FeatureCAM 3D Course 2 Days 2019

Automated to make parts
faster
Training Course
Contact UK Support and Training
Contact UK Support and Training
Autodesk UK Customer Support

Tel: 0121 683 1010
Fax: 0121 7665 565
uksupport@autodesk.com
Autodesk UK Training
Tel: 0121 683 1050
Fax: 0121 7665 511
uktraining@autodesk.com
Talbot Way, Small Heath Business Park, Birmingham

B10 0HJ
Autodesk FeatureCAM 2019

© Copyright 2018 Autodesk, Inc. All rights reserved
Lesson Plan 3D Machining
Daily Training schedule
09.00am - Morning session (Times may vary)
10.45am - Morning Coffee Break
12.25pm - Lunch
01.00pm - Afternoon session
02.30pm - Afternoon Break
05.00pm - Finish (4.00pm Friday)
Lesson Plan
FeatureCAM 3D 2-day course
Day 1
Lesson 1 - 3D Roughing Strategies, Z Level, Parallel, Plunge, Vortex. (Trainee exercises)
Lesson 2 - 3D Finishing strategies, Parallel and Corner Finishing - Multi-Pencil. (Trainee exercises)
Lesson 3 - Hairdryer example. (Trainee exercises)
Day 2
Lesson 4 - More 3D Finishing Strategies. (Trainee exercises)
Lesson 5 - 4 axis Rotary example. (Trainee exercises)
Lesson 6 - Further examples to work through. (Trainee exercises)
Questions and Answers

© Copyright 2018 Autodesk, Inc. All rights reserved
Lesson 1 – 3D Roughing Strategies
Lesson 1
3D Roughing Strategies
Overview
One of the first tasks to complete when machining a 3D solid model is the
roughing operation. The following lesson works through these steps. The
strategies covered are: - 3D Roughing Strategies in a single operation. Z
Level, Plunge and Parallel.
Lesson Objectives
• Using the Import Wizard to align part, set Stock and position Setup1.
• Creating a Stock Curve from solid model. Selecting the curve as Stock.
• Surface selection – Part Surface and Check Surface. Select by Colour.
• Machining strategy Options – Offset Spiral, Continuous Spiral, Zigzag,
Vortex.
• Offset Direction – Automatic, In to out, Out to in.
• Classify slices as 3D Pocket or 3D Boss.
• Re-machining options – None, Multiple Tool diameters, Step Cutting.
• Plunge and Parallel 3D Roughing Strategies overview.
Start
• Double click on the FeatureCAM Icon to Start FeatureCAM. Select Milling
Setup > Unit of Measure. Select Millimeter > Initial Stock Dialog, Select
None, Select Create New Document.
• Select File > import and select model, Lesson 1 - 3D Roughing

Strategies Y-BranchDuct.x_t from your instructors preferred location

© Copyright 2018 Autodesk, Inc. All rights reserved 1.1
Select Next 4 times. Set Stock Dimensions to Zero all around and
1mm +Z. Set Datum (Setup1) to the Centre of the job. Then set Z -
1mm. Select No to Is the Part Indexed. Select Finish.
We can assume that the outer profile has been completed in another
operation. We are now going to Rough machine our part using Z Level
Roughing.
Selected surfaces are known as Part Surfaces. The surfaces that are not
selected, are known as check Surfaces. You can use the Select Check
Surfaces dialog to specify areas you do not want to machine. The surfaces we
want to machine are Orange.
• Create a Face Feature to machine the top surface. Then select Home Tab
> Select and Edit Panel > Select > Select by Colour/Type.
Select the Orange colour for our selection.
• Select OK.

1.2 © Copyright 2018 Autodesk, Inc. All rights reserved
• Select Home tab > Part Program Panel > Features > From
Surface > Surface Milling.
• Select Next twice. Select Choose a single operation. Select Next.
• Select Roughing Strategies > Z Level.

• Select Next. Then select 3D Pocket. Select Next.
• Select Next and choose the Shorter 12mm endmill. Select Finish.

Check Surfaces are surfaces we do not want to machine.
• Select Check Surfaces then pick the top 3 surfaces of our model. This will
prevent FeatureCAM from machining these surfaces. Change the Z
Increment to 3mm in Z Level > Rough1 > Milling. Select Set and Apply.
Select Ok to close the menu. Change Finish allowance = 1.25

Simulation options
• Select Home tab > Simulation Panel > Sim Mode > 3D to
simulate the machining processes.
• Then Select the Play icon from the

graphics screen to start the simulation.
• Move the slider Bar to increase or decrease the simulation speed.
The toolpath can be optimised by changing the Retract / Plunge height to

Relative Retract. This will rough machine the selected model as shown.

We have more options available as shown below.
Try using the Continuous spiral and Zigzag options. You will see the
difference in the strategies. Use Centerline Simulation to see the different
results.
• Please select the Remachining tab. Enter a list of roughing tool diameters
separated by commas, to enable multiple Rough passes. Enter 16,8 Select
Z Level > rough1 > Milling > Z Increment = 3 for the 16mm endmill.
• Select Z Level > rough6 > Milling > Z Increment = 1.5 for the 8mm
endmill.
The image on the next page shows the roughing process with a 16mm
endmill and 8mm endmill.

Vortex (Information Only)
Vortex machining is an area clearance strategy that rapidly removes material from a
3D part while controlling tool load. The engagement angle never exceeds, by
more than 15%. This eliminates excessive tool load. This enables you to
increase feed rates. As the tool approaches the maximum engagement angle
changes for optimum machining, the toolpath changes to a trochoidal path
to avoid tool overload. Because FeatureCAM controls the tool engagement,
you can increase the depth of cut, which minimizes machining time. Vortex
machining is frequently used in combination with Step cutting to minimize
terracing while maximizing the metal removal rate. With optimum settings,
Vortex machining greatly reduces machine cycle times.
• Double click the srf_mill1 operation in PartView. Select Z Level. Then

select Vortex. Select Remachining. Enter the following values.

The main slice clears most of the material. The intermediate slices remove
the terraces remaining after the main slice.
Detect material thicker than - Enter a threshold value. FeatureCAM ignores
rest material that is thinner than the specified threshold.
Expand area by - Enter the distance by which to expand the rest areas,
measured along the surface. Use with the Detect material thicker than value
to reduce the areas to be machined to the details and then to offset these
areas slightly to ensure that all the detail is machined.
FeatureCAM will use just one tool for this operation.
• Remember to Unset the Z Increment. Rough1 > Milling.

Plunge Roughing (Information Only)
The tool rapidly removes the material from the part by a series of drilling
operations along parallel lines in the X or Y direction. The distance between
the parallel passes and the shape of the part determines the amount of
material left

1.10 © Copyright 2018 Autodesk, Inc. All rights
reserved
Parallel Roughing (Information Only)
Parallel roughing is like Z Level Zigzag in that the toolpaths are parallel to an
axis, either X, Y or at an arbitrary angle. Unlike Zigzag the user does not
have the option to make a profiling pass at each level. Instead of profile
passes the strategy makes a 3D Parallel semi-finish toolpath over the whole
part to remove the cusps left by the initial roughing operation. Due to the
nature of the toolpath the default tool chosen is a 10mm ball nosed cutter.
This has a Stepover of 10% Direction of cut is in the Y axis. Check surfaces
is enabled.

Lesson 2 – 3D Finishing Strategies
Lesson 2
3D Finishing Strategies
Overview
FeatureCAM has wide variety of Finishing strategies. The strategy that is

chosen will have a considerable influence on the surface finish achieved.
Lesson Objectives
• Apply finishing strategies to complete the part.
• Strategies used are Parallel, Corner Re- Machining 0.35mm finishing
allowance to the original Parallel operation.
• Add Leads to Toolpaths and Relative retract and Plunge.
• Set the Solid model as a part compare target.
• 3D Simulate and Part Compare of the finished part.
Start
We will use the 3D simulation and Save this as a starting point. Rename the
Roughing Strategies using appropriate naming conventions. For example.
• Select Face and Z Level two tool roughing from PartView. Then Run the
3D simulation.
• Then select Home tab > Simulation > Results > Use results as a
starting point.
We will start by finish machining the main apertures using Parallel Finishing.
• FeatureCAM will use the same surfaces selected from the previous Z
Level Roughing operation.

• Unselect the Facing operation from PartView. Then double clicking the z
level two tools operation. Unselect this operation in Process. Then
select Add a new process.
• Select Parallel (Direction) Automatic then select Finish. Double click

Parallel finish and change the tool by selecting Tools. Change the tool to
an 8mm Ballnose tool. Select Milling and change the Stepover to
0.35mm. Select Set and Apply and Ok.
Simulation options
• Then Select the Play

icon from the graphics screen to start the simulation.

We now need to machine the corners from the previous operation. We also
need to let FeatureCAM know that we have used an 8mm Ball Nose tool
to finish the part. FeatureCAM will then know how much material to take
out.
• Add another process and select Corner Remachining. Select Next and
select Along. Then select Remachining and enter 8.00 as the previous
tool and then select Finish.
You may want to change the finishing tool to a 5mm diameter tool to finish
the corners.

Leads
To add a smoother connection between passes, we have an option to add

loops on all Stepovers, plunges and retracts.
• To do this double click on finish under Parallel and select Leads. Change
to the following settings.
Relative Retract and Plunge
To minimise the amount of retracts on our part we can change the Retract
and Plunge values. Select rough or finish and set the following values.

Part Compare
FeatureCAM can check if any material has been left from previous
machining operations. This is called Part Compare.
• Right click on the solid model in PartView. Then select Use solid as a
Part Compare Target.

Simulation options
• Select Home tab > Simulation Panel > Sim Mode > 3D Simulation
to simulate the machining processes.
• Then Select the Play icon

from the graphics screen to start the simulation.
Then select Home tab > Simulation Panel > Show > Part Compare

Lesson 3
Hair Dryer example
• Overview
We have machined a part using some of the 3D roughing and finishing

strategies in the previous example. We will now explore more strategies and
Curve extraction in the following example.
Lesson Objectives
• Open Lesson 3 – Hairdryer example and then create a mirrored copy of the
original.
• Using select by colour for selection to rough and finish machine the Hair
Dryer side1
• Using End to set roughing and finishing final depths.
• Create a Silhouette curve and then Project to UCS. Join curves to create
one curve
• Mirror curve using Reflect.
• Create Setup2 then using the 3D Pocket option to rough and finish side 2
using Z Level Rough and Parallel 3D machining strategies.
• Create a Groove feature from curve to finish side 2 to depth.
Start
• Select File > Open and then Select Lesson – 3 Hairdryer.fm from your
Instructors preferred location.
Please note this is a read-only file so you cannot override the original.
• Select the solid model from PartView.
Autodesk
© Copyright 2018 Autodesk, Inc. All rights reserved 1
• From the Home tab > Select & Edit Panel > Transform.
• Select Reflect and Copy.
We are mirroring about the YZ Plane, X distance is Zero.
• Select Apply and OK to close the menu.
Notice that the models have been saved with different colours that can be
used for selecting surfaces.
• From the Select Menu select the small down arrow and choose
• Select by Color/Type choose the following colour.
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2 © Copyright 2017 Autodesk, Inc. All rights reserved
All the surfaces with that colour will be selected.
Create a new Feature.
Surface > Surface Milling.
• Select Next select Choose a Single operation. Select Next.
• Choose Z Level under Roughing strategies. Keep selecting next until

you get to Tooling. Select a shorter 12mm tool. Select Finish.
• Double click on the new surface milling feature and under rough1 >
Milling change the Z Increment to 2mm. Also, double click on Retract /
Plunge and change this to the following.
This will drastically reduce the amount of retracts for this operation.
• Select OK and then Apply.
Autodesk
Have a look at the machining?
• Select 3D Simulation
The problem we have is that FeatureCAM has completely machined down

to the full material depth. If you were holding this in a vice we would have
machined into the vice.
To prevent this from happening, please complete the following.
Milling Change the Z End to -19.04mm.
Create Parallel machining
• Create a Parallel machining operation with a Stepover of 0.35mm select a 6mm

Ballnose tool. Select process and add a Parallel to the existing Z Level
machining process.
As an exercise on Curve extraction we will now create a curve from the

silhouette of the part. Then project to UCS, and then join the curves.
• Select Construct > Manufacturing > Silhouette Curves.
• Use the default settings. Select Apply.
We now have 4 curves which need to be projected up to the UCS and then
joined together.
• Manually select Curve1 in PartView. Then select Construct tab > Curves
panel > From Curves > Project to UCS
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Repeat for all curves. Then Join the four curves into one curve. If there are
gaps between one curve and another. Create a Line between or use Trim /
Extend to join the curves together.
• Create a Side Feature and select the curve you have just created. Offset
from Curve Z location = -16, Depth = 3, remove the Roughing
Operation. Also, untick Ramp from top. Change the tool to a 6mm
endmill.
Run 3D Simulation to make sure everything is as you expect it to

be.
• Select the joined Curve used in the Side operation. Select Transform
Select Reflect and Copy.
We are mirroring about the YZ Plane, X distance is Zero.
• Select Apply and OK to action the command.
• Select the Side Feature in PartView and Add the new curve. Check Side
Control of the new curve. Change direction so the arrow is pointing on the
outside.
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Machining Side2
We will now create Setup2 to machine the other side of the part.
• Double click on Setup1 and select New.
• Choose Align to stock face.
• Select Bottom and select the Center+ In offset enter -5.000 in Z
We will be using the 5mm left on to hold part in a vice. We will now 3D
Rough the part using Z Level Roughing using 3D Pocket.
From the Select Menu select the small down arrow and choose
Select by Color / Type choose the following colour.
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FeatureCAM has now selected the surfaces as shown above.
• Using Z level roughing and Parallel. Machine the selected surfaces using
3D Pocket.
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• Change the Tool to a short 12mm diameter Ball end.
Milling change the Z Increment to 1mm. Also, double click on Retract /
Plunge and change this to the following.
• Create a Parallel machining operation with a Stepover of 0.35mm use a 6mm

Ball Nose tool.
To keep the material in one piece. Change the Z Start to zero for the Z
Level and Parallel as shown below.
The part is now roughed and finished on both sides. We now need to use a
grooving feature to machine the top face down to depth.
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• Using the two outside curves that we created earlier on Side1. Create a
Groove feature from Curve. Change Offset from curve Z Location as
24.04.
• Depth = 5.00
• Double click on Groove1 and under Slot change the plunge parameters
to the following.
• Change the base priority in Milling to 99. This will then move the groove
operation to the end of the operation list.
We have now completed our second 3D machining exercise.
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Lesson 4 – 3D Strategies Overview
Lesson Objectives
Roughing and Finishing Strategies

Parallel
Z Level Roughing and Finishing
Isoline
2D Spiral
3D Spiral
Radial
Flowline
Between 2 Curves
Specialized Strategies
Horizontal + Vertical
Steep and Shallow
Corner Remachining
Pencil
Vortex Rough with Pre-Drill.
Z Level Rough with Stock model.
Swarf
Start
Topics Covered: - 3D Roughing and Finishing strategies using Lesson - 4

Finishing Strategies Start.fm.

• Select File > Open then select Lesson – 4 Finishing Strategies Start.fm
(Read only) from your instructors preferred location.
Autodesk
• Notice that the key surface machining features are colour coded.
• Hide the Fixture Select PartView > Solids +. Right Click and select Hide
Selected.
• Select Front View .
• Box select the top surfaces. As shown below.
Create a Z Level rouging operation to remove the top material, leaving the
material around our key machining features.
• Select Home tab > Part Program Panel > Features > Surface
Milling > Select Next. Select . Select Next. Select Choose a single
operation Select Next Select Roughing Strategies > Z Level.
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• Select Next. Select Options > Offset / Spiral. Select Classify slices as >
3D Boss.
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• Select Next twice. Select Search for another tool or make a new one.
• Select Next. Choose Tool Group and select Face Mill. Select a 50mm
Facemill from the BT40 – Training Crib Metric, or Training_2018 Crib.
Select Finish.
You may get a warning Bad Surface detected. Just ignore this?
• Select Operations > Z Level > Stock. Change the Overcut to % 99 Select
Apply and Ok to close the menu.
This will prevent the tool from making any unnecessary machining moves
outside the stock.
• From Operations > Rough1 Change Z Increment = 3mm as shown

below.
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• Select Finish Allowance and change this to = 1.25mm Remember to
select Set and Apply to action the change. Then select OK to close the
menu. Then Change the Retract / Plunge settings to reduce rapid moves
to save time. Change as shown below.
Create a Facing operation using Extract with Feature Recognition,
Dimension > Face > Extract with Feature Recognition
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Select the two top surfaces. Choose a 50mm Face Mill. Select Finish.
Select Dimensions and change the Thickness = 1.25. Select Apply and
OK to close the menu.
Change the Base priority for Z Level Roughing = 1
This will rearrange the Z level machining before the facing operation.
Simulation options
simulate
the machining processes.

Select Home tab > Simulation Panel > Results icon. Then select
Save Simulation Results.
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FeatureCAM has now saved the simulation as a.STL file to a known location.
• Select the Eject icon to cancel the simulation.
• Rename the first Z Level roughing operation from srf_mill1 to Z Level

Roughing. Right click on Z Level Roughing in PartView and Right Click
and select Hide Selected.
• Import the.STL file by selecting File > Import. Select Files of type and
select All. Then navigate to the.STL file. Select the file lesson 4 -
finishing strategies start. Stl. Then cancel the Import Wizard.
• Hide the Stl file from PartView. Select Home tab > Select & Edit Panel >
• Select Home tab > Select & Edit panel > Select Please choose
Select by Color / Type then select the light blue colour. Select OK.
Select Home tab > Part Program Panel > Features > Surface
Milling > Select Next. Select . Select Next. Select Choose a

single operation Select Next Select Finishing Strategies > Parallel and
change the settings in Strategy as shown below.
• Select Next. Change the Tool to a long series 8mm diameter Ball End
tool. Create a new one or change an existing tool. Exposed length =
110mm to clear the part. Change the Stepover to 0.5mm.
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Try changing the Parallel angle to see the different results.
• Rename this strategy to Parallel in PartView. Unselect Parallel in

PartView.
Z Level Finishing
This is a good technique for finishing steep walls or when you require a
consistent depth of cut. This can be used for undercuts using a Lollipop style
cutter.
Select Home tab > Select & Edit panel > Select please choose
Select by Color / Type then select the Dark blue colour.
Create a new Surface Milling feature.

single operation. Select Next. Select Finishing Strategies > Z Level
Finishing.
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• Select the options shown below.
• Select Next until you can select search for another tool. Select a 6mm Ball
nose tool. Select Finish.
• From PartView double click on the last machining operation and change
the Z Increment to 0.5mm and you will see the consistent step down on
the part. Change the Toolpath name to Z Level Finishing in PartView.
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Isoline
Advantages - Uniform finish with scallop height control. Disadvantages -

Milling works on a surface-by-surface basis. This can result in numerous
retracts.
Select the first light blue section of the model and choose the two-right
hand top surfaces as shown below.

single operation Select Next Select Finishing Strategies > Isoline.
Select Next until you can search for a tool and select a 6mm ball nose tool.
Select the tool then select Finish.
• Double click on the operation in PartView From PartView select

Operations Isoline > finish1 > Milling > Stepover and change the
Stepover = 0.5mm.
Autodesk
10 © Copyright 2018 Autodesk, Inc. All rights
reserved
You can see that the direction of cut is different for each surface.
Surface - The surfaces are machined in the order listed. Use
the and buttons to rearrange the surfaces in the list. Deselect

the check box next to a surface name to exclude it from the operation.
Start Curve - Isoline surfaces are made up of rows or columns of curves.
The Start Curve determines the first isoline curve used for machining the
surface.
Cut direction - Determines the direction that the tool cuts along the Isoline
curves.
Click Cut direction to change the direction

between increasing and decreasing.
Sequence - Determines the sequence in which the tool cuts the isoline
curves.
Click Sequence to cycle through the toolpath sequence options.
Click Set Isoline row / col to change the starting Isoline curve.
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• Change the Retract / Plunge settings to reduce rapid moves to save time.
Change the Toolpath name to Isoline in PartView.
2D Spiral
This toolpath produces an Offset style toolpath. The pattern has a cut
direction to either Spiral in or Spiral out.
• Select Home tab > Select & Edit panel > Select please choose
Select by Color/Type then select the Yellow colour.
operation Select Next Select Finishing Strategies > 2D Spiral. Select
Next. Choose either Spiral in or Spiral Out.
• Select Next until you can search for a tool and select a 6mm ball nose tool.
Select the tool then select Finish. Double click on the operation in
PartView and change the Stepover. From PartView select Operations
Spiral2d > finish1 > Milling > Stepover = 0.5mm.
• Select and change to the following.
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FeatureCAM will now machine in a single direction which is the preferred
strategy.
You can see from the image above that the toolpath is not consistent as the
side Stepover is greater than the top Stepover. Unlike Z Level that is
consistent.
Rename the Toolpath to 2D Spiral in PartView.
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3D Spiral
This 3D Spiral finishing technique is best suited to machining areas that

need a constant Stepover and works well on near-horizontal surfaces.
• Select Home tab > Select & Edit panel > Select Menu please
choose Select by Color / Type then select the Brown colour. The
image below shows the surfaces selected. Selection is Red.

single operation Select Next Select Finishing Strategies > 3D Spiral.
Choose the following options.
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• Choose an 8mm Ball Nose tool with an exposed length of 65mm and a
cutter length of 45mm. The Stepover is set to 1.25mm to show the spiral
effect of the toolpath.
• Change the Stepover to a smaller amount for example 0.35mm and look at
the results.
Rename the Toolpath to 3D Spiral in PartView.
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Radial
This strategy creates a radial pattern within a boundary and projects this
onto the model. The centre of the radial pattern is calculated automatically
unless you set a Centre point. This is then used as the centre of the radial
pattern.
• Select Home tab > Select & Edit panel > Select please choose
Select by Color / Type then select the Pink colour. The image
below shows the surfaces selected.

single operation Select Next Select Finishing Strategies > Radial.
• Accept all the defaults and select Finish. From PartView double click on
the Radial machining operation you have just created. Then select Milling.
• Select Center Point and use the Cursor Icon and snap to the centre
of the Feature.
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5.00 degrees 0.5 degrees
The images above show Stepover angles. The image on the right shows a
Loop Stepover.
Information on Lead types can be found by clicking on the following icon.

The current setting is shown below for the right-hand image.
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Flowline
This technique projects the isolines from one surface onto the surfaces of the
feature. The isolines are projected in the direction of the surface normal. To
project the isolines onto a surface we must create a surface first. The
following exercise will guide you through this process.
With Snap to Cylinder active draw a line from 2 points

working from top to bottom selecting the top two points at the centre of the
Brown feature.
Select the Shade surfaces Icon to un-shade the solid model.

Select the Line you have just created.
You will see at the bottom of the screen an option to Edit selected geometry
in text boxes.
• Select Length and change this to 50mm with an angle of -90. Hide all
existing features and Stock. Select Front View (Ctrl+2).
• Draw a Circle. Select Construct tab > Geometry Panel > Circle Center,
Radius
• 25mm and snap this to the bottom of the line. Select Offset then
offset the existing line 25mm to the right side.
• Extend the original line so it touches the bottom of the circle. Use Trim /
Extend and remove any unwanted geometry so it looks like the

following.
Before After
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• Create a curve working from top to bottom. Use Pick Pieces for
Open curves
• Select the curve you have just created and Transform this in Z
+30mm.
• Select Hide All Geometry by selecting and then draw another line
from the original two points at the top of the feature.
Select the Curve you have just created and select Construct tab >
Surfaces panel > From Curves > Revolve .
Create a Surface of Revolution. Use Custom Line, End Angle = 360.

For Axis use the small geometry line we created earlier.
• Select Apply and OK to close the menu.
Autodesk
Select Home tab > Select & Edit panel > Select please choose
Select by Color/Type then select the Brown colour.

single operation Select Next Select Finishing Strategies > Flowline.
Select Finish to accept the defaults. Rename srf_mill1 to Flowline.
Double click on Flowline and select the following menu.
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• Select the surface you have just created using the Pick Surface
icon. Select Apply and Ok to close the menu.
As an exercise compare this toolpath with 3D Spiral.
Between 2 Curves
This calculates toolpaths that are bounded by two curves. This finishing
operation is used to control the shape of the toolpath over multiple surfaces
by restricting the machining of the surface to be between the two specified
curves. Create two separate curves from the top edges of the light green
feature.
• Select Construct tab > Curves panel > From Surfaces > Surface Edges
from the pop down menu.
• From this menu select the pick edges icon pick the right-hand side
edge once, the curve has been created. Repeat for the left-hand edge.
You must select the edge in small increments to achieve the same result.
If reduction smoothing is ticked, this will

result in a smoother curve and produce a more accurate toolpath.
Once you have created both curves select the surfaces that are light green
using the selection method.
Autodesk

single operation Select Next Select Finishing Strategies > Between 2
Curves.
• Select Next until you get to Start Curve and End Curve. Select the two
curves created earlier. Select Finish.
• Change the tool to a 6mm Ball end tool.
You will see that you get one lead-in/out which results in a very efficient
toolpath.
• Rename the Toolpath to Between 2 Curves in PartView.
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Horizontal + Vertical + Steep & Shallow
This strategy combines two different toolpath operations, one for finishing
shallow portions of the part and one for finishing the steep regions. An X
parallel or spiral toolpath is applied to the shallow regions, and a Z level
finishing operation cuts the steep regions.
The last feature on our solid model has open features where potentially the
tool could enter if we chose a 3D machining strategy. We will go through
methods to patch the known areas to stop this from happening.
Create two separate curves from the top edges of each hole feature.
• Select Construct tab > Curves panel > From Surfaces > Surface Edges
from the pop down menu.
• From this menu select the pick edges icon pick each edge until, the
curve has been created. Repeat for the other hole.
• Select Construct tab > Surfaces panel > From Curves > Cap
Pick each curve.
• Box select all the surfaces shown above, except the Blue surfaces you
have just created.
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operation Select Next Select Finishing Strategies > Horizontal +
Vertical select finish to accept the default settings.
• Double click the new surface operation in PartView. Select Dimension.
• Then select Check Surfaces Select the following surfaces.
This will prevent the selected surfaces from being machined as shown below.
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This strategy combines two different toolpath strategies. A spiral or X
parallel toolpath is applied to the Horizontal regions, and a Z level finishing
operation cuts the Vertical regions.
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Steep and Shallow
Steep and Shallow toolpaths are like Horizontal + Vertical. Add another
process to Horizontal + Vertical and see the difference between the two
strategies.
• Rename the last strategy to horizontal + Vertical + steep & shallow.
Strategies covered
This concludes the use of this solid model. Save the file. Create a new
document.
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Corner Remachining

Import Model.
Select File > Import Select Lesson 4 – Rocket Section – Corner Re-
Machining.x_t from your instructors preferred location.
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• For this exercise select the following options.
• Select Next and change the following values for Step 1
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• Select Finish.
• Double click srf_mill1 in PartView.
• Select Check surfaces and select all the surfaces not used for machining as shown
below.
• Change the Z Level Z Increment to 4mm
• Change horizontal + Vertical Stepover to 0.5mm
Simulation options
• Select Home tab > Simulation Panel > Sim Mode > 3D
• Then Select the Play icon from the graphics screen to start the simulation.
The last tool used to machine the part was an 8mm Ball Nose tool. We are
now going to use the Remachining option – Combo Along and Across.
Autodesk
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• Double click srf_mill1 in PartView. Then select Process.
• Select Add new operation. select Corner Remachining.
• Select Combo Along and Across.

• Then Select the Remachining Tab enter the diameter
of the tool that you used last for machining.
FeatureCAM will now machine all the material left by the 8mm tool with a
smaller tool.
Autodesk
Pencil
Pencil milling is used to clean up corners or fillets of a part. Pencil milling

operations automatically detect corners less than or equal to the specified
radius (including sharp corners) and then create a single toolpath to clean
out these corners.
• Using the same example. Double click srf_mill1 from PartView.
• Select Process Then Unselect Remachining.
• Select Add new operation.
• Then select Pencil.
Corner Remachining is used to automatically mill regions that were not cut
by previous operations.
• From the Remachining Tab change the previous cutter value to 8mm.
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• Select Apply to action the new settings. Unselect the previous operations
in Process.
• Run Centerline Simulation for Pencil only and see the results.
This concludes the use of this part. Save the file and create a new Mill
Setup document.
Autodesk
Vortex Rough with Pre-Drill
Vortex machining is an area clearance strategy that rapidly removes material from a
3D part while controlling tool load. Vortex is best suited to solid carbide tools. In
most cases Vortex, will use the full flute length of the cutter.

Import Model.
• Select File > Import Select Lesson 4 - Swarf.x_t
• Align the larger left - hand edge to the X axis by selecting two points.
Then rotate the X direction 270 degrees. Or three button presses of the
Rotate x direction 90 degrees around Z axis.
• Use the Compute stock size from the size of the part. Allow 5mm all
around and 1mm on top or +Z.
• Move the Setup to the Centre and then move the Z -1mm so the G54 is on
top of the part. Select Finish to complete the Wizard.
We are now going to Z Level rough using Vortex. Because we are using
such a large Step down using Vortex. The top of the part will not be roughed
out.
We will then create a Stock model from the Z Level Vortex roughing
process. Then use the stock model to efficiently remove the material from
the top of the job. This will minimise any fresh air cuts.
Autodesk
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Milling > Select Next. Group select all surfaces. Select . Select
Next. Select Choose a single operation. Select Next. Select Roughing
Strategies and Z Level. Select Next. Select Vortex with 3D Boss. Select
Next. Select a 20mm endmill with a cutter length of 61mm. Select
Finish.
• Double click on the srf_mill1 in PartView. Under Z Level select the Non-
Cutting Moves. Change this to Automatic and
select increase feed rate for non-cutting moves to 2000 MMPM. Select OK.
• Then select rough1 > Milling change the Z increment to 70mm. Select
Leads and then select Plunge to pre-drill location and change the drill
diameter to 25mm. Select Apply.
The 20mm endmill will then enter at the same point as the pre-drill. We also
need to restrict the depth as we may be holding the part in a vice.
• Change the Z End = -55. Then change Leave allowance = 2mm. Then
Select Finish.
Simulation options

Because we have such a large step down the top of the part has not been
roughed out. We need to capture the 3D Simulation results and create a
Stock model that can be used in another Z Level roughing strategy.
• With the 3D Simulation, still active on the screen, select the Results icon
then select Save Simulation results FeatureCAM will open a menu

Save STL
Autodesk
• Save the STL file in your instructors preferred location.
• Rename the srf_mill1 to Z Level Rough in PartView.
• Import the Lesson 4 – Swarf.Stl file. Then cancel the wizard.
• Hide Stock1, Hide Z Level Rough Feature, Hide Stl model.
Create a new 3D Machining operation. To rough out the remaining material

on the ends.
Milling > Select Next. Group select all surfaces. Select . Select
Next. Select Choose a single operation. Select Next. Select Roughing
Strategies and Z Level. Select Next. Select Offset / Spiral with 3D Boss.
Select Next. Select a 20mm endmill with a cutter length of 61mm. Select
Finish.
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Edit this operation.
• Select Z Level > Stock. Then select Use Solid model and select lesson
4 – Swarf.stl
• Then select rough1 > Milling. Change Z End = -17 and change Z
Increment = 2mm. Change the Finish Axial Allowance = 2 and Finish
Allowance = 2
• Unselect the first Z Level roughing operation.
• Select Stock1 in PartView and select User-Defined and Stock Solid

select the Lesson 4 – Swarf.Stl. Select Ok and Apply.
• Select Home tab > Simulation Panel > Sim Mode > 3D
• To Simulate the machining processes.
• Select the Play icon from

the graphics screen to start the simulation.
• Cancel the 3D Simulation. Rename operation to z level roughing op-2.

Then Hide the Feature. Unselect in PartView.
Autodesk
Swarf
Swarf cutting calculates toolpaths that cut with the side of the tool. This
works only on developable surfaces because the tool must be in contact with
the surface for the whole cutting depth.
Milling. Select Next.
Select all vertical faces on the inside.
• Select Next. Select the key to input the selected surfaces. Select
Next.
• Select Choose a Single Operation. Select Next. Select Swarf. Select

Next. Choose a 16mm R5 tool or make a new one. Select Finish.
• Double click on the Swarf machining strategy in PartView and select

finish1 > Milling. Change the Leave axial allowance = 0.1 Change
Direction to Unidirectional.
• Select Multiple cuts (Multicut Strategies) and change the Z increment to

10mm. Select Set and Apply.Then select the Leads tab and select the
following.
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• Select Home tab > Simulation Panel > Sim Mode > Centerline
• To Simulate the machining processes.
• Select the Play icon from

the graphics screen to start the simulation.
Please note that Swarf will not apply Cutter Compensation to the machining
process.
• Rename the Strategy to Swarf in PartView.
We will now machine the large centre pocket using Z Level finishing. Create a
new Surface Milling operation. Select the bottom large pocket and the side 5mm radius
all around.
Milling. Select Next. Select the following surfaces.
Autodesk
• Select the key to input the selected surfaces. Select Next.
• Select Choose a Single Operation. Select Next. Select Finishing
Strategies > Z Level. Select Next. Then set the following.
• Select Next until you can search for another tool. Choose a 16mm R5 tool
or make a new one. Select Finish.
• From Dimension > Check Surfaces. Select Show All and select these surfaces.
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• Select finish1 > Milling and change the Z Increment = 4mm. Select Set
and Apply and OK to close the menu.
Machine the remaining smaller inside pockets using Spiral 2D. Use the same
tool 16mm R5 and Stepover and Leadin/Out.
• Create a 2.5d Side Feature to finish the outside profile.
The only face left is the top face which can be machined using the Between
2 curves Strategy. Have a go at creating two curves for the top edge and
then create the machining strategy Between 2 curves to finish the part.
You can use an Endmill to machine the top surface. FeatureCAM will allow for
the leading and trailing edges of the Endmill on the surface.
Autodesk
Summary
Lessons Completed
Roughing and Finishing Strategies
Parallel
Z Level Roughing and Finishing
Isoline
2D Spiral
3D Spiral
Radial
Flowline
Between 2 Curves
Horizontal + Vertical
Steep and Shallow
Corner Remachining
Pencil
Vortex Rough with Pre-Drill.
Z Level Rough with Stock model.
Swarf
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Lesson 5 – 4 Axis Rotary
Lesson 5
4 Axis Rotary Overview
Lesson Objectives
Machining a 4 Axis Rotary part.
Start
• Select File > Import then select Lesson 5 – 4 Axis Rotary. X_t from your
instructors preferred location.
• Select Next until you get to the Stock Type. Select Round and X axis.
• Select Next until you get to Stock Dimensions. Use Compute Stock
from the size of the part. Enter zero for Front, Back, OD.
• Select Next and then select the Right Hand, hand to set the Setup on the
right-hand side.
• Select Next and select 4 axis Positioning and select Index around the
Stock X Axis. Select Finish.
That is, it the setup and alignment is now complete. We are now ready to
machine our part.

Machining 4 Axis Rotary.

• Group select the solid model to select all surfaces.
• Create a new Surface Milling Feature.
• Select Next and select Choose a Single Operation. Select Next.
• Select Next and pick Four Axis Rotary as the toolpath type.
• When you get to the cutter type pick a short 10mm Ball nose tool. Select
Finish.
• Adjust the Leave Allowance to 2.5mm as there is no roughing operation

for this strategy. Leave the Stepover at 1.25mm
• Select Finish1 > Milling change the Index Start Coordinate to 5mm
• Then change the Index End Coordinate to -80mm
The image shows the 3D Simulation of the roughed-out part.

• Cancel the 3D Simulation.
• From PartView Copy and Paste the original srf_mill1 machining strategy.
• Edit the copy and change the leave allowance to Zero and the Step over to
0.35mm. Change the Index End Coordinate to -100
• Run 3D Simulation to see the results.
• Save the file to a known location.

Lesson 6 – Further examples to work through
Lesson 6
Further examples to work through
Overview
Have a go at machining the following examples.
Lesson Objectives
• Work through the following examples
Start
• Select File > Import then select Lesson 6 - Formed Case Liner-
Tool.SLDPRT from your instructors preferred location.
Use the Wizard to align the part and then have a go at machining the model.
Remember to move Setup1 to part centre.
A suggestion for machining this part would be to use Z Level Roughing.

Then Steep and Shallow to finish. Use check surfaces for the top flat
faces. Part surfaces for everything else.


• Select File > Import select Lesson 6 - Primary_Case side 1.x_t from
your instructors preferred location.
Your part should be orientated as shown below.
Machine this part using Z level roughing, 3D Spiral to finish. Pencil

machining to machine residual stock.
• Save your file. Create a new Mill Setup part document.
• Select File > Open and select Lesson 6 - Primary_Case side 2.fm
Your part should be orientated as shown below.


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Contact UK Support and Training

Autodesk UK Customer Support

Fax: 0121 7665 565

Fax: 0121 7665 511

Talbot Way, Small Heath Business Park, Birmingham

Autodesk FeatureCAM 2019

Daily Training schedule

09.00am - Morning session (Times may vary)

10.45am - Morning Coffee Break

01.00pm - Afternoon session

02.30pm - Afternoon Break

05.00pm - Finish (4.00pm Friday)

Lesson 3 - Hairdryer example. (Trainee exercises)

Lesson 5 - 4 axis Rotary example. (Trainee exercises)

Lesson 6 - Further examples to work through. (Trainee exercises)

Questions and Answers

Autodesk FeatureCAM 2019

• Select File > import and select model, Lesson 1 - 3D Roughing

Autodesk FeatureCAM 2019

Select the Orange colour for our selection.

Autodesk FeatureCAM 2019

• Select Next twice. Select Choose a single operation. Select Next.

• Select Roughing Strategies > Z Level.

Autodesk FeatureCAM 2019

• Select Next. Then select 3D Pocket. Select Next.

Autodesk FeatureCAM 2019

Check Surfaces are surfaces we do not want to machine.

Autodesk FeatureCAM 2019

• Then Select the Play icon from the

• Move the slider Bar to increase or decrease the simulation speed.

The toolpath can be optimised by changing the Retract / Plunge height to

Autodesk FeatureCAM 2019

We have more options available as shown below.

Autodesk FeatureCAM 2019

Vortex (Information Only)

• Double click the srf_mill1 operation in PartView. Select Z Level. Then

Autodesk FeatureCAM 2019

FeatureCAM will use just one tool for this operation.

• Remember to Unset the Z Increment. Rough1 > Milling.

Autodesk FeatureCAM 2019

Plunge Roughing (Information Only)

Autodesk FeatureCAM 2019

Parallel Roughing (Information Only)

Autodesk FeatureCAM 2019

FeatureCAM has wide variety of Finishing strategies. The strategy that is

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select Add a new process.

• Select Parallel (Direction) Automatic then select Finish. Double click

• Then Select the Play

Autodesk FeatureCAM 2019

Autodesk FeatureCAM 2019

To add a smoother connection between passes, we have an option to add

Relative Retract and Plunge

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machining operations. This is called Part Compare.

Autodesk FeatureCAM 2019

to simulate the machining processes.

• Then Select the Play icon

• Move the slider Bar to increase or decrease the simulation speed.

Autodesk FeatureCAM 2019

We have machined a part using some of the 3D roughing and finishing

• Select the solid model from PartView.