Contents

Using Tutorials

Tutorial 1in mm

Tutorial 1in inch

Tutorial 2

Tutorial 3

Tutorial 4

Tutorial 5

Tutorial 6

Tutorial 7

Tutorial 8

Tutorial 9

Tutorial 10
Using tutorials
The tutorials guide you through the actual programming process for a few sample parts. When you complete all the tutorials you will be able to
use CAPSturn independently without any guidance.

To get the tutorials, click on the tutorials book in the help. A list of tutorials indicating the topics covered in it appears. Double click on the first
tutorial.
Perform the actions listed. At the end of each section, you will find a Back button which leads you to the previous section and a Next button
which leads you to the next.
Clicking on underlined text leads to additional information on the topic.
If you need information not available in the Tutorial, use the context sensitive Help in the software.
The programming process consists of the following 8 steps:

Steps Operation Menu option

Step 1 Start new program File
Step 2 Define work setup
Step 3 Draw the part Geometry
Step 4 Draw the Blank Geometry
Step 5 Perform Machining Machining
Step 6 Select Machine Machines
Step 7 View tool path Tool path
Step 8 Generate NC program NC program

You will notice that till View tool path the order of the steps is the same as in the main menu and icon bar. To do a program you will be following
this order from Left to Right.
Tutorial 1
In millimeters

This tutorial illustrates,

• Creating geometry.
• Selecting tools.
• Performing Rough turning and Finish turning.
• Viewing tool path.
• Generating documents.

Part drawing

200
110 240
80

180 60 120
184

Part Blank
All dimensions are in MM.
 Steps to NC program
Start a new program Start new program à Define work setup à Draw the part à Draw the Blank à Perform
Machining à Select Machine à View tool path à Generate NC program

Start CAPSturn. To do this, double click on the CAPSturn icon

or
Select Start → Programs → Cadem → CAPSturn 7.0.

Select File → New .

The Work setup dialog box appears.

Steps to NC program
Define work setup Start new program à Define work setup à Draw the part à Draw the Blank à Perform
Machining à Select Machine à View tool path à Generate NC program

The Work set up data is divided into Setup data 1, Setup data 2 and Documentation. Setup data is required for machining, and
documentation is related to the details of the program. Entering the Setup data is mandatory, while General data is optional.

Enter the data as shown below, leaving the remaining entries unaltered.

Setup data 1
• Against the prompt Workpiece material click on and select Steels, high carbon low alloy TS 550-750 N/mm2 from the list
• Enter the Part load + unload time as 30.
• Specify Limiting spimdle speed as 3000.
• Enter Jaw position absolute Z as -210.
• Enter 5 against the prompt Clearance Z.
• Enter 200 against the prompt Clearance OD.

Click on Setup data 2 tab and enter the data as shown below.
• Enter the Tool change position as, Rear turret X= 300 Z= 100
• Select the Units as MM by clicking on it.
• Click on Documentation tab to enter the documentation or click on the OK button to save and exit work setup.

Click on Documentation tab and enter the data as shown below.

• Part number as FN 0023.
• Part name as SHAFT.
• Setup number as 1.
• Fixture as CHUCK.
• Enter the name of the Programmer against the prompt Programmer.
• Enter the Remark as MODIFIED PROGRAM FOR CASTING.

i A fast way of moving between edit boxes is through the TAB key. Press TAB to move to the next edit box, or SHIFT+TAB
(hold down the SHIFT key and press TAB) to move to the previous box.

Click on OK to exit from the Work setup dialog box.

Save the File

• Select File → Save .

• Enter the file name as SHAFT. This CAPSturn file will now be saved as SHAFT.CPT
Draw the part

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path à
Generate NC program

Select Geometry on the menu bar. The geometry menu appears, with options for drawing and editing objects.

Select Drawà à Multiline .

• The prompt Specify the start point is displayed in the status bar at the bottom left portion of the screen.
• The start point can be specified either using the mouse or by entering through keyboard. Enter the value 0,0 using the keyboard and
press Enter.
• The prompt Specify the next point is displayed in the status bar.
• Enter 60, 0 to specify the co-ordinate X60, Z0 and press Enter.
• Enter the following co-ordinates in sequence:
60, -80
120, -80
120, -110
180, -110
180, -200
Click the right mouse button and then select Done to end the part shape drawing.
Define the Part
• Select Define à Define Part.
• The prompt Select the start point of the contour appears in the status bar.
• Select the point 1 as shown below.

• At the prompt Do you want to select the end point of the part? Click on No.
• Click on Yes at the prompt Create part shape?

The part now appears as shown below.

This ends the part definition.

Draw the blank

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path à
Generate NC program

• Select Draw à Multiline .

• Enter the following co-ordinates in sequence, at the prompts Specify the next point that appear on the status bar.
0, 1
184, 1
184, -239
• Click the right mouse button and then click on Done to end the blank drawing.

Define the Blank

• Select Define à Define Blank.
• The prompt Select the start point of the contour appears on the status bar.
• Click near point 1 as shown below.

• At the prompt Do you want to select the end point of the blank? click on No.
• Click on Yes at the prompt,Create blank shape?

This ends the blank definition.

The part and blank now looks as shown below.

Perform machining

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path
à Generate NC program

Click on Main to return to the main menu, then select Machining

i If you use the menu to change from Geometry to Machining, Machining to Tool path, etc., you must come to the Main menu
each time before you select an option. Clicking on an icon takes you straight to the selected mode. Using icons is faster.

The operations on this component involves the following:

Rough turning.
Finish turning.
Select a turning tool

• Select Tools → Turn . The tool selection dialog box appears.

• Enter the data as given below: Leave all the other entries unchanged.
Process name as EXTERNAL TURN (Rough).
Select Manufacturer as GENERAL-MM
Select Tool type as External turn
Select Tool material as Carbide
Select Tool name as PCLNL 2020 K11 R0.8
Click on the OK button.

Perform rough turning operation

• Select Turn à Contour turn .

• Select the start point of machining at the prompt Select the start point of machining on the PART, as shown below.
• At the prompt Select second point of machining on the PART, click on the end point of the portion to be turned, as shown below.

End point of
machining
Start point of
machining

Enter the data in the dialog box as shown below, leaving all the other entries unchanged.
• Enter Rough turning against the prompt Operation name.

Note that the cutting parameters for roughing operation are automatically picked from the database.
• Click on the OK button.

After roughing operation, the job will appear as shown below.

End the tool

A tool change is performed using the End option. To end the tool

• Click on End in the menu bar . The dialog box for End of tool appears.
• Do not alter any entries in the dialog box.
• Click on the OK button.

This completes the rough turning operation.

Select a finish turning tool

• Select Turn . The tool selection dialog box appears.

• Enter the data as given below: Leave all the other entries unchanged.
Process name as EXTERNAL TURN (Finish).
Select Manufacturer as GENERAL-MM
Select Tool type as External turn.
Select Tool material as Carbide.
Select Tool name as PDJNL 2020 K11 R0.4
• Click on the OK button.

Perform Finish turning operation

First, you need to specify the area along which the machining is to be performed.

• Select Turn à Finish turn

• At the prompt Select the start point of machining on the PART, click on the start point on the part to be turned as shown below.
• At the prompt Select second point of machining on the PART, click on the end point on the part to be turned as shown below.

End point of
machining

Start point of
machining

Enter the following data in the dialog box that appears leaving all the remaining entries unaltered.
Enter Finish turning against the prompt Operation name.
• Click on the OK button.

Note that the cutting parameters for finishing operation are automatically picked from the database.
Select machine

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path
à Generate NC program

The Work setup, Geometry definition, and Machining are independent of any machine. All functions after this are however dependent on
the machine since they use the machine’s mechanical data like feed rate and spindle speed limits, spindle power, etc. The machine must
be selected before doing the following :
• Viewing the toolpath
• Viewing the power graph
• Generating the NC program
• Generating the Time study sheet
• Generating the Tool list

To select a machine

Select Main → Machines . A list appears showing the list of machines.

• Click on the machine you want to select.
• Click on the OK button.

View tool path

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path
à Generate NC program

• Select Tool path from the menu bar . The tool path menu appears.

• Select Simulation → Solid mode .

• Select Simulation → Start.

The mode can be solid or line mode. You can make use of display options like Zoom, Pan etc. from the Display menu.

Generate NC program

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path à
Generate NC program

Click on Main return to the main menu.

• Click on NC program on the menu bar .

• Enter the program number in the dialog box that appears. Select OK.
• A status box indicating the location and status of the program generated appears.
• Click on the Edit button to view the NC program.
• The program file gets saved with the main file name and .PRG extension.
 Generate time study sheet

To generate the time study sheet,

• Click on Documents → Time study sheet .

• A dialog box appears with various formats of time study sheet preview. Select the required format and click on the View button.
• Click on the OK button to exit Time study sheet preview and again click on the OK button to exit time study sheet dialog box.

Generate tool list

To generate the tool list,

• Click on Documents → Tool list .

• A dialog box appears with various formats of tool list preview. Select the required format and click on the View button.
• Click on the OK button to exit tool list preview and again click on the OK button to exit tools list dialog box.

Generate power graph

• To generate the power graph, click on Power .
• A graph indicating the power consumed for each operation is displayed.
• Click on the OK button to exit power graph.

Tool layout sheet

• To generate the Tool layout sheet, click on Documents → Tool layout sheet .
• The tool layout sheet menu appears showing the format of the tool layout sheet.

• Click on the arrow buttons in the menu bar to switch between sheets.
Tutorial 1
In inches

This tutorial illustrates,

• Creating geometry.
• Selecting tools.
• Performing Rough turning and Finish turning.
• Viewing tool path.
• Generating documents.

Part & Blank drawing

8 9.5
4.5

3.25

φ7 φ 2.5 φ5 φ 9.1

Part shape Blank shape

All dimensions are in Inch

 Steps to NC program
Start a new program Start new program à Define work setup à Draw the part à Draw the Blank à Perform
Machining à Select Machine à View tool path à Generate NC program

• Start CAPSturn. To do this, double click on the CAPSturn icon

or
Select Start → Programs → Cadem → CAPSturn 7.0.

• Select File → New .

The Work setup dialog box appears.

Steps to NC program
Define work setup Start new program à Define work setup à Draw the part à Draw the Blank à Perform
Machining à Select Machine à View tool path à Generate NC program

The Work set up data is divided into Setup data 1, Setup data 2 and Documentation. Setup data is required for machining, and
documentation is related to the details of the program. Entering the Setup data is mandatory, while General data is optional.

Enter the data as shown below, leaving the remaining entries unaltered.

Setup data 1
• Against the prompt Workpiece material click on and select Steels, high carbon low alloy TS 550-750 N/mm2 from the
list.
• Enter the Part load + unload time as 30.
• Specify Limiting spimdle speed as 3000.
• Enter Jaw position absolute Z as -9.
• Enter 0.2 against the prompt Clearance Z.
• Enter 9.3 against the prompt Clearance OD.

Click on Setup data 2 tab and enter the data as shown below.
• Enter the Tool change position as, Rear turret X= 12 Z= 8
• Select the Units as Inch by clicking on it.
• Click on Documentation tab to enter the documentation or click on the OK button to save and exit work setup.

Click on Documentation tab and enter the data as shown below.

• Part number as FN 0023.
• Part name as SHAFT.
• Setup number as 1.
• Fixture as CHUCK.
• Enter the name of the Programmer against the prompt Programmer.
• Enter the Remark as MODIFIED PROGRAM FOR CASTING.

Click on OK to exit from the Work setup dialog box.

Save the File

• Select File → Save .

• Enter the file name as SHAFT. This CAPSturn file will now be saved as SHAFT.CPT
Draw the part

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path
à Generate NC program

• Select Drawà à Multiline .

• The prompt Specify the start point is displayed in the status bar at the bottom left portion of the screen.
• The start point can be specified either using the mouse or by entering through keyboard. Enter the value 0,0 using the keyboard and
press Enter.
• The prompt Specify the next point is displayed in the status bar.
• Enter 2.5,0 to specify the co-ordinate X2.5, Z0 and press Enter.
• Enter the following co-ordinates in sequence:
2.5,-3.25
5,-3.25
5,-4.5
7,-4.5
7,-8
• Click the right mouse button and then select Done to end the part shape drawing.

Define the Part

• Select Define à Define Part.

• The prompt Select the start point of the contour appears in the status bar.
• Select the point 1 as shown below.

• At the prompt Do you want to select the end point of the part? Click on No.
• Click on Yes at the prompt Create part shape?
The part now appears as shown below.

This ends the part definition.

Draw the blank

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path à
Generate NC program

• Select Draw à Multiline .

• Enter the following co-ordinates in sequence, at the prompts Specify the next point that appear on the status bar.
0,0.04
9.1,-9.46
9.1,0.04
• Click the right mouse button and then click on Done to end the blank drawing.

Define the Blank

• Select Define à Define Blank.

• The prompt Select the start point of the contour appears on the status bar.
• Click near point 1 as shown below.

• At the prompt Do you want to select the end point of the blank? click on No.
• Click on Yes at the prompt,Create blank shape?
This ends the blank definition.

The part and blank now looks as shown below.

Perform machining

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path
à Generate NC program

Perform turning operations

• Click on Main to return to the main menu, then select Machining

i If you use the menu to change from Geometry to Machining, Machining to Tool path, etc., you must come to the Main menu
each time before you select an option. Clicking on an icon takes you straight to the selected mode. Using icons is faster.

The operations on this component involves the following:

• Rough turning.
• Finish turning.

Select a turning tool

• Select Tools → Turn . The tool selection dialog box appears.

• Enter the data as given below: Leave all the other entries unchanged.
Process name as EXTERNAL TURN (Rough).
Select Manufacturer as GENERAL-Inch
Select Tool type as External turn
Select Tool material as Carbide
Select Tool name as DCLNL 124B R0.031
• Click on the OK button.
Perform rough turning operation

• Select Turn à Contour turn .

• Select the start point of machining at the prompt Select the start point of machining on the PART, as shown below.
• At the prompt Select second point of machining on the PART, click on the end point of the portion to be turned, as shown below.

End point of
machining
Start point of
machining

Enter the data in the dialog box as shown below, leaving all the other entries unchanged.
• Enter Rough turning against the prompt Operation name.
• Enter the Depth of cut as 0.04

The cutting parameters for roughing operation are automatically picked from the database.
• Click on the OK button.

After roughing operation, the job will appear as shown below.

End the tool

A tool change is performed using the End option. To end the tool

• Click on End in the menu bar . The dialog box for End of tool appears.
• Do not alter any entries in the dialog box.
• Click on the OK button.

This completes the rough turning operation.

Select finish turning tool

• Select Turn . The tool selection dialog box appears.

• Enter the data as given below: Leave all the other entries unchanged.
Process name as EXTERNAL TURN (Finish).
Select Manufacturer as General-Inch
Select Tool type as External turn.
Select Tool material as Carbide.
Select Tool name as DDJNL 123C R0.031
• Click on the OK button.

Perform Finish turning operation

First specify the Machining area.

• Select Turn à Finish turn

• At the prompt Select the start point of machining on the PART, click on the start point on the part to be turned as shown below.
• At the prompt Select second point of machining on the PART, click on the end point on the part to be turned as shown below.

End point of
machining

Start point of
machining

Enter the following data in the dialog box that appears leaving all the remaining entries unaltered.
• Enter Finish turning against the prompt Operation name.
• Click on the OK button.

The cutting parameters for finishing operation are automatically picked from the database.

• End the tool

Select machine

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path
à Generate NC program

The Work setup, Geometry definition, and Machining are independent of any machine. All functions after this are however dependent on
the machine since they use the machine’s mechanical data like feed rate and spindle speed limits, spindle power, etc. The machine must
be selected before doing the following :
• Viewing the toolpath
• Viewing the power graph
• Generating the NC program
• Generating the Time study sheet
• Generating the Tool list

To select a machine

Select Main → Machines . A list appears showing the list of machines.

• Click on the machine you want to select.
• Click on the OK button.

View tool path

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path à
Generate NC program

• Select Tool path from the menu bar . The tool path menu appears.

• Select Simulation → Solid mode .

• Select Simulation → Start.

The mode can be solid or line mode. You can make use of display options like Zoom, Pan etc. from the Display menu.
Generate NC program

8 steps to NC program
Start new program à Define work setup à Draw the part à Draw the Blank à Perform Machining à Select Machine à View tool path à
Generate NC program

Click on Main return to the main menu.

• Click on NC program on the menu bar .

• Enter the program number in the dialog box that appears. Select OK.
• A status box indicating the location and status of the program generated appears.
• Click on the Edit button to view the NC program.
• The program file gets saved with the main file name and .PRG extension.
Generate time study sheet

To generate the time study sheet,

• Click on Documents → Time study sheet .

• A dialog box appears with various formats of time study sheet preview. Select the required format and click on the View button.
• Click on the OK button to exit Time study sheet preview and again click on the OK button to exit time study sheet dialog box.

Generate tool list

To generate the tool list,

• Click on Documents → Tool list .
• A dialog box appears with various formats of tool list preview. Select the required format and click on the View button.
• Click on the OK button to exit tool list preview and again click on the OK button to exit tools list dialog box.

Generate power graph

• To generate the power graph, click on Power .
• A graph indicating the power consumed for each operation is displayed.
• Click on the OK button to exit power graph.

Tool layout sheet

• To generate the Tool layout sheet, click on Documents → Tool layout sheet .
• The tool layout sheet menu appears showing the format of the tool layout sheet.

• Click on the arrow buttons in the menu bar to switch between sheets.
Tutorial 2

This tutorial illustrates,

• Drawing complex jobs
• Performing Facing, Boring and turning operation
• Generating documents

85
33.5

27.5 95

φ 146 149
Part
φ 131 Blank

φ 116

φ 88.2

R 41.425 φ 82.85
50
φ 55.5

24 80
65
9.5
All dimensions are in MM.
 Steps to NC program
Start a new program Start new program à Define work setup à Draw the part à Draw the Blank à Perform
Machining à Select Machine à View tool path à Generate NC program

• Start CAPSturn. To do this, double click on the CAPSturn icon.

Or
Select Start → Programs → Cadem → CAPSturn 7.0.

• Select File→ New .

The Work setup dialog box appears.

Steps to NC program
Define work setup Start new program à Define work setup à Draw the part à Draw the Blank à Perform
Machining à Select Machine à View tool path à Generate NC program

Enter the data shown below in the Work setup dialog box that appears, leaving the rest unaltered.

Setup data 1
• Against the prompt Workpiece material click on and select Steels, structural / plain carbon TS 450-550 N/mm2
• Enter the Part load + unload time as 30.
• Specify Limiting spindle speed as 3000.
• Enter Jaw position absolute Z as -90.
• Enter 10 against the prompt Clearance Z.
• Enter 50 against the prompt Clearance ID.
• Enter 150 against the prompt Clearance OD.

Click on Setup data 2 tab and enter the as shown below.

• Enter the Tool change position as, Rear turret X= 300 Z= 200
• Select the Units as MM by clicking on it.

Click on Documentation tab and enter the data as shown below.

• Part number as 213 N 0023.
• Part name as WORMGEAR.
• Setup number as 1.
• Fixture as CHUCK.
• Enter the name of the Programmer against the prompt Programmer.
• Enter the Remark as CHECK FIXTURE NUMBER BEFORE MACHINING.
• Click on the OK button.

Save the file

• Select File → Save .
• Enter the file name as WORMGEAR.
Draw the part

8 steps to NC program
Start new program à Define work setup à Draw the part à Define Blank à Perform Machining à Select Machine à View tool path à
Generate NC program

Go to the Geometry menu.

• Select Draw à Line à Point – point .

• Enter 55.5, -64 as the start point of line and press Enter.
• Enter 55.5, -30 as the end point of the line and Press Enter.

• Select Draw à Multiline .

• Enter the following co-ordinates in sequence, against the prompts that appear on the status bar (Press Enter after entering each set of
values).
82.85, -35
82.85, -9.5
88.2, -9.5
88.2, 0
116,0
116, -27.5
131, -27.5
146, -33.5
146, -85
• Click the right button of the mouse and select Done.

• Draw a circle: Select Draw → Circle → Center- Radius .

• Enter 0, -24 against the prompt Specify the center point that appear on the status bar.
• Enter 41.425 against the prompt Enter the radius.

• Select Display à Zoom All from the menu bar . This is done to get all the objects drawn so far within the display screen.
This completes drawing the objects for the part shape. The drawing now looks as shown below.

Edit the part

The drawing drawn so far has to be modified by erasing unnecessary objects. To do this,
• Select Edit → Break .
• At the prompt Select an object, click on the circle on point 1 as shown in the figure.
• At the prompt Select the first break point click the right mouse button and select Intersection of, from the menu.
• Click on point 2 as shown in the figure below.
• At the prompt Select the second break point, click the right button of the mouse again, select Intersection of, and click on point 3.
 3

Erase unnecessary objects from the part shape

• Select Edit à Erase . At the prompt Select the objects (Press W to enclose them in a window), click on the point shown below, in
the figure.

Click
here
• Click the right button of the mouse and select Done to erase the selected object.

• Select Display à Zoom .

• At the prompts Specify the first corner of the window, click near point A as shown in the figure.
• At the prompt Specify the opposite corner of the window, click near point B as shown below.

A
Zoom
window

B
The area enclosed within the window gets enlarged

• Select Edit à Trim . Click on point 4 shown in the figure at the prompt Select the boundary object.
• Click on point 5 and then on point 6 at the prompt Select the object to be trimmed.
 6

5
• Press the right button of the mouse and select Done.
• Select Display à Zoom All.

Insert chamfers in the part.

• Select Edit à Chamfer . At the prompt Select the corner to insert chamfer, Click on point 1 as shown in the figure below.
• Enter 1 at the prompt Enter the chamfer length and press Enter.
• Click the right mouse button. The chamfer command is called again.
• Click at point 2 at the prompt Select the corner to insert chamfer.
• Enter 1 at the prompt Enter the chamfer length and press Enter.

Define the Part

• Select Define à Define part.

• The prompt Select the start point of the contour appears in the status bar, situated at the bottom left hand corner of the screen.
• Click near point 1as shown in the figure below.

• At the prompt Do you want to select the end point of the part?, Click on No.
• At the prompt Create part shape? click on Yes.
This ends the part definition.
Draw the part

8 steps to NC program
Start new program à Define work setup à Draw the part à Define Blank à Perform Machining à Select Machine à View tool path à
Generate NC program

• Select Draw à Multiline .

• Enter the following co-ordinates in sequence :
50,-80
50,1.5
149,1.5
149,-95
• Press the right button of the mouse and select Done from the menu.

Define the Blank

• Select Define à Define blank.

• The prompt Select the start point of the contour appears on the status bar.
• Click near point 1 as shown in the sketch below.

• At the prompt Do you want to select the end point of the blank ?, click on No.
• At the prompt Create blank shape ? click on Yes.
• Select Display à Zoom All

This ends the Geometry.

The drawing now looks as shown below.
Perform machining

8 steps to NC program
Start new program à Define work setup à Draw the part à Define Blank à Perform Machining à Select Machine à View tool path
à Generate NC program

Select a turning tool

• Go to the Machining menu.

• Click on Toolàà Turn . The tool selection dialog box appears with default data.
• Enter the data as given below. Leave the remaining entries unaltered.
Process name: EXTERNAL TURN / FACE.
Manufacturer: General-MM
Tool type: External turn.
Tool material: Carbide.
Tool name: PCLNL 2020 K11 R0.8
• Click on the OK button.

Note: If you have made a mistake in entering the data for any process, it can still be modified through the Edit menu in Machining.

Perform rough facing operation

• Select Turn à Plain Face .

• At the prompt Select start X on BLANK (Press P for selecting onPART), click near point 1as shown in the figure.
• At the prompt Select end X on BLANK (Press P for selecting on PART) click near point 2.
• At the prompt Select final Z on PART click on point 3.

• A dialog box appears with default values.

• Enter Rough facing against the prompt Process Name. Leave all the remaining entries unaltered
• Click on the OK button.
 Perform rough turning operation

• Select Turn à Contour turn .

• At the prompt Select the start of machining on the PART click near point 1 as shown in the figure.
• At the prompt Select the second point on of machining on the PART, click near point 2 as shown below.

2
1

• Enter the data mentioned below, leaving all the remaining entries unchanged, in the dialog box that appears.
Against the prompt Process Name enter Rough turning.
Change the Depth of cut to 5 mm.
• Click on the OK button.

Select a boring tool

• Select Tool à Bore . The tool selection dialog box appears with default data.
• Enter the data as given below leaving the remaining entries unchanged.
Process name: BORE ROUGH.
Manufacturer: General-MM
Tool type: Bore.
Tool material: Carbide.
Tool name: S20S-SCLCL 09-M R0.8
• Click on the OK button.

Perform rough boring operation

• Select Turn à Contour turn .

• At the prompt Select the start of machining on the PART click near point 1 as shown in the figure.
• At the prompt Select the end point of machining on the PART click near point 2.

• Modify the data as shown below in the dialog box that appears, leaving all the other entries unchanged.
• Against the prompt Operation name, enter Rough boring.
• Click on the OK button.
Select a turning tool for finishing

Select the tool PDJNL 2020 K11 R0.4 from the General-MM manufacturer database.

Perform finish facing operation

• Select Turn à Finish Face .

• At the prompt Select the start of machining on the PART click near point 1 shown in the figure.
• At the prompt Select the end point for machining on the PART click near point 2.

• Enter the Operation name to Finish facing in the dialog box that appears, leaving all the other entries unchanged.
• Click on the OK button.
• End the tool

Perform finish turning operation

• Select Turn à Finish turn .

• At the prompt Select the start of machining on the PART click near point 1 shown in the figure.
• At the prompt Select the end point of machining on the PART click near point 2.
• Change the Process Name to Finish turning in the dialog box that appears, leaving all the other entries unchanged.
• Click on the OK button.
• End the tool

Select a boring tool for finishing

Select the tool S25T-SDUCL 11-M R0.8 from the General-MM manufacturer database.
Perform finish boring operation

• Select Turn à Finish turn .

• At the prompt Select the start of machining on the PART click near point 1 shown in the figure below.
• At the prompt Select the end point of machining on the part click near point 2.

1
2

• Change the Operation name to Finish boring in the dialog box that appears, leaving all the other entries unchanged.
• Click on the OK button.
• End the tool

This completes all the machining operations on the part. We have however made a mistake. The depth of cut entered for the rough turning
operation is 5 mm, which is may be too high for the tool. Modify the operation to reduce the depth of cut to 3 mm.

To modify the process,

• Click on Edit .
• The Edit box appears with the list of all the tools selected and operations performed so far.
• Click on the operation Rough turning, then click on the Modify button.
• The prompt Do you want to reselect the machining area appears. Select No.
• The rough turning dialog box appears with the data entered earlier. Change the Depth of cut to 3.
• Click on the OK button.
• Click on the OK button to exit Edit dialog box.
Tutorial 3

This tutorial illustrates,

• Drawing and defining grooves.

• Performing grooving operation.
• Performing threading operation.

Part & blank drawing

100
A 70.92 110
50

Part φ 110 Blank 114

φ 94
φ 80

φ 36 φ 50
5
φ 30 26

70.92

Detail A

Chf. 1x45º typ. 70.92

R1 Typ.
All dimensions are in MM.
5º Chamfer all corners by 2 x 45º.
Start a new program
1. Start CAPSturn. To do this, double click on the CAPSturn icon
or
Select Start → Programs → Cadem → CAPSturn 7.0.

2. Select File → New .

3. The Work setup dialog box appears.

Define work setup

Setup data 1
• Against the prompt Workpiece material click on and Steels, free cutting TS 400 -700 N/mm2
• Enter the Part load + unload time as 30.
• Specify Limiting spimdle speed as 3000.
• Enter Jaw position absolute Z as -105.
• Enter 5 against the prompt Clearance Z.
• Enter 25 against the prompt Clearance ID.
• Enter 114 against the prompt Clearance OD.

Click on Setup data 2 tab and enter the data as shown below.
• Enter the Tool change position as, Rear turret X= 300 Z= 100
• Select the Units as MM by clicking on it.
• Enter the Documentation, if required or else click on the OK button.
• Save the file.

Draw the part

Go to the Geometry menu. Here, we will use the Quick shaft option to draw the part shape.
• Select Draw → Quick shaft → Horizontal line at start.
• At the prompt Specify the start point, enter 30,-100 and press Enter.
• At the next consecutive prompts Specify Z coordinate and Specify X coordinate, specify the following values in sequence and press Enter
after each value is entered.
-50
50
0
80
-50
110
-100
• Click on the right mouse button and select Done.
• Select Display → Zoom All .
Draw external groove

• Select Draw à Groove.

• Enter the data shown below in the dialog box that appears and click on the OK button.
Depth = 3
Base Width = 5
Chamfer at top = 1
Angle of sides = 5
Radius at base = 1
• Against the prompt Select the groove reference point, enter 110, -70.92.

Draw internal groove

• Select Draw à Groove.

• Enter the data against the respective prompts, in the dialog box that appears and click on the OK button.
Depth = 3
Base Width = 5
Angle of sides = 5
Groove type = Click on Internal.
• At the prompt Select the groove reference point, enter 30, -70.92.

• Break and trim the line over the grooves. To do this, select Edit à Break. Press the F1 key on the keyboard to get online help on Break
command. After breaking, trim the unwanted line on the groove. Break and Trim commands are also discussed in Tutorial 2.

Draw chamfer of 1 x 45º at all the sharp corners as shown in the part drawing and then define the part.

Draw the Blank

• Draw the blank using the Quick shaft à Vertical line at start option through the following points.
0,-110
26
3
114
-110
• Define the blank.

Perform machining
Perform the following operations by selecting appropriate tools. All the tools are available in General – MM manufacturer database.
• Rough face / turn the part
Rough face and turn the part using Conotur face and Contour turn operations respectively, after selecting a suitable turning tool.

• Rough bore the part

Rough bore the part using the Contour turn operation after selecting a suitable boring tool.

• Finish face / turn the part

Finish face and turn the part using Finish face and Finish turn operations respectively, using a suitable turning tool.

• Finish bore the part

Finish bore the part using the Finish turn operation using suitable boring tool.

The internal and external turning operations on the part are now complete.
Select an external grooving tool

• Select Toolàà External groove and enter the following data in the dialog box.
Process name = EXTERNAL GROOVE
Manufacturer = General – MM
Tool type = External groove
Tool material = Carbide
Tool name = 20 x 20, 2.0 W, 13 Depth, LH
• Click on the OK button.

Perform external grooving operation

• Select Groove à Radial . At the prompt Select the object at the start of the groove click anywhere on the groove as shown below.

Click here to
select groove

• Enter the following data in the dialog box that appears, leaving all the other entries unaltered.
Operation name = External grooving
Depth of cut = 2
Process = Select both Roughing and Finishing
• Click on the OK button.
• End the tool

Select internal grooving tool

• Select Toolàà Internal groove and enter the following data in the dialog box.
Process name = INTERNAL GROOVE
Manufacturer = General- MM
Tool type = Internal groove
Tool material = Carbide
Tool name = Dia. 16.0, 2.0 W, 4 Depth, LH
• Click on the OK button.

Perform internal grooving operation

• Select Groove à Radial.

• At the prompt Select the object at the start of the groove click on the groove.
• A dialog box appears with default data. Enter the following data against the respective prompts.
Operation name = Internal grooving
Process = Select both Roughing and Finishing
• Click on the OK button.
• End the tool.

Select external threading tool

• Select Toolàà External thread and enter the following data in the dialog box.
Process name = EXTERNAL THREAD
Manfacturer = General- MM
Tool type = External thread
Tool material = Carbide
Tool name = Thread 20 x 20, 60º, Depth 3.0, LH
• Click on the OK button.
Perform external threading operation

• Select Thread .
• At the prompt Select a line for threading click on the line as shown below.

Click here to
select groove

• Enter the data shown below in the dialog box that appears, leaving all the other entries unaltered.
Operation name = External threading
Thread pitch = 2
Thread depth = 1.2
Number of cutting passes = 6
Number of idle passes = 2
Entry distance = 2
Exit distance = -10
• The exit distance is entered as -10 to make the tool stop 10 mm before the end point of the line selected.
• Click on the Ok button.
• End the tool.

Select internal threading tool

• Select Tool à Internal thread and enter the following data in the dialog box that appears.
Process name = INTERNAL THREAD
Manufacturer = General- MM
Tool type = Internal thread
Tool material = Carbide
Tool name = Thread Dia.20.0, 60º, Depth 2.0, LH
• Click on the OK button.

Perform internal threading operation

• Select Thread .
• At the prompt Select a line for threading click on the line as shown below.

Start point of
threading
End point of
threading

• Enter the data shown below leaving all the other entries unaltered, in the dialog box that appears.
Operation name = Internal threading
Thread pitch = 2
Thread depth = 1.2
Number of cutting passes = 6
Number of idle passes = 2
Entry distance = 2
Exit distance = -10
• The exit distance is entered as -10 to make the tool stop 10 mm before the end point of the line selected.
• Click on the Ok button.
• End the tool
Tutorial 4

This tutorial illustrates,

• Define a Form tool

• Performing Single motions
• Prevent Tool gouge automatically

Part drawing & Blank drawing

90

80
50
Chm. 2 x 45º TYP. 100
40

φ 60
φ 55
Blank
φ 35 Part φ 30

20
All dimensions are in MM.
Stat a new program

1. Start CAPSturn. To do this, double click on the CAPSturn icon

2. Select File → New .

3. The Work setup dialog box appears.
4. Enter the Work setup with appropriate data referring to the drawing (Select the Program mode as Diameter).
5. Save the file as Roller.

Define the Form tool

Defining a form tool involves the following steps.

1. Drawing the form tool and saving it in the shape file.
2. Adding the tool to the FORMTOOLS-MM manufacturer.

Draw the Form tool

• Select Utilities → Form tool → Define from the Main menu.

• A dialog box appears with names of defined form tools.
• At the prompt File name, enter FORM4A and then click on the OK button.
• Select MM as the units in the dialog box that appears and click on the OK button.
The menu changes to the Geometry menu with the common drawing options enabled.
• Select Draw → Multiline. Draw the tool shape as a multiline through the following points (Refer the form tool drawing as reference).
Point X Z
1 1.172 3.414
2 8 6
3 8 10
4 24 10
5 24 13
6 28 15
7 70 15
8 70 4
9 13.657 4
10 6.828 0.586

• Click on the right mouse button and select Done.

• To draw an arc of radius 2 between points 10 and 1, select Draw → Arc → Start - End - Radius.
• At the prompt Specify the start point click on the right mouse button and select End of.
• Click on point 10 shown in the figure below.
• At the prompt Specify the end point, click on the right mouse button and select End of.
• Click on point 1 shown in the figure.
• Enter 2 as the radius and press Enter.

This completes the form tool definition. The defined form tool will look as shown below.

8 7

6
4
5
9
2
10 3
1

R2
Add the Form tool to the database

• Click on Main to return to the Main menu.

• The Prompt Do you want to save this form tool? appears. Click on Yes.
• Select Config → Tool and FS database. Enter cadem as the password.
• A dialog box with the list of manufacturer names appear. Select Form tools - MM manufacturer and then click on Tools.
• A dialog box with the list of tools appear.
• Select Tool type as Form tool. The list of form tools is displayed. Click on Add.
• Enter the following data against appropriate prompts in the dialog box.
Tool name = Relief tool
Form tool class = External turn.
Shape file name = FORM4A
Approach angle = 90
Nose angle = 0
Nose radius = 2
Hand of tool = Left
• Click on on the OK button.
• Click on the OK button to exit Form tools - MM manufacturer and again on the OK button to exit Tool and FS database.

Draw and define the Part and Blank

• Draw the Part as given in the drawing using options in the Geometry menu.
• Define the part.
• Draw the Blank as a bar stock of 60 mm diameter and 100 mm length.
• Define the blank.

Perform machining
Perform the following operations using a MTJNL 2020K16 R 0.8 tool.
• Face the part using the Plain face option.
• Rough turn the part through Contour turn option. Leave a finishing allowance of 0.5 mm along X and Z axis.

The pocket cannot be completely machined by a left-hand tool as shown below. The automatic gouge prevention facility prevents the back
edge of the tool from gouging into the part, and the area shown below is therefore left unmachined.

Unmachined area

• Select a Right hand tool and remove the unmachined area using Contour turn. Specify the start and end point of the contour as shown in
the figure as 1 and 2.
Unmachined
area

1 2

• Finish turn the part through Finish turn. Select a suitable tool, which can machine the whole of the outer diameter.
Select the Form tool

• Select Tool → Form tool.

• The tool selection dialog box appears. Enter the following data against respective prompts.
Process name = THREAD RELIEF
Manufacturer = Form tools - MM
Tool type = Form tool
Tool material = HSS
Tool name = Select Relief tool
• Click on the OK button.

Machine the relief groove using the Form tool

• Click on Single motions and select Start operation.

• Enter Operation name as Machining Relief in the dialog box that appears.
• Select Single motions → Spindle. A dialog box for specifying spindle speed appears. Enter the data shown below.
Constant cutting speed = Select On
Limiting spindle speed / Spindle speed = Enter 2000
Cutting speed =Enter 600
Spindle direction = Select CCW.
• Click on the OK button.
• Select Single motions → Rapid traverse.
• Press the Insert key on the keyboard.
• Enter 100 and -38 for X and Z respectively and click on OK.
• Select Single motions → Rapid traverse.
• Press the Insert key on the keyboard.
• Enter 34 for X and leave Z value blank. Click on OK.
• Select Single motions → Feed traverse. Press the Insert key on the keyboard.
• Set the Mode to Relative by clicking on it.
• Enter -6 and -3 for X and Z respectively. Enter 0.1 for the feed rate and click on OK.
• Select Single motions → End operation.
• End the tool.
Tutorial 5

This tutorial illustrates,

• Turn on the face of a component with a rotated tool
• Machining using Single motions.
• Parting the component.

Part & blank drawing

Chm. 2 x 45º TYP.

28
8

10 20º
φ 140
φ 130
Part Blank

φ 70

φ 50
φ 40
20

All dimensions are in mm

Draw the part shape

Start a new program.

Define the Work setup.
Draw the part shape (Refer to the Part geometry).
Define the part.
Draw the blank shape (Refer to the Blank geometry).
Define the blank.

Perform machining operations

• Complete Facing and turning the part using a suitable tool.

• Bore the part using a suitable tool.

Turning the pocket on the face

From the Tools menu, select Turn and enter the following data in the dialog box that appears.

• Select the external turning tool SVVBN 2020K 16 R0.8 and enter the following data in the tool selection dialog box.
• Enter FACE CONTOUR TURN as process name.
• Select General - MM as the manufacturer.
• Select Carbide as the tool material.
• Select SVVBN 2020 K 16 R0.8 tool from the list.
• Click on the Tool geometry button and set Rotation angle as -90 degrees.
• Click on the OK button.

Contour facing the pocket

• From the Turn menu, select Contour face.

• Select the start and end points of machining at the respective prompts, as shown below.

• In the contour facing dialog box that appears, enter suitable values against each prompt.
• End the tool.
This ends the contour facing operation in the face pocket.
Select a Parting tool

• Select Tool → External groove from the menu bar.

• In the dialog box that appears, enter the following data. Leave all the other data unaltered.
Enter PARTING for the process name.
Select General - MM as the manufacturer file.
Select Tool type as Parting.
Select Carbide as the tool material.
Select a parting tool 25 x 25, 2.0 W, 50 Depth, LH.

Performing parting operation

• Select Groove → Parting.

• At the prompt Specify the Z coordinate for parting off enter -23.
• In the dialog box that appears, enter the following parameters, leaving the rest unaltered.
Operation name = Parting off
Check Pecking required ? and enter the Peck depth as 5
Enter the Overshoot as 1
Enter Diameter for reduced Feedrate as 8
Click on the OK button.
• End the tool
All the operations on the component are now complete.

Modify a process

• Click on Edit.
• An edit box appears with the list of all the tools selected and operations performed so far.
• Select the tool or operation that you want to modify by clicking on it. Click on the Modify button.
• If you have selected a tool for modification, the tool dialog box appears. Make the necessary changes and click on the OK button.
• If you have selected an operation for modification, a prompt Do you want to reselect the machining area appears.
- Select yes if you want to change the machining area for that operation. Reselect the machining area at the respective prompts.
- Select No if you want to change only the dialog box entries and not the machining area.
• Click on the OK button after making the necessary changes.
• After all the changes are made, click on the OK button to return to the Machining menu.
 Tutorial 6

This tutorial illustrates how to perform an operation using Subprograms.

Subprograms are defined using Single motions.

The operations on this component include,
1. Facing and turning the part.
2. Grooving on step 1 with a form tool.
3. Grooving on step 2 with a form tool.

• Start a new program.

• Define the Work setup.
• Save the file as ROTOR.CPT.
• Draw and define the Part shape. Ignore the grooves when drawing the part since they are machined with a form tool using single motions.
• Draw and define the blank shape.
• Draw the form tool as per the dimensions given in the darwing and add it to Tool and FS database.
When defining the form tool, point ‘A’ shown in the drawing should be at 0,0, which is the reference edge for machining.

Part and blank dimensions

180 85

15 15
185 90

φ 100

φ 85 Part φ 50
φ 35 φ 104 φ 54
Blank

3 grooves of width = 10 2 grooves of width = 10

mm at 35 mm pitch mm at 35 mm pitch

All dimensions are in MM.

Define the subprogram
st nd
Here, you need to define two subprograms, one for the 1 step and one for the 2 step. To define the first subprogram,
• From the Main menu select Subprogram, then Define and enter Groove1 as the name of the subprogram.
• Select Single motions from the menu bar.
• Move the tool at Rapid by a relative amount Z-35 at the current X co-ordinate.
• Move the tool at a Feedrate by a relative amount X -11.5 at the current Z co-ordinate.
• Move the tool at Rapid by the relative amount X11.5 at the current Z co-ordinate.
• Click on Machining to return to the Machining menu.

To define the second subprogram,

• From the Main menu select Subprogram, then Define and enter Groove2 as the name of the subprogram.
• Select Single motions from the menu bar.
• Move the tool at Rapid by a relative amount Z-35 at the current X co-ordinate.
• Move the tool at a Feedrate by a relative amount X -11.5 at the current Z co-ordinate.
• Move the tool at Rapid by the relative amount X11.5 at the current Z co-ordinate.
• Click on Machining to return to the Machining menu.

This ends the subprogram definition.

Perform machining

Using a suitable turning tool, face and turn the part.

Select the form tool defined earlier.
Using Single motions,
• Specify the Operation name as Grooving.
• Specify a spindle speed.
• Move the tool to an absolute position of X = 58 and Z = 10 at a Rapid traverse.
• Select Subprogram from the menu bar and then select Call. Select Groove1 as the name of the subprogram from the list that appears and
enter 2 for the Number of calls.
• Move the tool to an absolute position X108 at the current Z co-ordinate through Single motions.
• Move the tool to to an absolute position Z-75 at the current X co-ordinate.
• Select Subprogram, then Call. Select Groove2 for the name of the subprogram to be called and 3 for the Number of calls.
• End the operation.
This completes all the machining operations on the component.

Form tool
25

100

13 A
10

10
Tutorial 7
Configuring databases

Configuring the databases involve,

• Adding a new Tool manufacturer in the database.
• Adding a tool to a tool manufacturer.
• Adding a tool material.
• Adding cutting parameters.

Here, you will configure the database for each functions mentioned above.

CAPSturn is shipped with a master database file turn.MDB in which all the tool manufacturer database, tools and cutting parameters, tool
and workpiece materials, machine list are stored. This file is stored in the directory in which CAPSturn is installed.

Configuring databases
Creating a new tool manufacturer

Whenever you create a new tool manufacturer it gets stored in turn.mdb file. You can either create a blank tool manufacturer in which case
you will have to enter all the tools, tool materials and cutting parameters right from scratch. Building a tool manufacturer this way consumes
a lot of time.
Hence, the easier and efficient method would be to create a new manufacturer and copy the data from an existing manufacturer into it. This
way you will only have to modify the names of tools, leaving the cutting parameters and tool materials unaltered.

• Select Config {bmc arrow.bmp} Tool and FS database from the Main menu.
• At the prompt for password, enter cadem.
• Click on Tool Manufacturer button.
• A list of existing tool manufacturers appears. Click on the Add button.
• Against the prompt Manufacturer name, enter First manufacturer – MM. Note: This is the name which will appear in the list of
manufacturers.
• Select the units as MM.
• Specify the remarks as New tool manufacturer included during training session.

So far you have specified all the details to create a new manufacturer. But as explained earlier, you need to copy the data from an existing
manufacturer into this new manufacturer. To do this,

• Check Copy data from an existing manufacturer?

• Against the prompt Manufacturer to copy select General – MM from the list. All the data from General – MM manufacturer will be
copied into this manufacturer.
• Click on the OK button.

Note: The process of copying data from an existing manufacturer may take some time depending on the amount of data in the selected
manufacturer.

Notice that the new tool manufacturer First manufacturer – MM is created in the list of manufacturers. Select the manufacturer and click on
Tools button. Note that the tools available in this manufacturer are similar to that of General – MM manufacturer.

• Click on the OK button to exit this dialog box.

Configuring databases
Adding a new workpiece material

Workpiece material is independent of any Tool manufacturer.

• Click on the Workpiece material button. A dialog box with the list of existing materials appear.
• Click on the Add button.
• Enter the material name as New raw material against the prompt Workpiece material.
• Enter the Hardness factor as 0.8 and Machining exponent as 1. These are the parameters required to determine the material
properties and is used in Power graph calculation.
• Click on the OK button.
• Click on the OK button to exit workpiece material dialog box.

Configuring databases
Adding a tool type in a tool manufacturer

Before you add a tool type, you need to understand the concept of Tool class and Tool type in CAPSturn.

Tool class
These are the basic category of tools which are used to perform an operation. E.g., Drill, Turning tool, Boring tool, Grooving tool etc.

Tool type

These are various types of tools under a tool class. E.g., Twist drills, Insert drills, Flat drills are all different types of tools under Drill tool class.

Tool classes are fixed within CAPSturn, and cannot be added, modified or deleted. Tool types can be defined by you to put tools in separate
categories (types) and make selection easier. A tool type is specific to a Tool manufacturer.

To add a tool tpe,

• Select the newly added tool manufacturer First manufacturer – MM from the Tool and FS database dialog box.
• Click on the Tool types button. A dialog box with the list of existing tool types appear.
• Click on the Add button.
• Enter the name of tool type as New tool type against the prompt Tool type.
• Against the prompt Tool class, select Drill from the list.
• Enter the safe height as 3 MM.

Here, you have assigned the ‘New tool type’ to ‘Drill’ tool class. This means that New tool type belongs to the tool class drill and hence you
can select the tools from this tool type only when you select a Drill in the Machining menu.

• Click on the OK button. Notice that the tool type appears in the list.
• Click on the OK button to exit Tool types dialog box.

Configuring databases
Adding a tool material in a tool manufacturer

• Select the tool manufacturer First manufacturer – MM from the Tool and FS database dialog box.
• Click on Tool material button.

A tool material is specific to a Tool type in a Tool manufacturer.

• Select New tool type from the list. This is the tool type newly added in the above manufacturer.
• Click on the Add button.
• Enter New material against the prompt Tool material.
• Click on the OK button. Notice that ‘New tool material’ is included in the tool type ‘New tool type’.
• Click on the OK button to exit Tool material dialog box.
Configuring databases
Adding cutting parameters

CAPSturn has a feature of automatically selecting the cutting parameters (Feed rate and cutting speed) for an operation. You configure the
parameters suitable to your machining conditions which will be automatically selected during machining.

• Select the tool manufacturer First manufacturer – MM from the Tool and FS database dialog box.

Click on Cutting parameters button.

Cutting parameters are specified for a combination of Workpiece material, tool type and tool material.

• Select the Workpiece material as New raw material.

• Select the Tool type as New tool type.
• Select the Tool material as New tool material.

Notice that when you select a tool type, the tool material configured under the selected tool type is only listed. This is because Tool material is
specific to a tool type.

• Click on the Parameters button.

• In the dialog box enter the following parameters.

Feed rate section Cutting speed section

Dia. range = 50; Feed rate = 0.1 Dia. range = 50; Cutting speed = 60
Dia. range = 100; Feed rate = 0.15 Dia. range = 100; Cutting speed = 80
Dia. range = 999; Feed rate = 0.2 Dia. range = 999; Cutting speed = 130

The above parameters specified means that,

1. 1. When the drill diameter selected is upto 50 mm, select a feed rate of 0.1 mm/rev. and a cutting speed of 60 m/min.
2. 2. When the drill diameter selected is above 50 mm and upto 100 mm, select a feed rate of 0.15 mm/rev. and a cutting speed of 80
m/min.
3. 3. When the drill diameter selected is above 100 mm and upto 999 mm, select a feed rate of 0.2 mm/rev. and a cutting speed of 130
m/min.

• Click on the Ok button to save the paraneters.

• Click on the OK button to exit cutting parameters dialog box.
Configuring databases
Adding a new tool in a tool manufacturer

• Select the tool manufacturer First manufacturer – MM from the Tool and FS database dialog box.
• Click on Tools button. A list of tools appear under the current tool type.
• Select the Tool type as New tool type from the list. This is the new tool type added to the list earlier.
• Click on the Add button.
• Enter the Tool name as New tool. Click on the Tool geometry button.

Notice that the dialog box that appears is for specifying the Drill parameters. This is because when you added the tool type ‘New tool type’, you
had assigned it to Drill TOOL CLASS.

• Enter the following parameters to specify the drill geometry.

Nose angle = 118

Web thickness = 0
Flute length = 80
Total length = 120
Diameter = 60
Hand of tool = Left

• Click on the Show tool button to view the line diagram of the drill. Click on the OK button.
• Click on the OK button in the tool geometry, tool data and the Add tool dialog boxes in sequence to exit the dialog box.
• Click on the OK button to exit Tool and FS database.

So far you have completed configuring the database for a single tool, tool type etc. Now, you can select these objects from the database
for a component and check the output, which will make the concept of CAPSturn Database clear.

Configuring databases
Checking the output with new tool manufacturer

To check the outputs, we go back to Tutorial 1. You will open tutorial 1 and save it in a different name and then insert a new drilling operation in
it.

• Open the file Shaft.CPT (This is the name in which you saved tutorial 1).
• Select File {bmc arrow.bmp} Save As. In the dialog box, enter the filename as Database test and click on the Save button.
• Go to the Machining menu.
• Click on Edit. Select Work setup and then click on the Modify button.
• Change the Workpiece material to New raw material. Click on the OK button.
• Click on the OK button to exit Edit dialog box and then save the file.
• Select Tool {bmc arrow.bmp} Drill.
• In the dialog box, enter a process name.
• Select the Manufacturer as First manufacturer - MM. Select Tool type as New tool type.
• Select Tool material as New material and Tool name as New tool.
• Click on the Tool geometry button. Notice that the geometry specified when adding the tool to the database is automatically picked up.
Click on the OK button.
• Notice that depending on the Hand of tool specified, the spindle direction is automatically selected (Here, Hand of tool was set to Left and
hence the spindle direction is selected as CCW). Click on the OK button.
• Select a drilling operation. In the dialog box, enter the Hole depth as 20.

Notice that the Cutting speed and Feed rate are automatically selected as 0.15 and 80 respectively. Cross check this with the parameters
specified in the Tool and FS database.
Manufacturer : First manufacturer - MM
Workpiece material : New raw material
Tool type : New tool type
Tool material : New material
Cutting parameters : You had specified the following parameters.

Feed rate section Cutting speed section

Dia. range = 50; Feed rate = 0.1 Dia. range = 50; Cutting speed = 60
Dia. range = 100; Feed rate = 0.15 Dia. range = 100; Cutting speed = 80
Dia. range = 999; Feed rate = 0.2 Dia. range = 999; Cutting speed = 130

When the drill diameter selected is above 50 mm and upto 100 mm, select a feed rate of 0.15 mm/rev. and a cutting speed of 80 m/min.
Here the drill diameter is 60 mm.

By now you should be understanding the relationship between Tool class and Tool type and how cutting parameters are related to Tool
manufacturer, Workpiece material, Tool material and Tool type.
Tutorial 8
Customising the machines list
During installation, CAPSturn displays the available machine names and prompts you to select the required ones. When you click on a
machine a brief explanation on its NC program format and it’s corresponding postprocessor file is displayed (Note: All the data required to
generate the NC program, Time study sheet etc. are stored in a postprocessor file). Select the machines which suit the program formats
that you want. It’s corresponding postprocessor files are copied to the CAPSturn folder and the machines are added to the machines list.
You can change the names of the machines later.

In this tutorial you will add a new machine to the machines list.

Adding a machine

To add a machine, you will first install a postprocessor file for the machine from the CD. To do this,

• Click on the Start menu of windows.

• Select Programs {bmc arrow.bmp} Cadem {bmc arrow.bmp} CAPSturn 7.0 – Add posts.
• A dialog box appears with a list of available machines. Select the machine named Tutorial and click on the OK button.
• A message appears indicating that the machine is installed. Click on the OK button.
• Open CAPSturn and check the machines list. Notice that the machine Tutorial is added to the machines list.

You have installed a new machine to the list. Now you will change the name of the machine to identify it uniquely.

• Select Config {bmc arrow.bmp}Machines list from the Main menu. Enter the password as cadem.
• Select the machine Tutorial. Click on the Modify button.
• Change the machine name to New machine.
• Leave the Folder for output files blank.

Notice that the postprocessor file is Tutorial. This is the file in which the mechanical parameters, NC program format etc. for the machine
are stored. This file has an extension of .GPT.

• Click on the OK button.

• Click on the OK button to exit machines list dialog box.
• Click on Machines in the main menu. Notice that the machine name Tutorial is changed to New machine.
• When you select this machine for generating the outputs, all the mechanical data and the NC program format is read from the
postprocessor file ‘Tutorial.GPT’ which was installed using the application Instcaps.
• Click on the OK button to select the machine.
Tutorial 9
Configuring machine Data
Customising the machine data involves:
Configuring machine's mechanical data. The mechanical data is used in,
NC program generation. Programmed spindle speeds and federates which exceed the machine's limits are clamped to the
specified limits.
Generating the power graph. The available spindle power is displayed in the graph.
Machining time estimation. The rapid traverse rate, axes and spindle acceleration/ deceleration times and execution times for
miscellaneous functions are used.
• Configuring the NC program format. This consists of three sessions; Word format, Block format and Cycle format.
Word format: Used to specify a code for a function and the format in which it should be output like with or without decimal etc.
Block format: Used to specify the format for a block in the NC program like Tool change block, program start block etc.
Cycle format: Used to enable or disable the cycles and specify the format in which the cycles should be output.

Building a postprocessor is a tedious process because you will need to specify the format for each and every parameter. Hence, it is
always recommended to modify an existing postprocessor and change the relevant parameters only. Here, you will open the postprocessor
file Tutorial.GPT and change some settings and parameters.

Machine mechanical data

• Select Config {bmc arrow.bmp} Postprocessor builder from the Main menu. Enter the password as cadem.
• Select File {bmc arrow.bmp} Open and open the file Tutorial.GPT.
• Click on Machine Data. In the dialog box, alter the following parameters leaving the remaining entries unchanged.
Machine name = Test machine
Rapid traverse rate = 18000
Tool change time in seconds = 2

• Click on Feed rate and Spindle speed tab.

Minimum feed rate = 0.01 0.0004
Minimum spindle speed = 50

• Click on Miscellaneous functions tab. Select Program stop and click on the Modify button.
• Enter the Function code as M02 and click on the OK button.
• Select Tool change and click on the Modify button. Enter the Function code as M06 and Execution time in secs as 2. Click on the OK
button.
• Click on History tab. Enter the following comment:
Postprocessor configured trial during learning session.
Machine: Test machine.
Control system: Fanuc 0TC.
Date of configuration: * * / * * / * *
Configured by: <ENTER YOUR NAME>

• Click on the OK button to exit Machine data. Save the file.

• Exit Postprocessor builder.
Configuring NC program format

The NC program format for this postprocessor is configured for a standard Fanuc 0TC controller and hence you need not make any major
changes in it. You can make some minor changes to make it more specific to your machine.

Configuring the Word format

• Select Word format from the Postprocessor builder menu.

• Select Threading motion and click on the Modify button.
• Change the Code for threading motion to G33.
• Click on the OK button and then click on the Save button.
• Click on the OK button to exit Word format.

Configuring the Block format

• Select Block format from the Postprocessor builder menu.

Here, the blocks that need to be altered to change the program output are,
Program start
Tool change

• Select Program start and click on the Modify button.

Notice that there are many variables that will be output as comments in the NC program like Program generation date, Workpiece material
etc. You can remove all the unwanted variables retaining the part name.

• In the dialog box, remove all the variables except the <#PROGRAM_NUM> variable.
• Position the cursor below <#PROGRAM_NUM> variable. To do this, press Enter.
• Click on List variables button. From the list of variables that appear, select COMMENTS_START_CHARS variable and then click on
the OK button. Similarly, insert the following variables in the dialog box.
PART_NAME
COMMENTS_END_CHARS
• Click on the Sample output button to view a sample of how the program would be output using these variables.
• Click on the OK button to exit this dialog box.
• Similarly, select Tool change block and click on the Modify button.
Here, you will configure this block to get an optional stop command (M01) before Process name in the NC program.

• Place the cursor at the end of second line (i.e. before <$PROCESS_NAME> variable) and press Enter.
• Select the variable <BLOCK_NUM> from List variables dialog box and click on the OK button.
• Enter the code M01 next to the variable <BLOCK_NUM>.
• Click on the Sample output button to view the sample and then click on the OK button.
• Click on the OK button to exit Block format.
Configuring NC program format

Configuring the Cycle format

• Select Cycle format from the Postprocessor builder menu.
• Select Drilling cycle and click on the Modify button.
• Against the prompt Should the cycle be output? Select Yes.
• Change the Addresses for the following parameters as mentioned below:
Final depth to Z
Safe height to R
Dwell at hole bottom to P
• Click on the Cycle Block button and then click on the Sample output button. Check whether the sample output is Ok. Click on the OK
button.
• Click on the OK button to exit drilling cycle dialog box.
• Similarly, configure the following cycles,
Deep drilling cycle
Reaming cycle
Right hand tapping cycle

• Click on OK button to exit Cycle format dialog box.

• Save the file and exit Postprocessor builder.

This completes the configuration of machine data. Now, select the machine New machine from the machines list. Generate and view the
NC program for Tutorial 2. Notice the changes in the program after modifying the postprocessor.
Tutorial 10
Customising DNC
Customising DNC involves specifying the communication parameters (baud rate, parity, etc.) of the machine.

• To go to DNC menu, select Utilities {bmc arrow.bmp} DNC from the Main menu.

Test the COM port of the computer

Prepare a loop back connector with the pin configuration shown below. Use a 9 pin or a 25 pin connector depending on the type of
connector on the port to be tested.

9 pin connector 25 pin connector

2 2
3 3
7 4
8 5
1 6
4 8
6 20

• Select DNC {bmc arrow.bmp} Test ports.

• Select the port to be tested from the list.
• At the prompt Insert loopback connector in port insert the connector in the specified port and click on the OK button.
• The handshake signals are first tested and then the transmit and receive signals. Transmit and receive are tested at all baud rates
from 110 to 38400.
• If the port passes the test at all baud rates, a message Test completed. Port is OK appears in the status box. Click on the OK button
to exit test mode.

If the port is defective get it rectified. If the port is proper, proceed to set the communication parameters for the machine.

Adding a machine

• select Settings {bmc arrow.bmp} Enable settings. Enter the password as cadem. The password is case sensitive.
• Select Settings {bmc arrow.bmp} Machine data. Click on the Add button.
• In the dialog box change the following parameters, leaving all the remaining entries unaltered.
Machine name = Machine 1
Control system = Fanuc
• Click on DNC param tab.
Select the port number which was tested, from the list.
Baud rate = 9600
Parity = Even
Data bits = 7
Stop bits = 2
Handshake = Hardware
• Leave all the other settings in the remaining tabs unaltered.
• Click on the OK button. Click on the OK button to exit Add machine dialog box.

You have now configured the communication parameters on the PC. The similar settings must be made on the machine controller too. The
parameter settings to be made on the controller are Baudrate, parity, data bits, stop bits and communication mode (ie; set it to ISO).

You can also note the current setting on the controller and set it on the PC.
Transmitting a program from PC to machine

Communication can be in Manual, Auto or Simultaneous mode. Here you will try to transmit and receive a program to the machine in
Manual mode.

Whenever you do a communication, it is recommended to make the receiving end ready to receive the program. Here the receiving end is
the machine.

• Put the machine in Read mode.

On the PC,
• Select DNC {bmc arrow.bmp} Manual mode.
• Double click on the machine and select Transmit program from the menu that appears.
• In the dialog box that appears, select a program file (Program file will have an extension of .PRG).
• Click on the Open button.

If the communication is successful, DNC will give a message ‘Program transmitted’. Check the program on the controller.

Receiving a program from machine to PC

Now, the receiving end is the PC.

On the PC,
• Double click on the machine and select Receive program from the menu that appears.
• In the dialog box that appears, enter From machine as the file name in which the received program must be saved.
• Click on the Save button.

If the communication is successful, DNC will give a message ‘Program received. Check the program in the NC editor.