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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Alphacam
Supported Operating Systems

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

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

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

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

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

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

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

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

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

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

This setting only affects non-final passes; when checked, a radius is introduced into sharp tool path
corners. This is the default.
This will lower machine stresses, reduce tool path length, maintain tool speed and reduced cycle time.
It will, however, generate more NC code. When unchecked, all tool path corners have an angle from
the profile, however sharp.
Figure 15 - High Speed cornering on Figure 16 - High Speed cornering off
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3D Machining
Take Account Previous Machining

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

When checked, the tool will use the assigned feedrate in the cycle when moving down in the Z axis
during the cycle. This is a safe option when the amount of stock material is unknown. When
unchecked, the tool will rapid to the safe distance above the area to be machined then feed into
position.
Avoid Rollover
Check this to eliminate the tool roll-round on the outer corners of open pocket geometry where
damage may occur to delicate materials. This is mainly for use with wireframe and prismatic type solid
geometry.
Figure 25 - Avoid Rollover inactive Figure 26 - ; Avoid Rollover Active
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3D Machining
#1 Z Contour Roughing Example

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

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

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

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

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

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

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

; Associate for auto-update used for subsequent operations to reduce machining of areas already
worked on in previous operations.
Allows you to apply a BMP, JPG or PNG file to the simulation process
to visualise the actual material being cut.
Select Texture
Note that this may slow down simulations on very complex parts as
the image is mapped to the resultant shape.
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3D Machining
Figure 28 - Handrail prior to adding material stock
Figure 29 - Handrail with stock material applied
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3D Machining
First stage Roughing

Select tool
Select MACHINE > Select Tool
Figure 30 - Z Contour Roughing Tool selection
Select the Flat-25mm with holder
Select MACHINE > 3D Machining
Select the Z Contour Rouging

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

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

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

To make the drawing clearer to work on, from the Layers page of the Project Manager,
un-tick Toolpaths and in the User Layers section, Materials.
Figure 38 - Turn off Toolpaths and Material
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3D Machining
Create the Side Work Plane
Select WORK PLANES > Slice Through Work Volume

When prompted, <LClick> on the dotted line of the Work volume running along the X axis to create the new
Work Plane.
Figure 39 - Correct line for the creation of the front side Work Plane
Create the second roughing tool path
Select MACHINE > 3D Machining

Select the Z Contour Rouging option from the first on screen dialogue option.
As we are working on a different plane than Flat Land, this warning will appear.
Figure 40 - Warning dialogue shown when not working on Flat-Land
<LClick> [OK] to continue.
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3D Machining
General
Figure 41 - Z Contour Roughing Auto-update material option active
Change the option on the General tab to ~ Auto Update material from previous operations.
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3D Machining
Levels and Cuts
Figure 42 - Alter the Lower Z Limit for the second face
On the Levels and Cuts tab, adjust the Lower Z Limit to -75.
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3D Machining
All the remaining tabs are unaltered so <LClick> [OK] to complete, then <LClick> on the Handrail Solid Model
as the item to machine to create the tool paths.
Once the tool path has been generated, run the Solid Simulation to observe how the tool path has
disregarded the previously machined area and only worked on the sections that remain.
Figure 43 - Simulated side machining highlighting only the areas machined
This method can be applied many times over on the same part depending on the nature of the Roughing that
is required.
More Work Planes would need to be created on the reverse face and possibly the ends and across an angle to
fully complete the rough machining of this part.
Prismatic Geometry note second stage

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

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

In the HOME > Configure > General dialogue box is the ability to turn on ; Use Background Processing
for 3D Machining when working with 3D machining cycles. This functionality permits the use of unused
processor capacity in your pc to be applied to the complex calculations required when creating and editing 3D
machining cycles.
Figure 44 - Where to set the Background processing option
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3D Machining
During the calculation period, the operation that is being worked on will display the “Processing” tag to
indicate that it is being worked on.
Figure 45 - Tool paths showing the Processing marker
More than one item can be processed at a time and you can also Abort the calculations by <RClick> on the
operation and choosing the only option from the pop up menu, if you feel that you have made an error or
wish to adjust any settings.
Figure 46 - <RClick> menu for a Processing tool path
Allowing Background Processing frees up the waiting time that you would have had to leave Alphacam
alone, so that you can continue to add further operations or geometry items.
3D Machining 33

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ALPHACAM 2020

Windows is a trademark of Microsoft Corporation.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

#12 ~ Pencil Tracing ............................................................................................................... 181

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FIGURE 52 - LEAD IN/OUT LINKS EXPLANATION 37

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

FIGURE 158 - PARALLEL CYCLE SET TO UP MILL 109

FIGURE 211 - RADIAL GENERATED DECORATIVE TOOLPATH 145

FIGURE 264 - REST MACHINING TOOL DATA TAB 180

FIGURE 317 - LEAD IN/OUT LINKS EXPLANATION 217

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

FIGURE 423 - CONSTANT CUSP EXAMPLE FILE 287

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

Conventions used in this manual

Denotes a <LClick> or Primary Mouse Button Click.

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

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

This is a highlighted note to emphasise information

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

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

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

x The order is not important.

Recommended Operating Systems and Hardware for

Supported Operating Systems

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

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

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

The adjustment is only made to XY feeds; it is not applied to any Z feeds.