3

Table of Contents

MACHINE OVERVIEW............................................................................................... 3
CURVE 5 AXIS........................................................................................................... 5
OUTPUT FORMAT ....................................................................................................... 5
3 axis output format ............................................................................................. 6
4 axis output format ........................................................................................... 10
5 axis Output format .......................................................................................... 15
CURVE TYPE............................................................................................................ 19
TOOL AXIS CONTROL ................................................................................................ 35
Lines.................................................................................................................. 35
lines Rel to dir .................................................................................................... 41
Plane ................................................................................................................. 49
From point ......................................................................................................... 55
To point.............................................................................................................. 60
PROJECTION ........................................................................................................... 67
FILTER ENTRY EXIT............................................................................................... 73
DRILL 5 AXIS........................................................................................................... 79
OPTPUT FORMAT..................................................................................................... 79
Output format 3 axis .......................................................................................... 79
Output format 5 axis .......................................................................................... 83
ENTITY TYPE ........................................................................................................... 89
TOOL AXIS CONTROL ................................................................................................ 95
Plane ................................................................................................................. 95
TIP CONTROL......................................................................................................... 101
Orginal Point .................................................................................................... 101
SWARF 5 AXIS ...................................................................................................... 105
OUTPUT FORMAT................................................................................................... 105
Output format 4 axis ..................................................................................... 105
Output format 5 axis ..................................................................................... 109
WALLS.................................................................................................................. 115
TIP CONTROL......................................................................................................... 123
FLOW 5 AXIS......................................................................................................... 129
C-HOOKS............................................................................................................... 139
ROLLDIE ............................................................................................................... 139
CONTAIN 5 AXIS ..................................................................................................... 157
FOCUS.................................................................................................................. 167
Focus4xb. Dll ................................................................................................... 167
Focus5ax. Dll ................................................................................................... 177



4

3
Machine overview

Concept: 5 axis machining is becoming more common. It saves time and money by
not requiring multiple set-ups and allows machining in areas where conventional
machining can not access. There are two types 5 axis machining, simultaneous and
positioning. Simultaneous 5 axis machining uses all 5 axis at the same time. This
includes Curve 5 axis, Swarf 5 axis, and Flowline 5 axis. Aerospace and mold and
die industries use 4 and 5 axis Swarf machining to remove material requiring
undercut tool motion. Curve 5 axis applications include laser machining to trim the
excess material of stamped parts. Five axis positioning, sometimes referred to as 2 +
3, indexes to desired tool plane and then outputs 3 axis tool motion. This includes
Drill 5 axis and any other tool paths that requires a 2 axis rotation to position a new
tool plane.

Programming: The position of the part on a 5 axis milling machine is crucial for a
correct tool path. There are many variations in 5 axis machine designs and in these
examples, A axis is a rotary head mounted in X and B rotates the spindle around Y.
You must know where the machines center of rotation for each axis is. Once the Y
and Z axis .000 positions are known, these values will always be used in setting up a
part. Y and Z .000 are at the A axis center of rotation. You also need to know where
B axis rotation is relative to the A axis. Tool length vectors and 5 axis cutter comp are
calculated from the difference of the rotation length and actual tool length.




5

Curve 5 axis
Output format

Filename: Output Format.MC8
Review selection parameters for Output Format: 3axis, 4axis, 5axis


Toolpath/ Multiaxis/ Curve 5 axis/

The following parameters screen is displayed

6


3 axis output format

3 axis Output Format: Outputs 3 axis code. Tool follows the curve at contact point.
Surface(s) compensation and Bull, Ball, and Spherical tools are supported.

Output format: 3 axis The Tool Axis Control options will be grayed out

Curve Type: 3D curves. When selecting this button ( 3D Curves), the chain
boundaries menu is displayed. Chain the green contour in a CW direction. Multiple
contours can be selected.

Tip Control: Comp to surfaces Select the red spherical surface

Projection: Normal to Plane

After selecting O.K., you are prompted to select the Tool Axis Control surface. Select
the spherical red surface.


7

Tool Parameters

Select a 1.000 flat endmill


Multiaxis Parameters

8
Clearance: 4.0 incremental
Retract: 0.25 incremental
Feed Plane: .1 incremental

Tip comp: Tip
Stock to leave: 0.0

No Filter or Entry/ Exit


Curve5ax Parameters

Tool Control
Offset: None
Tool vector length: 1.0
Curve Following Method: Chord height 0.001 Maximum step 0.1
Gouge Processing: Look Ahead 100
Minimize corners in toolpath ON
Gap Settings: use default settings

9


Backplot the toolpath. The tool maintains contact with the surface while following the
3D contour. 3axis NC code is generated



10
4 axis output format

4 axis Output format: Locks an axis to output 4 axis code. Set the axis to rotate
about in the parameters pages.

Filename: Output format.MC8

Toolpaths/ Multi axis/ Curve5ax



Output format: 4 axis Tool axis points through drive curve

Curve Type: 3 D Curves Chain the green 3D contour CW direction

Tool Axis Control: Surface Select the red spherical surface

Tip Control: Comp to surface Select the red spherical surface

Projection: Normal to Plane


11

Tool Parameters

Select a 1.000 bullnose endmill with a .125 corner radius


Multi Axis Parameters

Clearance: 4.0 incremental
Retract: 0.25 incremental

12
Feed Plane: .1 incremental

Tip comp: Tip
Stock to leave: 0.0

4
th
Axis: X Axis This is the axis the part will rotate around

No Filter or Entry/ Exit


Curve 5 axis parameters

Tool Control
Offset: None
Tool vector length: 1.0
Curve Following Method: Chord height 0.001 Maximum step 0.1
Gouge Processing: Look Ahead 100
Minimize corners in toolpath ON
Gap Settings: use default settings

13


Backplot the toolpath. Tool axis vectors rotate around the specified X axis only. 4 axis
NC code is generated. The tool axis points through the drive curve, and comps to the
surface, if the option is used.



To calculate the tool position along the locked axis when using Comp to surface and
a Vector Depth:
1.) The tool axis is projected through the 3D curve as defined by Tool Axis
Control (surface). This determines the vertical retract position (2). The contact
point between tool and surface is calculated (3). From this point, vector depth
(-.500) is applied (4).

14


15
5 axis Output format

Filename: Output format.MC8

Toolpaths/ Multi axis/ Curve5ax



Output format: 5 axis

Curve Type: 3D Curves Chain the green 3D contour in CW direction

Tool Axis Control Surface Select the red spherical surface
Tip Control: Comp to surface Select the red spherical surface

Projection: Normal to Plane

16

Tool Parameters

Select the .500 chamfer mill from the tool library


Multiaxis Parameters

Clearance: 4.0 incremental

17
Retract: 0.25 incremental
Feed Plane: .1 incremental

Tip comp: Tip
Stock to leave: 0.0

No Filter or Entry/ Exit


Curve 5 ax Parameters

Tool Control
Offset: None
Vector depth -.1
Tool vector length: 1.0
Curve Following Method: Chord height 0.001 Maximum step 0.1
Gouge Processing: Look Ahead 100
Minimize corners in toolpath ON
Gap Settings: use default settings


18


Backplot the generated toolpath. The tool axis vectors stay normal to the surface
along the contour. 5 axis NC code is generated



19
Curve type

Filename: Curve Type 3D example.MC8

Review selection parameters for: Curve Type: 3D
Tool axis control: Surface
Tip Control: On projected curve
Projection: Normal to Plane



Toolpaths/ Multiaxis/ Curve5ax



20
Output Format: 5 Axis

Curve Type: 3D Curves Uses chains as curves for the curve 5-axis toolpath. Chain
Blue circle

Tool Axis Control: Surfaces Determines the tool axis direction by staying normal to
a selected surface. Choose the Surface button to return to the graphics window and
select a surface.
All / Surfaces/ Done

Tip Control: On Projected curve Compensates the tip of the tool to the selected 3D
curves or surface edges as they are projected onto a surface. Only available if a
surface is used for tool axis control.

Projection: Normal to Plane Projects the curves normal to the current tool plane.
Only available for 4-axis or 5-axis output when 3D curves are selected and a surface
is used for tool axis control.


Tool Parameters

Select a .250 diameter spherical endmill


21

Multiaxis Parameters

Clearance 4.0 incremental
Retract: OFF
Feed Plane: .10 incremental

Tip Comp: Tip

Stock to leave on drive surfaces: 0.0

No Filter and Entry/ Exit


22

Curve 5 axis Parameters

Tool Control
Offset: None
Vector depth: -.125
Tool vector length: 1.0
Curve Following Method: Chord height 0.001 Maximum step 0.1
Gouge Processing; Look Ahead 100
Minimize corners in toolpath ON
Gap Settings use default settings



Backplot the toolpath. The tool will follow the 3D curve and stay normal to the surface


23


24
Filename: Curve Type Surface Edge One.MC8
Review selection parameters for Curve Type: Surface edge, One



Multiaxis/ Curve5ax / Toolpaths



Output Format: 5 Axis

Curve Type: Surface Edge, One
Select the Surface Edge button to choose the surface to extract the edge curves from
as indicated below. Position the arrow on desired edge and cut direction when
prompted.


25


Tool Axis Control: Surfaces Surface is grayed out which does not allow the
reselection of other surfaces for Tool Axis Control. The Surface Edge option
generates surface curves on the edges. These edge curves have the surface normal
information for Tool Axis Control. The other (4) Tool Axis Control options are
available.

Tip Control: Comp to surfaces Offsets the tip of the tool to the selected 3D curves
or surface edges as they are projected onto multiple surfaces.
Select the surface used to extract the edge curve.

Projection: Unavailable


Tool Parameters



26
Select a .125 diameter flat endmill


Multiaxis Parameters

Clearance: 4.0 incremental
Retract: .25 incremental
Feed Plane: .10 incremental

Tip comp: Tip
Stock to leave: 0.0

Filter and Entry/ Exit options OFF


27

Curve5ax Parameters

Tool Control
Offset: Left
Radial offset: .0625
Vector depth: -.05
Tool vector length: 1.0
Curve Following Method: Chord height .001 Maximum step 0.10
Gouge Processing: Infinite look ahead
Minimize corners in toolpath ON
Gap Settings: use default settings




28
Backplot. The toolpath follows the surface edges and the tool axis maintains
perpendicularity to the surface(s).



29
Filename: Curve Type Surface Edge All.MC8
Review selection parameters for Curve Type: Surface edge, All



Note: Surfaces generated from cross sections such as Revolved and Coons have a
seam. This toolpath will drive along the seam and the perimeter.



Multiaxis/ Curve5ax / Toolpaths


30


Output Format: 5 Axis

Curve Type: Surface Edge, All
Select the surface to extract the edge curves from. Position the arrow on the desired
edge to start on and specify the Curve 5-axis direction.

Tool Axis Control: Surfaces Surface is grayed out which does not allow the
reselection of other surfaces for Tool Axis Control. The Surface Edge option
generates surface curves on the edges. These edge curves have the surface normal
information for Tool Axis Control. The other (4) Tool Axis Control options are
available.

Tip Control: Comp to Surfaces

Projection: Not available


31

Tool Parameters

Select a .250 diameter flat endmill


Multiaxis Parameters

Clearance: 4.0 incremental
Retract: .25 incremental

32
Feed Plane: .10 incremental

Tip comp: Tip
Stock to leave: 0.0

Filter and Entry/ Exit options OFF


Curve 5 axis Parameters

Tool Control
Offset: Left
Radial offset: .125
Vector depth: -.05
Tool vector length: 1.0
Curve Following Method: Chord height .001 Maximum step 0.10
Gouge Processing: Infinite look ahead 100
Minimize corners in toolpath ON
Gap Settings: use default settings

33


Backplot




35
Tool axis control
Lines

Filename: Tool Axis Control lines.MC8
Review selection parameters for Tool axis control: Lines
Lines are used to define tool axis orientation. The tool axis will interpolate
between defined lines along a 3D curve or surface edge.



Toolpaths/ Multiaxis/ Curve5ax


36


37
Output Format: 5 Axis

Curve Type: 3D Curves ( Chain/ Options/ Color Mask ) Chain the red curve at the
base of boss



Tool Axis Control: Lines Sets specific direction for the tool axis along the toolpath.
Rel to Dir N : Sets how the tool transitions between
selected line positions in the curve 5-axis toolpath. If set
to N (No), makes a straight transition between tool axis
directions. If set to Y (Yes), changes the tool axis along
the toolpath relative to the toolpath direction.

Select green lines. Order does not matter but vector direction does. All line vectors
must be pointing toward the tool holder.


38


Tip Control: Comp to Surfaces/ Solids/ Faces Y, Solids N



Projection: Unavailable



39

Tool Parameters

Select a .500 diameter spherical endmill. The part has .25 radii around the boss and
flange.


Multiaxis parameters

40
Clearance : 4.0 incremental
Retract : .25 incremental
Feed Plane : 10 incremental

Tip Comp : Tip

Stock to leave on drive surfaces: 0.0

No Filter or Entry/ Exit


Curve5ax Parameters

Tool Control
Offset: Left
Radial offset: .25
Tool vector length: 1.0
Curve Following Method: Chord height 0.001 Maximum step 0.1
Gouge Processing; Look Ahead 100
Minimize corners in toolpath ON
Gap Settings use default settings


41


Backplot toolpath: The tool axis vector transitions between defined lines.


lines Rel to dir

Filename: Tool Axis Control lines Rel to Dir.MC8

42
Review selection parameters for Tool axis control: Lines/ Relative to direction
N/Y
Lines are used to define tool axis orientation. The tool axis will interpolate
between defined lines along a 3D curve or surface edge. Rel to dir N/Y will
determine how the interpolation of tool axis vectors are handled between lines
along the drive curve.



Toolpaths/ Multiaxis/ Curve5ax



Output Format: 5 Axis

Curve Type: 3D Curves CW Chain the bottom red curve

43



Tool Axis Control: Lines Sets specific direction for the tool axis along the toolpath.
You can control the type of transition between the selected directions (Rel to dir).
Choose the Lines button to return to the graphics window
Select the blue lines. Order does not matter. All line vectors must be pointing toward
the tool holder.
Rel to dir is set to N Relative to direction set to N will interpolate tool axis
vectors in a more direct transition between the lines



Tip Control: On selected curve

44

Projection: Unavailable


Tool Parameters

Select a .2500 diameter spherical endmill.



45
Multiaxis parameters

Clearance 4.0 incremental
Retract: .25 incremental
Feed Plane: .10 incremental

Tip Comp: Tip

Stock to leave on drive surfaces: 0.0

No Filter or Entry/ Exit


Curve5ax Parameters

Tool Control

Offset: None
Radial offset: 0.0
Tool vector length: 2.5
Curve Following Method: Chord height 0.001 Maximum step 0.1
Gouge Processing; Look Ahead 100
Minimize corners in toolpath ON
Gap Settings use default settings


46


Backplot toolpath: The tool axis vector transitions between defined lines in a direct
path.


Notice tool axis, especially through the corners. The tool vectors motion resembles a
swept surface using the bottom radius as the across contour and the two tangent
lines as along contours


47


Change the REL to DIR parameter to Y. This will change the tool axis interpolation
along the drive curve relative to drive direction.
Operations Manager/ Geometry/ Lines



Regenerate and backplot
This will output toolpath vectors similar to a swept surface using the lines as acoss
contours and the bottom curve as the along curve


48


49
REL to DIR Y


REL to DIR N


Plane

Filename: Tool Axis Control Plane.MC8
Review selection parameters for Tool axis control: Plane

50
Tip Control: Comp to surfaces
A plane is used to define tool axis orientation. The tool axis will remain
perpendicular to the plane along a 3D curve or surface edge. This is similar to
a 3D contour toolpath using tool planes but has the ability to compensate the
tip to surfaces or solid faces.



Toolpaths/ Multiaxis/ Curve5ax



Output Format: 5 Axis

Curve Type: 3D Curves Chain blue 3D curve


51


Tool Axis Control: Plane Keeps the tool axis constant to a selected plane. Choose
the Plane button to return to the graphics window and select a plane using the Define
Plane menu.
Plane/ Entity/ Select a line representing the X axis, then Y axis. Flip plane,
if necessary, so that the plane normal is pointing toward the tool holder.

Tip Control: Comp to Surfaces/ All/ Surfaces/ Done

Offsets the tip of the tool to the selected 3D curves or surface edges as they are
projected onto multiple surfaces. Only available if a surface is used for tool axis
control. Choose the Comp to Surfaces button to select the compensation surfaces in
the graphics window.


52


Select a .250 diameter flat endmill


Multiaxis Parameters

Clearance 4.0 incremental
Retract: .25 incremental
Feed Plane: .10 incremental

53

Tip Comp: Tip

Stock to leave on drive surfaces: 0.0

No Filter or Entry/ Exit

Curve 5 axis Parameters

Tool Control

Offset: Right
Radial offset .125
Tool vector length: 1.0
Curve Following Method: Chord height 0.001 Maximum step 0.1
Gouge Processing; Look Ahead 100
Minimize corners in toolpath ON
Gap Settings use default settings


54


Backplot the toolpath. The tools axis will be perpendicular to the defined plane while
following the 3D curve. Cutter compensation is applied to the right and tip control is
based on the surfaces.



%%
N100 G25A3.1831
N102 G90 G17
N104 T1 M6

55
N106 G141 S2139 M03 R
N108 G35
N110 G00 G90 X-2.3305 Y.3199 A-1.3294 B79.1372 R
N112 Z11.8826 R
N114 G01 X-1.1997 Z5.9901 F6.42
N116 G00 X-.4459 Z2.0618
N118 G01 X-.4271 Z1.9636
N120 X-.4025 Y.3125 Z1.954
N122 X-.3294 Y.3156 Z1.9171
N124 X-.2592 Y.3143 Z1.8793
N126 X-.1923 Y.3089 Z1.8406
N128 X-.13 Y.2996 Z1.8025
N130 X-.0715 Y.2863 Z1.765
N132 X-.017 Y.2693 Z1.7277
N134 X.0332 Y.2489 Z1.6921
N136 X.0789 Y.2253 Z1.6585
N138 X.1216 Y.198 Z1.6259
N140 X.1612 Y.1673 Z1.5944
N142 X.3826 Y.1485 Z1.3407








From point

Filename: Tool Axis Control From Point.MC8
Review selection parameters for Tool axis control: From Point
Tool Axis vectors will be generated through a point
Tip Control: Comp to surfaces


56


Toolpaths/ Multiaxis/ Curve5ax



Output Format: 5 Axis

Curve Type: 3D Curves Chain the Blue 3D contour


57


Tool Axis Control: From Point Select the point above the geometry

Tip Control: Comp to surfaces / All/ Surfaces/ Done

Tool Parameters

Select a .500 diameter spherical endmill

58

Multiaxis Parameters

Clearance 6.0 incremental
Retract: 5.0 incremental
Feed Plane: .10 incremental

Tip Comp: Tip

Stock to leave on drive surfaces: 0.0

No Filter No Entry/Exit


59

Curve 5 axis Parameters

Tool Control

Offset : None
Vector depth : -.05
Tool vector length : 10.0
Curve Following Method: : Chord height 0.05 Maximum step 0.1
Gouge Processing; : Look Ahead 100
Minimize corners in toolpath : ON
Gap Settings : use default settings




60
Backplot the toolpath. Tool axis is contained through a point. Tip control is based on
selected curves.



To point

Filename: Tool Axis Control To Point.MC8
Review selection parameters for Tool axis control: ToPoint
Aims a tool axis vector to a selected point


61


Toolpaths/ Multiaxis/ Curve5ax



Output Format: 5 Axis

Curve Type: 3D Curves Chain green contour around bottom of geometry


62


Tool Axis Control: To Point Aims the tool axis direction to a selected point. Choose
the To Point button to return to the graphics window and select a point
Select the point below the geometry

Tip Control: On Selected Curve


Tool Parameters

Select a .125 diameter spherical endmill


63

Multiaxis Parameters

Clearance 4.0 incremental
Retract: .25 incremental
Feed Plane: .10 incremental

Tip Comp: Tip

Stock to leave on drive surfaces: 0.0

No Filter or Entry/ Exit


64
Curve 5 axis Parameters

Tool Control
Offset: Left
Radial offset .0625
Vector depth -.0625
Tool vector length: 1.0
Curve Following Method: Chord height 0.001 Maximum step 0.1
Gouge Processing; Look Ahead 100
Minimize corners in toolpath ON
Gap Settings use default settings


Backplot the toolpath. All tool axis vectors terminate to a single point


65







67
Projection

Filename: Projection normal to surface.MC8
Review selection parameters for Projection: Normal to surface
When possible, for faster projection calculations, project the curve onto the surface
before entering toolpath parameters and use Projection method Normal to Plane.
Use Normal to surface when projecting on vertical walls.



Toolpaths/ Multiaxis/ Curve5ax



68
Output Format: 5 Axis

Curve Type: 3D Curves Chain contour around the middle of part

Tool Axis Control: Surface Select all surfaces

Tip Control: On Projected Curve Select all surfaces

Projection: Normal to surface. Max distance 0.1 Projects the curves normal to the
tool axis control surface. Only available for 4-axis or 5-axis output when 3D curves
are selected and a surface is used for tool axis control.


Tool Parameters

Select a .500 bullnose endmill


69

Multiaxis Parameters

Clearance 6.0 incremental
Retract: OFF
Feed Plane: .10 incremental

Tip Comp: Tip

Stock to leave on drive surfaces: 0.0

No Filter and Entry/ Exit

70

Curve 5 axis Parameters

Tool Control
Offset: None
Vector depth 0.0
Tool vector length: 1.0
Curve Following Method: Chord height 0.05 Maximum step 0.1
Gouge Processing; Infinite look Ahead
Minimize corners in toolpath OFF
Gap Settings use default settings



Backplot the toolpath. The contour is projected Normal Surface


71






73
Filter entry exit

Filename: Filter.MC8
Backplot the unfiltered toolpath



From the Operations Manager, select the Parameters icon
Under Multiaxis Parameters, select Filter.

Filter: Eliminates unnecessary tool moves in the toolpath to create smoother
movement.

Tolerance: When a distance between a point in the toolpath and the new line
or arc is less than or equal to the tolerance, Mastercam automatically
eliminates the tool move from the toolpath. Mastercam continuously eliminates
moves until the entire toolpath lies within the maximum tolerance.

Look Ahead: Mastercam looks at this number of points at a time to filter.
Ranges from 1 to 100. 100 works well in most cases. Decreasing the number
of points from the default of 100 may increase the filter speed but reduce
optimization.

Input the values below.

Regenerate and backplot the toolpath.


74




Filtered toolpath Tolerance .001

Entry/ Exit: Sets the tool motion at the beginning and end of the multiaxis toolpath.
Not available for rotary 4-axis or flowline 5-axis toolpaths. Use ENTRY5AX.DLL
c-hook

Get Entry Exit.MC8 and backplot the toolpath


75


Toolpath without entry exit vector. Starts and ends on wall and on bottom plane or
surface

From the Operations Manager, select the Parameters icon
Under Multiaxis Parameters, select Enty Exit and input the values below.



76
Approach / Retract height: Begins the entry curve at an additional height above the
part to avoid gouging. Completes the exit curve at an additional height above the part
to avoid gouging.

Entry Curve/ Exit Curve: Creates an entry arc on every pass with the tool held at
the necessary orientation for the first cut. Creates an exit arc on every pass with the
tool held at the necessary orientation for the last cut.

Length: Sets the span of the entry curve along the wall in the direction the
tool travels

Thickness: Sets the dimension of the entry curve away from the wall.

Height: Sets the dimension of the entry curve away from the floor measured
along the tool vector.

Direction

Left Places the entry curve to the left along the direction of the toolpath
Right Places the entry curve to the right along the direction of the toolpath
Pivot angle Pivots the entry curve.

Curve tolerance Control the difference between a theoretical curve and its linear
approximation. A lower tolerance produces a more exact entry or exit curve, but may
result in larger NC files and longer processing times.


77


Regenerate and backplot the toolpath. Starts and ends away from walls and
bottom plane or surfaces


78



79
Drill 5 axis
Optput Format
Output format 3 axis

Filename: Drill Output format.MC8
Review selection parameters for Output Format: 3 axis



Toolpaths/ Multiaxis/ Drill 5-axis


80


Output Format: 3 axis Limits the tool positions to a single vector (direction). If
selected, you can only select points as geometry, using a surface for tool axis control
is not available, and projected points cannot be used for tip control.

Entity Type: Points Drills selected points. Choose the Points button to return to the
graphics window and select points for the toolpath using the Drill Point Manager
menu.
Window in the green points

Tool Axis Control: Parallel to Line Positions the tool axis parallel to a single
selected line. Choose the Parallel to Line button to return to the graphics window and
select a line.
Select the red line. Set vector towards the tool holder




81
Tip Control: Surface Comp Offsets the tip of the tool to the selected points as they
are projected onto multiple surfaces. In this case, parallel to a line. Choose the
Surface Comp button to select the compensation surfaces in the graphics window.

Select the outside surface.


Tool Parameters

Select a .0625 drill


82

Drill Parameters

Clearance 1.0 incremental
Retract: .25 incremental
Top of stock 0.0 incremental
Depth: -0.1 incremental

Tip Comp: OFF

Cycle: Peck drill

Backplot the toolpath. A 3 axis toopath is generated by creating a drill vector through
each point along the parallel line selected. The toolpath vector is then modified so
that the tip control is at the surface.


83







Output format 5 axis

Filename: Output format 5axis.MC8
Review selection parameters for Output format: 5 axis


84


Toolpaths/ Multiaxis/ Drill 5-axis



Output Format: 5 axis Provides 2 degrees of freedom for tool vectors in any
direction.

Entity Type: Points Drills selected points. Choose the Points button to return to the
graphics window and select points for the toolpath using the Drill Point Manager
menu.
Window in the red points.


85
NOTE: The points were projected to the surface prior to selecting. Using Projected
point from Tip Control would project the points to the closest surface vector (
horizontally)

Tool Axis Control: Surface Tool axis will be normal to the surface through each
point. Select the bold dark red surface



Tip Control: Projected point Offsets the tip of the tool using the projected point on
the surface as the reference point. Not available for 3-axis output.



86
Tool Parameters

Select a .020 drill


Drill Parameters

Clearance 2.0 incremental
Retract: .50 incremental
Top of stock: 0.0 incremental
Depth -0.1 incremental

Tip Comp: OFF

Cycle: Peck drill

Backplot the toolpath. A 5axis toolpath is generated from the surface normal through
each point


87




89
Entity type

Filename: Entity type Points/ lines.MC8
Review selection parameters for Entity type: Points/ lines



Toolpaths/ Multiaxis/ Drill 5-axis



Output Format: 5 axis

Entity Type: Points/ Lines Drills holes using a reference point at the endpoint of a
line. The line determines the tool direction. Choose the Points/Lines button to return

90
to the graphics window and select points and attached lines. If selected, tool axis
control is not available and projected points cannot be used for tip control.
Window in the red points.

Tool Axis Control: Not available

Tip Control: Surface Comp Select the conical surface


Tool Parameters


91


Select a .025 drill


Drill Parameters

Clearance 4.0 incremental
Retract: 1.0 incremental
Top of stock: 0.0 incremental

92
Depth 0.0 incremental

Tip Comp: OFF

Cycle: Peck drill

Backplot the toolpath. 5axis toolpath vectors are generated based on the line through
a point. Tip control is comped to the cone surface


Tip Control Surface Comp Tip Control Surface Comp
Depth = .000 incremental Depth = .000 incremental
No tip comp Tip comp ON / Breakthrough amount
.000

The depth is output to the tip The depth is output to the tip
But calculated as if the tip were Calculated from shoulder
the full diameter contact point


93



95
Tool axis control

Plane

Filename: Tool axis control Plane.MC8
Review selection parameters for tool axis control: Plane



Toolpaths/ Multiaxis/ Drill 5-axis




96
Output Format: 5 axis

Entity Type: Points Window in the (4) blue points.

Tool Axis Control: Plane Determines the position of the tool axis by projecting
points perpendicular to a plane. Choose the Plane button to return to the graphics
window and select a plane using the Define Plane menu.
Plane/ Entity/ Solid Face/ Select the face as defined below / set Direction so
that the plane vector points toward the tool holder.



Tip Control: Surface Original Point


97

Tool Parameters

Select a .125 drill


Drill Parameters

Clearance 4.0 incremental

98
Retract: 1.0 incremental
Top of stock: 0.0 incremental
Depth 0.0 incremental

Tip Comp: ON Breakthrough amount 0.00

Cycle: Peck drill

99
Backplot the toolpath. 5axis toolpath vectors are generated based on the selected
plane.




101
Tip control

Orginal Point

Filename: Tip control Original point.MC8
Review selection parameters for tip control: Original point



Toolpaths/ Multiaxis/ Drill 5-axis



102

Output Format: 5 axis

Entity Type: Points / Lines Window in the red points.

Tool Axis Control: Unavailable
Tip Control: Original Point


Tool Parameters

Select a .500 flat endmill


103

Drill Parameters
Clearance 0.75 incremental
Retract: 0.25 incremental
Top of stock: 0.0 incremental
Depth -0.1 incremental

Tip Comp: OFF

Cycle: Peck drill

Backplot the toolpath. The original point is used for Tip Control.


104



105
Swarf 5 axis
Output Format

Output format 4 axis

Filename: Swarf output format 4 axis.MC8
Review selection parameters for Output Format: 4 axis



Toolpaths/ Multiaxis/ Swarf 5-axis



Output Format: 4 axis Creates tool vectors parallel to a plane that is perpendicular
to the 4th (rotary) axis. You can select the X or Y axis as the 4th axis.

106

Walls: Surfaces Select All/ Color/ 12 / Done Select the first surface as shown below
and drag the start vector arrow to the bottom of the surface. Toggle the direction to
climb mill

Tool Axis Control: No Fanning

Tip Control: Surfaces Select All/ Color/ 3 / Done





107
Tool Parameters

Select a 1.000 bullnose cutter with a .25 radius

Multiaxis Parameters

Clearance 2.0 incremental
Retract: .25 incremental
Feed plane .10 incremental
Compensation in computer: Left
Tip Comp: Tip
Stock to leave on drive surfaces: 0.0

4
th
Axis: X axis Sets which axis is used as the 4
th
axis to rotate the part around.
Only available for 4-axis output from curve 5-axis, swarf 5-axis, and rotary 4-axis
toolpaths.



108
Entry/ Exit

Swarf 5axis parameters

Wall Passes
Number of Passes: 1
Stock to Leave on Walls: 0.0
Floor Passes
Number of Passes: 1
Retract Between Passes: Off
Wall Following Method
Chord Height: .001 Maximum Step: 0.1
Floor Gouge Processing
Look Ahead: 100
Minimize Corners in Toolpath: On
Fanning Feedrate: 0.0
Tool Vector Length: 1.0

Backplot the toolpath. A 4axis toolpath is generated along the walls and tangent to
the floor surface. Notice how the start of the toolpath is at the midpoint of the first
surface selected.

109

Output format 5 axis

Filename: Swarf output format 5 axis.MC8
Review selection parameters for Output Format: 5 axis



Toolpaths/ Multiaxis/ Swarf 5-axis

110



Output Format: 5 axis Provides 2 degrees of freedom for tool vectors in any
direction.

Walls: Surfaces
All / Color / 10
Fanning: Fan Distance .375 Determines the minimum distance that the tool travels
between the corner position and a position where the tool sits perpendicular to the
floor. A larger fan distance creates a wider fan.

Tool Axis Control: Plane Uses a plane for the toolpath floor and to position the
contact point of the tool. Choose the Plane button to return to the graphics window
and select a plane for the floor using the Define Plane menu.
Select Z = constant/ Enter Z when prompted for Enter z-coordinate of plane
and select an endpoint on the bottom surface (1.4517)


111

Tool Parameters

Select a .250 spherical endmill

Multiaxis Parameters

Clearance 2.0 incremental
Retract: .25 incremental
Feed plane .10 incremental

112

Compensation in computer: Left

Tip Comp: Tip

Stock to leave on drive surfaces: 0.0

Filter: Tolerance .001, Look ahead 100



Entry/ Exit:
Approach height: 2.0 Retract height: 2.0
Entry Curve: Exit Curve:
Length: .5 Length: .5
Thickness: .25 Thickness: .25
Height: .25 Height .25
Direction: Left Direction: Left
Pivot angle: 0.0 Pivot angle: 0.0




113

Swarf 5axis parameters

Wall Passes
Number of Passes: 1
Stock to Leave on Walls: 0.0
Floor Passes
Number of Passes: 1
Retract Between Passes: Off
Wall Following Method
Chord Height: .001 Maximum Step: 0.1
Floor Gouge Processing
Look Ahead: 100
Minimize Corners in Toolpath: ON
Fanning Feedrate: 0.0
Tool Vector Length: 1.0

Backplot the toolpath. A 5 axis toolpath is generated along the walls and tangent to
the floor surface.


114




115
Walls

Filename: Swarf 5 axis walls chains.MC8
Review selection parameters for wall selection using chains



This is a typical pocket of an aircraft part. It was converted from CATIA and the
surfaces do not form nice flat, uniform, rows or upper and lower edges. This may
cause problems when selecting surfaces for walls.


By creating a line and projecting it onto the surface walls, the projected curves can be
use to define the upper and lower rails of the surfaces.

116


Project these lines onto the surface walls.
From the Front Cplane, Create/ Curve/ Project/ All/ Surfaces/ Done
Select the (2) lines just created as projection curves
Done/ Options
Decrease the Step Method Chord height to .0001
Make sure Join Results is not active


Do it




117
The defining chains for the walls have been created, the part is ready to be
programmed.

Toolpaths/ Multiaxis/ Swarf 5-axis



Output Format: 5 axis Provides 2 degrees of freedom for tool vectors in any
direction.

Walls: Chains / Sync by entity/



Select the bottom then the upper chain



Choose a CCW direction to climb mill


118
Fanning: OFF

Tool Axis Control: Surfaces All / Color / 117


Tool Parameters

Select a .500 bullnose with a .125 radius

119

Multiaxis Parameters

Clearance 2.0 incremental
Retract: .25 incremental
Feed plane .10 incremental

Compensation in computer: Left

Tip Comp: Tip

Stock to leave on drive surfaces: 0.0

Filter: Tolerance .001, Look ahead 100



Entry/ Exit:
Approach height: 2.0 Retract height: 2.0
Entry Curve: Exit Curve:

120
Length: .5 Length: .5
Thickness: .25 Thickness: .25
Height: .25 Height .25
Direction: Left Direction: Left
Pivot angle: 0.0 Pivot angle: 0.0




Swarf 5axis parameters

Wall Passes
Number of Passes: 1
Stock to Leave on Walls: 0.0
Floor Passes

121
Number of Passes: 1
Retract Between Passes: Off
Wall Following Method
Chord Height: .001 Maximum Step: 0.1
Floor Gouge Processing
Look Ahead: 100
Minimize Corners in Toolpath: ON
Fanning Feedrate: 0.0
Tool Vector Length: 1.0

Backplot the toolpath. A 5 axis toolpath is generated along the walls and tangent to
the floor surface.



123
Tip control

Filename: Swarf tip control lower rail.MC8
Review selection parameters for tip control: lower rail



A 5 axis toolpath needs to be generated around the outside of this part. The part is
too large for the machine so the surface is split in half and will be done in two setups.

The first surface to be machined can be displayed by:
Alt-E (hide) / Group / swarf wall 1



Toolpaths/ Multiaxis/ Swarf 5-axis


124


Output Format: 5 axis

Walls: Chains/ Sync by entity Define the lower contour. Set direction to climb mill
Define the upper contour. Set direction to climb mill
Tool Axis Control: No Fanning

Tip Control: Lower Rail -0.1 Positions the center of the tool at the lower rail of the
toolpath. The lower rail is the lowest surface edge if you selected surfaces for the
walls. This option can be used if the part does not have a floor.


Tool Parameters


125
Select a .750 diameter flat endmill


Multiaxis Parameters

Clearance 2.0 incremental
Retract: .25 incremental
Feed plane .10 incremental
Compensation in computer: Left
Tip Comp: Tip
Stock to leave on drive surfaces: 0.0
Filter: ON
Tolerance: .002
Look ahead: 100




126


Entry/ Exit:
Approach height: 3.0 Retract height: 3.0
Entry Curve: Exit Curve:
Length: .4 Length: .4
Thickness: .4 Thickness: .4
Height: .0 Height .4
Direction: Left Direction: Left
Pivot angle: 0.0 Pivot angle: 0.0


Swarf 5axis parameters

127
Wall Passes
Number of Passes: 2
Step over: .015
Stock to Leave on Walls: 0.0
Floor Passes
Number of Passes: 1
Retract Between Passes: ON
Wall Following Method
Chord Height: .001 Maximum Step: 0.1
Floor Gouge Processing
Look Ahead: 100
Minimize Corners in Toolpath: ON
Fanning Feedrate: 0.0
Tool Vector Length: 1.0

Backplot the toolpath. A 5 axis toolpath is generated along the walls and follows the
contour of the lower rail.




129
Flow 5 axis

Filename: Flow 5 axis.MC8

This file uses Lead/ Lag, Side tilt, and FLOOR5AX.DLL



Flowline toolpaths can undercut surfaces. This file has side walls that are bowed and
does not allow Swarf cutting. A 5 axis flowline toolpath can be used to machine these
walls.

Note: As of initial release of V8, Flowline toolpaths are NOT gouge checked. Flat and
bull nose cutters can be used but may violate surface geometry. Spherical endmills
with radii larger then the geometry radii can also gouge. Use the C-hook FLOOR5AX
after toolpath generation to eliminate the toolpath from violating surface geometry.

Toolpaths/ Multiaxis/ Flow 5-axis

The new dialog boxes found in Drill, Curve, and Swarf 5 axis toolpaths have not been
implemented in the current Flow 5 axis toolpath. Tip control options are unavailable.
From the displayed menu, select the left wall surface as shown below


130


Selection of multiple surfaces is allowed but they must form a row. A row consists of
adjacent surfaces edges that are equal in length and tangent. If the surface edges
can be used to create a single coons patch surface, these surfaces would form a row.
When surface edges do not form a row, it is necessary to recreate the surfaces and
generate a single coons patched surface.

After selection of the surface defined above, the Tool Parameters page appears.

131

Tool Parameters:

Select a .500 diameter spherical endmill
Multiaxis Parameters


132
Clearance 2.0 incremental
Retract: .25 incremental
Feed plane .10 incremental

Compensation in computer: Not available. Offset, Cut direction, Start point and
step over are input the same as Flowline 3 axis

Tip Comp: Center

Stock to leave on drive surfaces: 0.0

Filter: OFF

Entry/ Exit: Not Available


Flow 5 axis parameters

Cut control

Distance: Off Sets the length of each tool movement as an absolute distance.

Cut tolerance: .001 Determines the accuracy of the surface toolpath.

Stepover control

Scallop height: .005 Adjusts the stepover between cuts to create leftover
material at a specific height.
Cutting method: One Way Sets the tool motion for the flowline toolpath.

133
Lead / Lag angle: -80 Tilts the tool at an angle in the direction of the toolpath
(lead) or opposite the direction of the toolpath (lag).

Side tilt angle: -80 Tilts the tool at a right or left angle while traveling in the
direction of the toolpath.

Depth limits: Not used Sets the minimum and maximum machining depths for the
flowline 5-axis toolpath.

Gap settings: Not available

Edge settings: % of cut tolerance: .001


Once all the parameters have been set, the Flowine offset and cut direction menu is
displayed.



Set the offset to the inside of the surface and start from the top as displayed above.

Backplot the generated toolpath. If the tool axis vectors are upside down or on the
wrong side of desired toolpath motion, invert the angular direction.


134


Lead angle 80 degrees Side angle 80 degrees

You will notice that the tool violates the floor surface. As mentioned at the beginning
of this exercise, tip control options are unavailable in Flow5ax. This can be fixed
using the Floor5ax C-hook.





135

Generate a .NCI file

Activate the Floor5ax C-hook
Specify the .NCI filename to read (the file just created Flow 5axis.NCI )
A select surfaces menu is displayed
Select the surfaces that toolpath comes in contact with. The wall and floors ( Group /
floor5ax surfaces )
Input a tolerance (.001 )
Specify .NCI filename to write. I suggest something different then the file being read (
Flow 5axis_Floor.NCI )

A new .NCI file is written
Import the .NCI file into the Operations Manager and Backplot



136





Backplot the merged file


137



139
C-hooks
Rolldie

Rolldie generates a toolpath that uses the centerline of a slot or boss and offsets the
vector. This produces parallel walls on cylindrical parts by offsetting the tool before
calculating an angle.
This differs from contour toolpaths that use axis substitution. Axis substitution
offsets the contour first, then generates the vector through the center of
rotation. This will result in tapered side walls.



NOTE: Rolldie programs the centerline of a boss or cavity and calculates cutter comp
distance based on the taper mill diameter and angle. The tools diameter must
equal the slot or boss width. This is fine to generate the correct toolpath, but the
backplot and Verify tools may be incorrect.

For this example, the taper mill comes to a point. The tools diameter can not
be defined to a point and the C-hook cannot offset .000 diameter. The toolpath
will be incorrect


140

To generate the proper offset, the tool must be defined with the diameter equal
to the slot or cavity width. The offsets are correct but the backplot or Verified tool
will be displayed incorrectly. It will show a flat bottom on the tool.
To generate the desired toolpath and have the tool backplot and Verify
correctly, create a custom profile for a taper tool and select the Profile/ Custom
option.



This Custom Profile is a .MC8 file save that was saved in the
C:/MCAM8/MILL/TOOLS subdirectory. Make the radius 1.000 to scale properly.


141


In the Define Tools/ Parameter page, select the .MC8 tools name



142


There are only a few rules when generating a roll die program:

1. Must define and program a tapered tool in order to generate a toolpath that
ramps the tool up in the corners. A taper tool will automatically compensate
offset and depth based on the tools diameter and angle.
2. The tools diameter is equal to the width of the cut (boss or slot).
3. Always program to the centerline of the slot or boss.
4. If programming a contour, additional geometry may need to be created for the
desired toolpath. This may require the chaining of the entire contour and
setting the AUTO REVERSE to N
5. Basic geometry, lines and arcs are preferred instead of splines.

The following example will review the above conditions. Open the file called
Rolldie8.MC8

This example reviews creating a knife edge and vertical walls for a roll die.

Given:
A flat pattern of the desired output.
Requirements: The outside diameter of the roll die would be 4.1 inches
The knife-edge has parallel sides .200 wide and .100 deep. The knife edge had a 90-
degree included angle to the sharp edge.
A .500 wide clearance trough, .100 deep around the knife-edge. This also must be
parallel to the knife edge sides.

The toolpath requires the pocketing of material around the knife edge. The outside
boundary is calculated from the circumference of the cylinder and represented in the
flat state. (Cir = ? Dia , C=? (4.1)=12.8805).
A little stock is added to the distance to overlap the toolpath.

143
It is not necessary to roll the geometry but it is helpful when reviewing backplotted
geometry

To roll the geometry, select Xform/ Roll and chain the green contour.
Input desired Roll parameters. Refer to On-line Help for detailed explanation of each
parameter.

For this example, based on the design requirements and machine tool configuration,
axis of rotation is set to X.




144


The process used to cut this example is to (1) pocket out the middle material, (2)
machine the knife edge, and (3) finish sides. The finish and knife-edge toolpaths will
be generated using Rolldie.
Before programming the pocket toolpath, offset the knife-edge centerline the width of
the knife-edge (.100 on each side). This will be an island for the pocket toolpath.
To do this: Xform / Ofs ctour/ Chain/ Partial/ select the beginning of the
contour, Wait Y/ select the end of the contour, then the beginning again (the
start and end arrows will be at the same point but pointing in opposite
directions) End here/ Done. Input desired Offset Contour parameters.


145




Toolpaths/ Pocket , Chain the outside rectangle and the offset contour as an island.
Done
In the tool parameters page, use a .375 flat endmill, select the Rotory Axis button.
The A axis on the machine tool is along the X axis so use the Substitue Y axis option.
Set rotation direction to CW and an A rotary diameter of 4.1 is used to determine the
proper angular rotations. O.K.


146




In the pocketing parameters, set the depth incrementally to -.2 and the XY stock to
leave at .05. This allows the rolldie contour toolpath to cleanup the side walls.

147
In the rough/ finishing parameters, set the desired parameters



The toolpath should look similar to this.



148
To generate the knife edge rolldie toolpath: ( Rolldie.dll )
Activate the Rolldie C-hook with Alt-C

Chain the slot centerline. Clear colors, chain green contour (one way). Done

The contour parameter page appears
You must select a taper tool for the toolpath to pick up in the corner. For
proper toolpath offset, depth, backplot and Verify, the tool should have been
defined as mentioned at the beginning of this document.
The tools diameter as the width of the slot or boss. In this case, the width of the knife
is .200. It is desirable to have the tip of the tool go beyond the intersection. To extend
.01 beyond the edge intersectoin .02 has been added to the width (.220 diameter).



Select the rolldie taper mill that was defined at the beginning of this example


149


In tool parameters, set axis Rotary axis parameters as you would a contour toolpath
using axis substitution.



In Contour parameters, input Clearance height and feed plane values. Top of
stock, depth, and stock to leave should be .000. Cutter compensation should be

150
set to OFF. Cutter compensation and depth calculations are done within the Rolldie
C-hook based on the rotary axis diameter, tool diameter and angle.



Upon completion of the contour parameters, A new menu is displayed. Here set
Corners to (R)oll the cutter around corners, Chordal deviation will be set to .0001,
Auto reverse is set to Y. Auto Reverse returns the contour to the start position
reversing the offset direction to the opposite side on the way back.


151




Backplot the generated toolpath and notice how the tool will taper up the inside
corner and no A axis motion is output when machining the outside of the knife edge
opposite the corner.

152




The clearance trough will be programmed slightly differently. Rolldie requires that the
centerline be programmed, but the tool we are using is a flat endmill and only tapered
and chamfer tools will pick up in corners. The toolpath will fishtail in the inside corner,
so it is necessary to create additional geometry.

Blank the offset contour. Create a fillet along the rolldie centerline. The radius
will equal at least half of the cutter diameter (.250) plus half the wall thickness
(.100) a little clearance of .025 is added to ensure smooth toolpath motion.

Create/ fillet/ Trim N/ specify radius (.375) and select the tangent arcs
(reference below illustration for location). Break the tangent arcs at the
enpoints of the newly created arc and original arcs.

153


Open the Rolldie.dll file (ALT-C). To get the proper contour toolpath around the
corners, Auto reverse can not be used. This requires the programmer to manually
chain the contour in both directions. The first direction, which machines the inside of
the contour, uses the new arc. On the way back, the path uses the sharp corner part
of the contour. Upon completion, the start and end arrows should be at the same
location, pointing in different directions.
Chain/ Partial, select the start of the contour/ Wait Y. Select each segment of
the contour in both directions. The start and end arrows should be at the
same location, pointing in opposite directions.



Select a .500 diameter flat endmill. Input tool and rotary axis parameters.

154


Since a tapered tool is not being used, a depth value needs to be input (-.300).
Cutter compensation is set to Off, Stock to leave should be set to .100, half the
width of the knife edge. Cutter comp is not applied to flat endmills with Rolldie.




155
Input Rolldie parameters. The only thing that needs to be done is set the Corners to
roll and Chordal deviation
to .0001. The contour was chained in both directions so Auto Reverse is not
required. Set to N



The toolpath should look like this.

156


Select all the toolpaths and Verify



157
contain 5 axis

Contain5. Dll

Filename: Contain5.MC8

Review selection parameters for the Contain5.Dll c-hook Contains the shank
of a 5 axis tool inside a chained boundary (or boundaries) or to a point.
Converts a 3 axis toolpath to a 5 axis toolpath in the process.

Restrictions:

1. Only spherical tools are supported
2. Containment is done to the tool axis, not the tool edge
3. Only G0 and G1 from the input file are converted to five axis positions.



158


Isolate the split surface defined above. ALT-E / Group/ Split surface



Generate a flowline toolpath on this surface. Flowline is the only toolpath that will
undercut a surface

Toolpaths / Surface/ Finish / Flowline

Select the displayed surface

159

Tool Parameters

Select a .500 spherical endmill. For the purpose of backplotting, change the tools
parameters

Diameter: .500
Arbor Diameter: .300
Flute: .25
Shoulder: .25
Tool Type: Auto

160

Surface Parameters



Clearance 2.5 Absolute
Retract: .25 Absolute
Feed plane .25 Incremental

Tip Comp: Center

Stock to leave on drive surfaces: 0.0

Use Check surfaces: Not used

Prompt for tool center boundary: Unavailable


161
Filter: ON
Note: If using Filter option, DO NOT create arcs. Contain5.Dll converts G0 and G1
moves

Tolerance: .01
Look Ahead: 100



Recut: On
Saves a recut (*.REC) file for the multiaxis toolpath for faster toolpath regeneration.

Direction: Not used


Finish flowline parameters

Cut control

Cut tolerance: .005 Determines the accuracy of the surface toolpath.
Check flowline motion for gouge: OFF This MUST be OFF for the toolpath to
undercut surface

162
Stepover control

Distance: .100 Sets the stepover between cuts as an absolute distance.

Cutting method: One Way

Gap settings:



Gap size
% of stepover: 300
Motion < Gap size keep tool down
Broken
Do not check for gouge in gap or retract

Edge settings



163
Sharp corner tolerance

% of cut tolerance: 100



Set Offset, Cut / Step direction and Start so that the toolpath Climb mills the inside
surfaces from top to bottom.

A 3 axis flowline toolpath is generated.

To machine this part, the shank of the tool cannot violate the surface walls. This will
require the tool axis to be contained in safe zone. This zone should be as far away
from the surface as possible to minimize tool axis rotation. To determine a safe
position for the tools axis, create a wire frame profile of the tool and position it in the
model at the surface limits.
Below illustrates the position of a contain point where the tool will not violate
the walls.

164


But this contain point will cause unnecessary tool axis motion at the start of the
toolpath


Place the contain point or curves as far away from the start of the toolpath as
possible. Make visible level 5

165


Once you have determined the Contain position, you are ready to run the Contain5
C-hook. This program uses the 3 axis .NCI file so create it before entering the C-
hook.

ALT-C / Contain5
You are prompted for the .NCI file name to read. Select the .NCI file just created (
contain5.NCI)
You are then prompted for the output file name. A 5 is added to the input file name
automatically. Accept this toolpath name (contain55.NCI), or input desired filename.

Next you are prompted to define the containment boundary. This can be any 2D
geometry or point. Select the intersection point of the tool axis centerline.



166
Backplot generated .NCI file ( Contain55.NCI)

The tool axis is contained though selected point.



167
Focus

Focus4xb. Dll

Filename: Focus4xb.MC8
Review selection parameters for the Focus4xb.Dll c-hook
Contains the shank of a 4 axis (rotate about the B axis) tool vectors through
horizontal lines defined by a start and end point. The tool axis vectors interpolate
between the points.



Generate a Flow5ax toolpath on this surface.

Toolpaths / Multiaxis / Flow5ax

Select the displayed surface


168
Tool Parameters


Select a .500 spherical endmill. For the purpose of backplotting, change the tools
parameters

Diameter: .500
Arbor Diameter: .300
Flute: .25
Shoulder: .25
Tool Type: Auto

Even though the tool is displayed as a half of a sphere, by defining the tool type as
spherical, the back of the tool is correctly compensated

The actual tool will be a .500 ball with a .300 diameter shank. You can create the
actual tool profile as a .MC8 file, select the custom profile option, and reference this
profile under Define Tool Parameters, see below(Custom Tool Profile.MC8). This will
backplot and verify the correct tool profile.

When creating the custom tool geometry, the actual diameter must equal
1.000 to scale correctly

169




170
Surface Parameters

In order for FOCUS4XB to generate correct tool axis positions, the RETRACT
parameter MUST be OFF

Clearance 2.0 Absolute
Retract: OFF
Feed plane .10 Incremental

Tip Comp: Center

Stock to leave on drive surfaces: 0.0

Use Check surfaces: Not available

Filter: OFF

Flow5axis parameters

Input desired parameters


171

Cut tolerance: .001
Scallop height: .005
Cutting method: One Way
Lead/lag angle: 0.0
Side tilt angle: 0.0

Gap settings: Not available
Edge settings: Use default Sharp corner tolerance 100% of cut tolerance

Set Offset, Cut / Step direction and Start so that the toolpath Climb mills the inside
surfaces from top to bottom.

172


A 5 axis flowline toolpath is generated.
This backplot shows the tool profile using the Auto Profile Option



To machine this part, the shank of the tool cannot violate the surface walls. This will
require the tool axis to be contained through a safe zone. To determine a safe
position for the tools axis, create a wire frame profile of the tool and position it in the
model at the physical limits. (Make visible Level 2) Modify/ Drag/ Translate Rotate
Below illustrates the start and end point positions the tool axis will interpolate
through

173


Once you have determined the Start and End positions, you are ready to run the
Focus4axB C-hook. This program uses the 5axis tool vectors, from the previously
created Flow5axis tool path, to offset the tool. Focus4axB generates tool axis vectors
through horizontal lines defined from the start and end point. Horizontal orientation is
relative to the Cplane.

ALT-C / Focus4XB
Select the Operation button
You are prompted to select an Operation



174


Select the Flow5axis operation/ O.K.

The remaining Focus Chook options are now available



Toggle the Start Focus Point button and select the previously determined start point.

Toggle the End Focus Point button and select the previously determined end point

Select the Approach/ Retract button

175


Entry
Approach Vector (Rapid) 2.0 This is the initial incremental distance from
the first contact point that the tool will start from. This distance is along the first
tool axis vector.

Approach Normal (Feed) 0.1 This is the incremental distance, normal to
the surface, the tool will feed to start the machining pass

Exit
Retract Vector (Rapid) 4.0 This is the incremental distance from the last
contact point (or retract normal point, if used), along the last tool axis vector,
the tool will retract. It is usually larger than the Approach vector since the tool
is deeper in the part.

Retract Normal ( Feed) 0.1 This is the incremental distance, normal to
the surface, the tool will retract from the part prior to moving to the next
position.

Step Over Method
Direct: Moves directly from one pass to the next. The tool will stay in contact
with the surface between passes

Use Approach/ Retract Normals: Applies Approach/ Retract Normal vectors
between passes. In this case, the tool will retract 0.1 normal from the surface,
step down to the next depth and feed into the part 0.1, normal to the surface,
and begin the next pass.

Use Approach/ Retract Normals and Vectors: This will cause the tool to retract
the tool out of the part between each pass. It applies both a Normal retract
(.01) at end of pass, and the Exit Normal out of the part (4.0). It then uses the
Entry Vector (2.0) and then the Entry Normal (.01) and begins next pass. This
option can be used for One Way machining on open surfaces.


176
NOTE: If the original Flow5ax toolpath uses a Retract parameter, set in the Multiaxis
parameters, the tool will ignore the Step Over Options
and retract the specified incremental distance between each pass.

Toggle the Execute button



The toolpath is created and placed in the Operations Manager

Select OK

Backplot the Focus file. This backplot shows the tool as defined with a Custom Profile


177


Focus5ax. Dll

Filename: Focus5ax.MC8
Review selection parameters for the Focus5ax.Dll c-hook
Contains the shank of 5 axis tool vectors through a defined start and end point. The
tool axis vectors interpolate between the points.



Generate a Flow5ax toolpath on this surface.

178

Toolpaths / Multiaxis / Flow5ax

Select the top blue surface surface


Tool Parameters


Select a .500 spherical endmill. For the purpose of backplotting, change the tools
parameters

Diameter: .500
Arbor Diameter: .300
Flute: .25
Shoulder: .25
Tool Type: Auto

Even though the tool is displayed as a half of a sphere, by defining the tool type as
spherical, the back of the tool is correctly compensated

The actual tool will be a .500 ball with a .300 diameter shank. You can create the
actual tool profile as a .MC8 file, select the custom profile option, and reference this
profile under Define Tool Parameters, see below(Custom Tool Profile.MC8). This will
backplot and verify the correct tool profile.
When creating the custom tool geometry, the actual diameter must equal
1.000 to scale correctly

179




180
Surface Parameters


In order for FOCUS4XB to generate correct tool axis positions, the RETRACT
parameter MUST be OFF

Clearance 2.0 Absolute
Retract: OFF
Feed plane 0.1 Incremental

Tip Comp: Center

Stock to leave on drive surfaces: -.250
The Probe data used to generate the port surfaces are from the center of the
.500 ball probe. A negative stock to leave is required for correct geometry
machining.

Use Check surfaces: Not available

Filter: OFF

Flow5axis parameters

Input desired parameters


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Cut tolerance: .001
Scallop height: .005
Cutting method: One Way
Lead/lag angle: 0.0
Side tilt angle: 0.0

Gap settings: Not available
Edge settings: Use default Sharp corner tolerance 100% of cut tolerance

Set Offset, Cut / Step direction and Start so that the toolpath Climb mills the inside
surfaces from top to bottom.

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A 5 axis flowline toolpath is generated.
This backplot shows the tool profile using the Auto Profile Option, tip comp
Center, with .250 stock to leave.



To machine this part, the shank of the tool cannot violate the surface walls. This will
require the tool axis to be contained through a safe zone. To determine a safe

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position for the tools axis, create a wire frame profile of the tool and position it in the
model at the physical limits. (Make visible Level 2) Modify/ Drag/ Translate Rotate
Below illustrates the start and end point positions the tool axis will interpolate
through


Once you have determined the Start and End positions, you are ready to run the
Focus5ax C-hook. This program uses the 5axis tool vectors, from the previously
created Flow5axis tool path, to offset the tool. Focus4axB generates tool axis vectors
through horizontal lines defined from the start and end point. Horizontal orientation is
relative to the Cplane.

ALT-C / Focus5ax
You are prompted to select an Operation
Select the Operation button



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Select the Flow5axis operation/ O.K.

The remaining Focus Chook options are now available



Toggle the Start Focus Point button and select the previously determined start point.

Toggle the End Focus Point button and select the previously determined end point

Select the Approach/ Retract button

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Entry
Approach Vector (Rapid) 2.0 This is the initial incremental distance from the
first contact point that the tool will start from. This distance is along the first
tool axis vector.

Approach Normal (Feed) 0.1 This is the incremental distance, normal to
the surface, the tool will feed to start the machining pass

Exit
Retract Vector (Rapid) 4.0 This is the incremental distance from the last
contact point (or retract normal point, if used), along the last tool axis vector,
the tool will retract. It is usually larger than the Approach vector since the tool
is deeper in the part.

Retract Normal ( Feed) 0.1 This is the incremental distance, normal to the
surface, the tool will retract from the part prior to moving to the next position.

Step Over Method
Direct: Moves directly from one pass to the next. The tool will stay in contact
with the surface between passes

Use Approach/ Retract Normals: Applies Approach/ Retract Normal vectors
between passes. In this case, the tool will retract 0.1 normal from the surface,
step down to the next depth and feed into the part 0.1, normal to the surface,
and begin the next pass.

Use Approach/ Retract Normals and Vectors: This will cause the tool to retract
the tool out of the part between each pass. It applies both a Normal retract
(.01) at end of pass, and the Exit Normal out of the part (4.0). It then uses the
Entry Vector (2.0) and then the Entry Normal (.01) and begins next pass. This
option can be used for One Way machining on open surfaces.


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NOTE: If the original Flow5ax toolpath uses a Retract parameter, set in the Multiaxis
parameters, the tool will ignore the Step Over Options
and retract the specified incremental distance between each pass. The toolpath
with be calculated incorrectly

Toggle the Execute button



The toolpath is created and placed in the Operations Manager

Select OK

Backplot the Focus file. This backplot shows the tool as defined with a Custom Profile
and an offset (.250) surface.


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