speed Feed Calculation in ESPRIT
When the user is calling the Speeds and Feeds calculation from the operation dialog, the calculation will first look at
the tool diameter (Reference diameter in Turning) used for the current operation, then it will compare this value to the
tool diameter in the database (based on the current Standard, Part Material Class and Condition, Type of Cut and Tool
Material). The Speeds and Feeds calculation will follow some rules after the comparison of the two values to return the
right speeds feeds.
The tool diameter is smaller than the smallest tool diameter in the database
The tool diameter is smaller than the smallest tool diameter available in the database for the current filter. The feed
speed calculator will look in the current speed feed data to find the smallest tool diameter.
The tool diameter is smaller than the smallest tool diameter — one match
When looking in the database, the feed speed calculator found only one case that matches this criterion. The feed
speed calculation will return the feed speed data of the smallest tool diameter (with no regard to the cut depth).
The tool diameter is smaller than the smallest tool diameter — multiple matches
When looking in the database, the feed speed calculator found multiple cases that match this criterion.
The feed speed calculation will return the feed speed data of the smallest tool diameter and using the cut depth, it will
return the feed speed data based on the rules:
• Exact match on the Cut depth: the calculation will return the feed speed data of the smallest tool diameter with the
exact match for the cut depth
• The cut depth is smaller than the smallest cut depth in the smallest tool diameter group: the calculation will return
the feed speed data of the smallest tool diameter with the smallest cut depth
• The cut depth is larger than the largest cut depth in the smallest tool diameter group: the calculation will return the
feed speed data of the smallest tool diameter with the largest cut depth
• No exact match on the cut depth but in between the smallest of the largest cut depth in the smallest tool diameter
group: the calculation will return the feed speed data of the smallest tool diameter adjusted with the cut depth
(linear interpolation)

The tool diameter is smaller than the smallest tool diameter — multiple matches

The tool diameter is larger than the largest tool diameter in the database
The tool diameter is larger than the largest tool diameter available in the database for the current filter. The feed speed
will look in the current speed feed data to find the largest tool diameter.
The tool diameter is larger than the largest tool diameter in the database — one match
speed calculation will return the feed speed data of the largest tool diameter (with no regard to the cut depth).
The tool diameter is larger than the largest tool diameter — multiple matches
The feed speed calculation will return the feed speed data of the largest tool diameter and using the cut depth, it will
return the feed speed data based on the rules:
• Exact match on the Cut depth: the calculation will return the feed speed data of the largest tool diameter with the
exact match for the cut depth
• The cut depth is smaller than the smallest cut depth in the largest tool diameter group: the calculation will return the
feed speed data of the largest tool diameter with the smallest cut depth
• The cut depth is larger than the largest cut depth in the largest tool diameter group: the calculation will return the
feed speed data of the largest tool diameter with the largest cut depth
• No exact match on the cut depth but in between the smallest of the largest cut depth in the largest tool diameter
group: the calculation will return the feed speed data of the largest tool diameter adjusted with the cut depth (linear
interpolation)

The tool diameter is larger than the largest tool diameter — multiple matches

The tool diameter is an exact match in the database
The feed speed calculator is able to find a match for the tool diameter in the database for the current filter.
Exact match for the tool diameter — one match

speed calculation will return the feed speed data of the tool diameter (with no regard to the cut depth).
Exact match for the tool diameter — multiple matches

The feed speed calculation will return the feed speed data of the tool diameter and using the cut depth, it will return
the feed speed data based on the rules:
Exact match on the Cut depth: the calculation will return the feed speed data of the tool diameter with the exact
match for the cut depth
The cut depth is smaller than the smallest cut depth in the tool diameter group: the calculation will return the feed
speed data of the tool diameter with the smallest cut depth.
The cut depth is larger than the largest cut depth in the tool diameter group: the calculation will return the feed speed
data of the tool diameter with the largest cut depth
No exact match on the cut depth but in between the smallest of the largest cut depth in the tool diameter group: the
calculation will return the feed speed data of the tool diameter adjusted with the cut depth (linear interpolation).

Exact match for the tool diameter — multiple matches

There is no match in the database
The feed speed calculator cannot find a match for the tool diameter in the database for the current filter AND the tool
diameter is in between the smallest and the largest tool diameter (see chapter 1 or chapter 2 if not).
The feed speed calculator will find the closest lower and upper tool diameter. Then, the feed speed calculator will
return the speed feed data adjusted with the tool diameter between the lower and the upper speed feed data (linear
interpolation).
No match for the tool diameter — one match

When looking in the database, there is only one match for the lower/upper tool diameter. The feed speed calculator
will return the speed feed data of the lower/upper tool diameter for the calculation of the interpolation.
The lower node for the tool diameter 6 is the tool diameter 5.

No match for the tool diameter — multiple matches
When looking in the database, there are multiple matches for the lower/upper tool diameter.
Rule: The feed speed calculator will get the lower/upper tool diameter, and will returns the interpolated feed speed
value of the lower and upper close cut depth for the lower/upper tool diameter.
The upper node for the tool diameter 6 is the tool diameter 10 which contains three speeds feeds data. The upper
close cut depth is 10 and the lower close cut depth is 5. The feed speed calculator will return the adjusted value
between the cut depth 5 and 10 (linear interpolation).

Speed Feed Interpolation — Method
When the lower and upper feed speed data is determined, the feed speed calculator will use the tool diameter to
interpolate the feed speed data (linear interpolation).
Example 1:
The Feed Speed calculator will first get the lower and upper node, and then the interpolation will give 0.068
Example 2:
The Feed Speed calculator will first get the lower and upper node, and then the interpolation will give 0.064

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Conference Proceedings

Welcome to ESPRIT® World Conference 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ESPRIT World Conference 2008 1

— You Will Learn —

ESPRIT World Conference 2008 3

4 ESPRIT For All

ESPRIT World Conference 2008 5

6 ESPRIT For All

ESPRIT World Conference 2008 7

Opening the Reference Files Status dialog File Status

8 ESPRIT For All

Updating a modified file Re-linking to a file that has a newer revision

ESPRIT World Conference 2008 9

Restoring the components of an assembly

10 ESPRIT For All

Associativity and ESPRIT FX™

ESPRIT World Conference 2008 11

12 ESPRIT For All

Modify the original CAD model.

ESPRIT World Conference 2008 13

14 ESPRIT For All

New Machining menu New KnowledgeBase menu

ESPRIT World Conference 2008 15

16 ESPRIT For All

New graphical tabs Setting the General tool parameters

ESPRIT World Conference 2008 17

New Tool Shank page Tool Shank definitions

18 ESPRIT For All

ESPRIT World Conference 2008 19

New SUB-ELEMENTS mode in the Status area Enable SUB-ELEMENTS mode

20 ESPRIT For All

ESPRIT World Conference 2008 21

22 ESPRIT For All

— You Will Learn —

ESPRIT World Conference 2008 23

1 Create the model

24 ESPRIT Mold For All

3 Extract curves from the model to create the stock

ESPRIT World Conference 2008 25

5 Start the stock definition

26 ESPRIT Mold For All

7 View the stock

ESPRIT World Conference 2008 27

9 Import all the tools from a file

28 ESPRIT Mold For All

11 Create the first roughing on the part

ESPRIT World Conference 2008 29

13 View the CPU processing time

30 ESPRIT Mold For All

15 Show the stock during simulation

ESPRIT World Conference 2008 31

17 Calculate the re-machining toolpath

32 ESPRIT Mold For All

19 Create a finishing operation

ESPRIT World Conference 2008 33

21 Define the machining mode

34 ESPRIT Mold For All

23 Calculate the finishing toolpath

ESPRIT World Conference 2008 35

25 End the simulation and return to the graphic environment

36 ESPRIT Mold For All

27 View the NC code

ESPRIT World Conference 2008 37