Copyright 2006 MecSoft Corporation.

i
RhinoCAM & VisualMill
Mold making Tutorial


Machining a Ring Mold





Copyright 2006 MecSoft Corporation All rights reserved.
Rhinoceros is a registered trademark and Rhino is a trademark of Robert McNeel &
Associates.
RhinoCAM & VisualMill are registered trademarks of MecSoft Corporation.
Copyright 2006 MecSoft Corporation. ii
Table of Contents
1. Introduction.......................................................................................................2
Strategy to Machine the Ring Mold......................................................................... 2
Main Programming Steps...................................................................................... 2
2. Creating the Programs for Bottom half of the mold............................................3
Load and Locate Part ........................................................................................... 3
Create Stock Model ............................................................................................. 4
Create the tools for machining this mold................................................................. 5
Save Tool library ........................................................................................... 5
Set Feeds & Speeds............................................................................................. 6
Set Clearance plane............................................................................................. 7
Create Horizontal Roughing operation. ................................................................... 7
Display Generated Toolpath........................................................................... 11
Simulate Horizontal roughing operation........................................................... 13
Create Facing operation ............................................ Error! Bookmark not defined.
Display Generated Toolpath.................................. Error! Bookmark not defined.
Simulate facing operation .................................... Error! Bookmark not defined.
Create Finishing operations................................................................................. 13
Select the regions for parallel finishing ................................................................. 14
Create the Machining Operation........................................................................... 15
Display Generated Toolpath........................................................................... 17
Simulate parallel finishing operation ............................................................... 17
Select the region for Second and Third parallel finishing.......................................... 18
Create the Machining Operation........................................................................... 19
Display Generated Toolpath........................................................................... 20
Simulate parallel finishing operation ............................................................... 21
Display Generated Toolpath........................................................................... 22
Simulate parallel finishing operation ............................................................... 23
Create Radial Machining operation ....................................................................... 24
Select the regions for radial machining................................................................. 24
Create the Machining Operation........................................................................... 25
Display Generated Toolpath........................................................................... 27
Simulate radial machining operation............................................................... 27
3. Post-Processing the Programs .........................................................................29
4. Creating the Programs for Top half of the mold ...............................................30
Load and Locate Part ......................................................................................... 30
Create Stock Model ........................................................................................... 31
Load Tool Library......................................................................................... 32
Copyright 2006 MecSoft Corporation. iii
Create Horizontal Roughing operation. ................................................................. 32
Display the generated tool path ..................................................................... 34
Simulate Horizontal Roughing operation.......................................................... 34
Create Facing operation ..................................................................................... 35
Display the generated tool path ..................................................................... 35
Simulate Facing operation............................................................................. 35
Create Slot Roughing operation........................................................................... 36
Select the regions for Slot Roughing............................................................... 37
Create the Machining Operation........................................................................... 38
Display the generated tool path ..................................................................... 40
Simulate Slot Roughing operation .................................................................. 40
Create Slot Finishing operation............................................................................ 41
Select the region for Slot Finishing ................................................................. 41
Create the Machining Operation........................................................................... 42
Display the generated tool path ..................................................................... 42
Simulate Slot Finishing operation ................................................................... 43
Create Horizontal Finishing operation ................................................................... 43
Select the region for Horizontal Finishing......................................................... 44
Create the Machining Operation........................................................................... 45
Display the generated tool path ..................................................................... 45
Simulate Horizontal Finishing operation........................................................... 46
Create Radial machining operation....................................................................... 47
Select the regions for radial machining ........................................................... 47
Create the Machining Operation........................................................................... 48
Display the generated tool path ..................................................................... 48
Simulate Radial machining operation .............................................................. 49
5. Post-Processing the Programs .........................................................................51
6. Machining the Ring Mold on Techno machine...................................................52
Tool setup........................................................................................................ 52
Secure the Stock on to the table.......................................................................... 52
Setting Machine Zero......................................................................................... 52
Checking Machine Zero ...................................................................................... 53
Load the file, Pre-process and Preview ................................................................. 54
Completed Part ................................................................................................. 54

Copyright 2006 MecSoft Corporation 2
1. Introduction
At this point of the tutorial you have created the Ring Mold.3DM or Ring Mold.vmp
file and planning to machine this part using RhinoCAM or VisualMill.
This tutorial will illustrate machining this Ring Mold using 3 axis-milling operations.
This tutorial will introduce the usage of several 3 axis operations such as Horizontal
roughing, parallel finishing and Radial machining.
Strategy to Machine the Ring Mold
We will machine the Ring Mold completely using 3 axis operations.
The part itself will be machined out of a 2 x 2 inch x inch wax
The stock may be held to the machine table or the spoil sheet on the table using
double-sided tape or by clamps. This tutorial explains the use of tabs to hold the
part while machining. The tabs are broken off after the machining operation is
complete.
Tools used for machining this parts are inch flat end mill, and 1/8 inch and 1/16
inch ball mill.
The machine tool used will be a Techno-Isel DaVinci servo controlled router.
Main Programming Steps
In creating programs for each setup, the following steps will be followed:
Set the Machine zero point or Locate geometry with respect to the machine
coordinates
Create / Select the tool used for machining
Set the feeds and speeds
Set the clearance plane for the non-cutting transfer moves of the cutter
Select the machining regions for containing the cutter to specific areas to cut
Select the machining operations and set the parameters
Generate the toolpath
Simulate the toolpath.
You may have to repeat either all or part of these steps for subsequent operations.


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2. Creating the Programs for Bottom half of the mold
Load and Locate Part
1. First load the file Ring Mold Bottom.3dm or Ring Mold
Bottom.vmp
2. In the browser, select the Setup tab and pick the Locate
Geometry button. Select the options shown in the dialog and
select the OK button.
Once this step is performed the model will be moved such that the world
coordinate zero is position at the lowest face and the lower left corner of
the 3D model. In this exercise we will use the world coordinate zero point
as the zero point of the machine tool.



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Create Stock Model
1. On the Setup tab in the browser click (create/ load stock) button in the
toolbar and select Box Stock option
2. Select the settings shown and also enter the numbers shown in the dialog and
select the OK button.
3. Click on the Stock tab on the browser to see the stock you just created.
Once this step is performed the stock model is created and positioned such that
the world coordinate zero is at the top left corner of the stock model and also
aligned with the lowest Z face of the stock model.
Note: Remember this setting will be used again while setting up the
machine zero

This dialog box may appear different in the earlier versions of VisualMill.
Copyright 2006 MecSoft Corporation 5

Create the tools for machining this mold
1. Select the Tools tab in the browser window and click on (Create tool) button in the toolbar. In the
dialog box enter Diameter = 0.25, Flute length = 0.75, Tool length = 2.5
2. Name the tool as FlatMill1 and select the Save as New Tool button


Repeat the step to create 1/8-inch flat mill (Tool # 2) and 1/16-inch ball mill (tool#3). Make sure the
tool numbers are in the order in which the tools will be used in machining.


Save Tool library

We will use these same tools for machining the top half of the mold. It will be easier to
Copyright 2006 MecSoft Corporation 6
Save these tools and reuse them later. To do this select the save tool library Icon
from the tools tab and save the file as RingMold.CSV. Icon appears as shown below


Set Feeds & Speeds
1. Select the Mops tab in the browser and click on (Set Feeds and Speeds)
button in the toolbar
2. Enter the values for feeds and speeds as shown below.

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Set Clearance plane
1. Select the Mops tab, Click on (Set Clearance plane)
2. Select Automatic setting



The clearance plane is the plane in which all non-cutting transfer motions take place. The
clearance plane should be defined as a plane that is above all of the geometry that is being
machined to ensure that the tool will not hit any of the geometry while it is transferring
from one location to another. These transfer motions will typically take place using a rapid
federate (unless otherwise specified by the user in the feeds & speeds dialog).

Create Facing operation operation.
For this operation we will use inch flat mill. In the tools dialog box select this tool.

Copyright 2006 MecSoft Corporation 8
Select the regions for facing operation
1. Using region selection tools select the rectangle for 2 axis facing operation
2. The curve is shown below, highlighted in the selection color (red in this case as
shown)





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Create Facing operation
1. Select the Mops tab, Click on (2 1/2 Axis operation) button and
select Facing
2. Set Tolerance to 0.01, Stock to 0, compensation to None
3. Set Cut Direction to mixed, Cut start side to Bottom, Angle of cuts to 0
4. Set Step over control to 25%



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1. Select the cut levles tab, Set total depth to 0
2. Set Rough depth, finish depth to 0, Repeat the same for Depth/cut also



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1. Select the Entry/Exits tab, Set values to default values as shown below
2. Press Generate to create tool path


Copyright 2006 MecSoft Corporation 12


Display Generated Toolpath

If the Hide Toolpath button is unchecked you will see the tool path as shown.




Copyright 2006 MecSoft Corporation 13
Simulate Facing operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below.



Create Finishing operations
First we will do a parallel finishing operation using 1/8 ball mill and then we will use
1/16-inch ball mill to do final fishing operation. Now in the Tools tab select BallMill1 as
the tool for this operation.
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Select the regions for parallel finishing
3. Using region selection tools select the inner curve and the four circles for parallel
finishing
4. The curves are shown below, highlighted in the selection color (red in this case
as shown)







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Create the Machining Operation
1. Select the Mops tab, Click on (3 Axis operation) button and select
Parallel finishing
2. Set Intol, outol to 0.001, Stock to 0
3. Set Cut Direction to mixed, Cut start side to Bottom, Angle of cuts to 0
4. Set Step over control to 25%






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1. Select the Entry / exit tab as shown
2. Set the approach motion to 0.025, Engage motion all set to zero
3. Set Cut transfer to skim
4. Click on Generate. Please wait it may take few minutes to generate toolpath





Copyright 2006 MecSoft Corporation 17


Display Generated Toolpath
If the Hide Toolpath button is unchecked you will see the tool path as shown.




Simulate parallel finishing operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below.


Copyright 2006 MecSoft Corporation 18
Next we will change the tool to 1/16-inch ball mill. In the tools tab select BallMill2
(Tool#3) for the upcoming operations.
Select the region for Second and Third parallel finishing
1. Using region selection tools select the inner curve for the next parallel
finishing
2. The curve is shown below, highlighted in the selection color (red in this case
as shown)







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Create the Machining Operation
1. Select the Mops tab, Click on (3 Axis operation) button and select
Parallel finishing
2. Set Intol, outol to 0.001, Stock to 0
3. Set Cut Direction to mixed, Cut start side to Bottom, Angle of cuts to 0
4. Set Step over control to 15%






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1. Select the Entry / exit tab as shown
2. Set the approach motion to 0.025, Engage motion all set to zero
3. Set Cut transfer to skim
4. Click on Generate. Please wait it may take few minutes to generate toolpath




Display Generated Toolpath

Copyright 2006 MecSoft Corporation 21
If the Hide Toolpath button is unchecked you will see the tool path as shown.


Simulate parallel finishing operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below.






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Next Parallel finishing operation is similar to the previous one except we will create the
tool path at 90 degrees to the previous one. An easy way to do it is to copy and paste
the previous parallel finishing operation and Select the parameters tab and change the
angle of cuts to 90 as shown below. Press Generate to create tool path.




Display Generated Toolpath

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If the Hide Toolpath button is unchecked you will see the tool path as shown.



Simulate parallel finishing operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below.



Next we will use Radial machining to finish the outer holes.
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Create Radial Machining operation
This operation will provide smooth finish to the four snap holes, which are used to
mate with the top half of the mold.
Select the regions for radial machining
1. Using region selection tools select the four circles for the next Radial
Machining
2. The curves are shown below, highlighted in the selection color (red in this
case as shown)





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Create the Machining Operation
1. Select the Mops tab, Click on (3 Axis operation) button and select
Radial machining
2. Set Intol, outol to 0.001, Stock to 0
3. Set Cut pattern to Zig Zag, Start point to Inside
4. Set Step over control to 15%






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1. Select the Entry / exit tab as shown
2. Set the approach motion to 0.025, Engage motion to zero
3. Set Cut transfer to skim
4. Click on Generate. Please wait it may take few minutes to generate toolpath









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Display Generated Toolpath

If the Hide Toolpath button is unchecked you will see the tool path as shown.



Simulate radial machining operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below.



Copyright 2006 MecSoft Corporation 28

Now we have completed the programming all the operations for the Bottom half of the Ring
Mold.
Save the file as Ring Mold_BottomComplete.3dm or Ring Mold_BottomComplete.vmp

Next you will create the G code file for machining this part
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3. Post-Processing the Programs
Once the toolpaths have been generated, they can be post-processed to a specific
machine controller. MecSofts products come with a set of post-processors to choose from.
You can post-process a single operation, or all operations at once. For post processing an
individual operation, right-click on its name in the Mops tab of the Browser and select
Post. You can also select multiple operations and right mouse click and select Post All to
post all of the selected operations. To post-process both of the created operations:
1. Select the Mops tab in the browser and select both of the operations created.
2. Right click the mouse button and select Post All
3. This will bring up the dialog shown below with a list of post-processors. Choose the
TechoIsel post processor
4. Enter Ring Mold Bottom.nc as the output file for G code file. (Chose the correct path
where you wish to write to this file). In the dialog shown below we have chosen to write
to the A: or the floppy disk drive.
5. Select the OK button and this will created the G-code file.



Copyright 2006 MecSoft Corporation 30
4. Creating the Programs for Top half of the mold
Since there is significant differences in top half of the mold as compared to the bottom
half of the mold we will use slightly different strategy for machining. We will use the
previously created tools. Many of the steps will be similar and in the following section
we will discus some of the changes that are necessary to create toolpath for the Top
half of the Ring Mold.
Load and Locate Part
1. First load the file Ring Mold Top.3dm or Ring Mold Top.vmp
2. In the browser, select the Setup tab and pick the Locate Geometry
button. Select the options shown in the dialog and select the OK button.
Once this step is performed the model will be moved such that the world
coordinate zero is position at the lowest face and the lower left corner of the
3D model. In this exercise we will use the world coordinate zero point as the
zero point of the machine tool.

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Create Stock Model
1. On the Setup tab in the browser click (create/ load stock) button in the toolbar
and select Box Stock option
2. Select the settings shown and also enter the numbers shown in the dialog and select
the OK button.
3. Click on the Stock tab on the browser to see the stock you just created.
Once this step is performed the stock model is created and positioned such that
the world coordinate zero is at the top left corner of the stock model and also
aligned with the lowest Z face of the stock model.
Note: Remember this setting will be used again while setting up the
machine zero

This dialog box may appear different in the earlier versions of VisualMill.



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Load Tool Library
The tools we need to machine the top half of the mold has already been saved. In the
Tools tab select the Icon to load the tools and select Ring Mold. CSV. This will bring
in the necessary tools.




Create Horizontal Roughing operation.
In the tools tab select the inch Flat mill as the tool for this operation.
All the settings for this operation is similar to the ones used for the Bottom half of the
mold except that the level at which the flat section of the mold is at 0.441 inch. Enter
the value for Cut Levels Bottom (B) to be 0.441 as shown below:

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Press Generate to create the tool path.
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Display the generated tool path
If the Hide Toolpath button is unchecked you will see the tool path as shown


Simulate Horizontal Roughing operation
Select the Stock tab in the browser and press to run the material
removal simulation. Once the simulation is completed the cut model will be
shown as below



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Create Facing operation
In this operation we will use 1/8 inch Flat mill and finish the top flat surface of the
mold. We can use the previous Horizontal roughing operation and rerun the tool path
with this smaller tool.
Right mouse click on the Horizontal roughing operation and copy and paste this
operation. Open the Tools tab (double click Flatmill1) as shown below and In the Tools
tab select Tool#2 which is 1/8 inch Flat.
Again Right Click the operations to rename the operation as Facing. Regenerate the
tool path by Pressing Generate.
Display the generated tool path
If the Hide Toolpath button is unchecked you will see the tool path as shown


Simulate Facing operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below
Copyright 2006 MecSoft Corporation 36



Create Slot Roughing operation
Here we will use a 1/8 Ball Mill to rough out the Slot for the mold by using Horizontal
Re-Roughing operation. Once the operation is complete rename the operation as
Slot Roughing.
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Select the regions for Slot Roughing
1. Using region selection tools select the rectangle for the slot
roughing
2. The curve is shown below, highlighted in the selection color (red
in this case as shown)


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Create the Machining Operation
1. Select the Mops tab, Click on (3 Axis operation) button and select
Horizontal Re-roughing
2. Set Intol, outol to 0.001, Stock to 0.01
3. Set Cut pattern to Stock offset pocketing, Cut Direction to Climb, Pocket start
side to Inside
4. Set Step over control to 25%


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1. Select the Engage/Retract tab as shown
2. Select Ramp, Set Angle to 5, Height to 0.01. Check Always engage in previously cut
area if possible
3. Set Linear Extension (D) to 0.275, Set Cut transfer to Skim.
4. Click on Generate, Please wait it may take few minutes to generate toolpath






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Display the generated tool path
If the Hide Toolpath button is unchecked you will see the tool path as shown


Simulate Slot Roughing operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below




Copyright 2006 MecSoft Corporation 41
Create Slot Finishing operation
Here we will use a 1/16 Ball Mill to finish the Slot for the mold by using Parallel
finishing operation. Once the operation is complete rename the operation as Slot
finishing.
Select the region for Slot Finishing
1. Using region selection tools, select the same rectangle for the slot
finishing
2. The curve is shown below, highlighted in the selection color (red
in this case as shown)



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Create the Machining Operation
1. Select the Mops tab, Click on (3 Axis operation) button and select Parallel
finishing
2. Set Intol, outol to 0.001, Stock to 0
3. Set Cut Direction to mixed, start side to Bottom
4. Set Step over control to 5%. Press Generate to create tool path.



Display the generated tool path
If the Hide Toolpath button is unchecked you will see the tool path as shown
Copyright 2006 MecSoft Corporation 43


Simulate Slot Finishing operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below



Next we will finish the other remaining areas of the top mold.
Create Horizontal Finishing operation
Here we will continue to use a 1/16 Ball Mill to finish the Slot for the mold by using
Horizontal finishing operation.
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Select the region for Horizontal Finishing
1. Using region selection tools select the inner curve for the next
horizontal finishing
2. The curve is shown below, highlighted in the selection color (red
in this case as shown)


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Create the Machining Operation
1. Select the Mops tab, Click on (3 Axis operation) button and select
Horizontal finishing
2. Set Intol, outol to 0.001, Stock to 0
3. Set Cut Direction to Climb / Conventional
4. In the Cut Levels tab, set the step over to 5%.
5. Press Generate to create tool path.



Display the generated tool path
If the Hide Toolpath button is unchecked you will see the tool path as shown
Copyright 2006 MecSoft Corporation 46


Simulate Horizontal Finishing operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below






Copyright 2006 MecSoft Corporation 47
Create Radial machining operation
Here we will continue to use a 1/16 Ball Mill to finish the Four snaps by using Radial
machining operation.
Select the regions for radial machining
1. Using region selection tools select the four circles for radial
machining
2. The curves are shown below, highlighted in the selection color
(red in this case as shown)



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Create the Machining Operation
1. Select the Mops tab, Click on (3 Axis operation) button and select Radial
Machining
2. Set Intol, outol to 0.001, Stock to 0
3. Set Cut pattern to ZigZag, Start point to inside
4. Set Step over control to 5%. Press Generate to create tool path.



Display the generated tool path
If the Hide Toolpath button is unchecked you will see the tool path as shown
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Simulate Radial machining operation
Select the Stock tab in the browser and press to run the material removal
simulation. Once the simulation is completed the cut model will be shown as below







Now we have completed the programming all the operations for the top half of the Ring Mold.
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Save the file as Ring Mold_Top Complete.3dm or Ring Mold_Top Complete.vmp

Next you will create the G code file for machining this part
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5. Post-Processing the Programs
Once the toolpaths have been generated, they can be post-processed to a specific
machine controller. MecSofts products come with a set of post-processors to choose
from.
You can post-process a single operation, or all operations at once. For post processing an
individual operation, right-click on its name in the Mops tab of the Browser and select
Post. You can also select multiple operations and right mouse click and select Post All to
post all of the selected operations. To post-process both of the created operations:
1. Select the Mops tab in the browser and select both of the operations created.
2. Right click the mouse button and select Post All
3. This will bring up the dialog shown below with a list of post-processors. Choose the
TechoIsel post processor
4. Enter Ring Mold Top.nc as the output file for G code file. (Chose the correct path where
you wish to write to this file). In the dialog shown below we have chosen to write to the
A: or the floppy disk drive.
5. Select the OK button and this will created the G-code file.



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6. Machining the Ring Mold on Techno machine
You will use the files Ring Mold Bottom.NC and Ring Mold Top.NC, the G code files
created for The Techno milling machine to machine the bottom and top half of the
mold.
Make sure you read the safety instructions recommended by Techno-Isel and follow
them strictly It is important to pay attention to these areas before you start
machining.
Follow these steps to machine the part:
Tool setup
Select the correct tool (0.25 inch Flat mill) and check for wear and tear. Using the
proper wrench fasten the tool firmly at the center of the spindle. Also it is important to
make sure the tool is vertical. Check this with a right angle set to the table.
Secure the Stock on to the table
Using a vise mount the stock 2 inch X 2 inch X 0.5 and 0.75 inch wax on to the Table as
shown.
3 M 411 long / DC tape was used for this tutorial.

Setting Machine Zero
Set the machine zero to the same location we have chosen in our machining setup
during programming. That is, the lower-left or south-west corner of the stock and also
flush with the top surface of the stock model.
The XY position of the zero can be set by eyeballing the zero settings such that the
tool center is located at the lower left corner. To set the Z zero position, place a thin
piece of paper on top of the stock model. Move the tool down slowly as the piece of
paper is jiggled back and forth. Stop the tools downward motion at once when the
piece of paper cannot be jiggled anymore on account of the tool pressing it against the
top surface of the block.
Once the tool is positioned at the desired location, using the Techno Control Panel
Zero all three coordinates, X, Y and use tool touch off method to set Z zero.
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Tool touch off set up is shown below.

Checking Machine Zero
Move the Tool up in the Z direction as well as the X and Y different to a different
location.
Using control panel, command the machine to travel to the zero position. The Tool
should move back to X and Y position that was selected above.
If it does not repeat the previous operation until you are sure that the zero point is
located correctly.
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Load the file, Pre-process and Preview
1. Using the control panel select File and load the posted file.
2. Once the file is loaded, select Preprocess and then Preview the toolpath
3. It is important to make sure that tool does not go below the top of the table. This can
be verified by checking the side view of the toolpath to make sure that there are no
tool motions below the bottom most cut level.
4. Set the Spindle to AUTO


Now you are ready to machine the part. Press start and the machine will pause for
loading the tool. Press Resume to Continue. The Spindle will turn on and tool will plunge
into the stock and profiling and engraving operations will be performed.
Completed Part
The completed parts should look like the part shown below: