VisualMILL 6.

0 for SolidWorks Getting Started Guide

VisualMILL 6.0 for SolidWorks Getting Started Guide

Welcome to VisualMILL 6.0 for SolidWorks Getting Started Guide .......................... 8

About this Guide ......................................................................................... 8
Where to go for more help ........................................................................... 8
Tutorial 1: Machining a Gasket ......................................................................... 9
Introduction ..............................................................................................10
Strategy to Machine the Gasket ................................................................10
Main Programming Steps .........................................................................10
Loading the Part Model ............................................................................10
Loading the VisualMILL Browser................................................................11
Preparing the part for Machining ..................................................................13
Setup Tab .............................................................................................13
Create Stock Geometry ...........................................................................15
Align Part and Stock ...............................................................................17
Set Machine Coordinate System (MCS) ......................................................18
Create Tools .............................................................................................20
Setting Feeds and Speeds ........................................................................22
Create Machining Operations .......................................................................23
2 ½ Axis Profiling.......................................................................................23
Select Machining Features/Regions ...........................................................23
Selecting the Tool ...................................................................................26
Set Feeds and Speeds .............................................................................27
Clearance Control ...................................................................................28
Specifying Cut Parameters .......................................................................29
Entry/Exit ..............................................................................................31
Simulate Toolpath ..................................................................................33
Creating a 2 ½ Axis Profile for the Outer Region .............................................34
Reports ....................................................................................................37
Shop Docs .............................................................................................38
Post Processing .........................................................................................39
Tutorial 2: Machining a Slotted Gear ................................................................41
Introduction ..............................................................................................42
Strategy to Machine the Slotted Gear ........................................................42
Main Programming Steps .........................................................................42
Loading the Part Model ............................................................................42
Loading the VisualMILL Browser................................................................43
Preparing the part for Machining ..................................................................45
Setup Tab .............................................................................................45
Create Stock Geometry ...........................................................................47
Align Part and Stock ...............................................................................49
Set Machine Coordinate System (MCS) ......................................................50
Create Tools .............................................................................................52
Setting Feeds and Speeds ........................................................................53

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Create Machining Operations .......................................................................54

2 ½ Axis Profiling.......................................................................................55
Select Machining Features/Regions ...........................................................55
Selecting the Tool ...................................................................................58
Set Feeds and Speeds .............................................................................59
Clearance Control ...................................................................................60
Specifying Cut Parameters .......................................................................61
Entry/Exit ..............................................................................................63
Simulate Toolpath ..................................................................................65
Creating an Engraving Operation..................................................................66
Select Machining Regions.........................................................................67
Select Tool ............................................................................................68
Specify Engraving Cut Parameters ............................................................69
Simulate Toolpath ..................................................................................71
Post Processing .........................................................................................72
Tutorial 3: Machining a Shaft Base ..................................................................74
Introduction ..............................................................................................75
Strategy to Machine the Shaft Base...........................................................75
Main Programming Steps .........................................................................75
Loading the Part Model ............................................................................76
Loading the VisualMILL Browser................................................................76
Preparing the part for Machining ..................................................................78
Setup Tab .............................................................................................78
Create Stock Geometry ...........................................................................80
Align Part and Stock ...............................................................................82
Set Machine Coordinate System (MCS) ......................................................83
Create Tools .............................................................................................85
Setting Feeds and Speeds ........................................................................86
Create Machining Operations .......................................................................87
2 ½ Axis Facing .........................................................................................87
Select Machining Features/Regions ...........................................................87
Specify Cut Parameters ...........................................................................89
2 ½ Axis Pocketing ....................................................................................92
Creating the Pocketing Operation #1 .........................................................92
Specify Cut Parameters ...........................................................................94
Creating the Pocketing Operation #2 .........................................................99
Copying a MOp.......................................................................................99
Hole Pocketing Operation .......................................................................... 104
Creating the Hole Pocketing Operation #1 ................................................ 104
Specify Cut Parameters ......................................................................... 105
Creating the Hole Pocketing Operation #2 ................................................ 109
2 ½ Axis Engraving Operation ................................................................... 113
Creating the Engraving Toolpath ............................................................. 113
2 ½ Axis Profiling..................................................................................... 117
Specifying Cut Parameters ..................................................................... 118
Post Processing ....................................................................................... 122
Tutorial 4: Simple V-Carving ......................................................................... 123
Introduction ............................................................................................ 124
Strategy to Machine the part .................................................................. 124
Main Programming Steps ....................................................................... 124
Loading the Part Model .......................................................................... 125
Loading the VisualMILL Browser.............................................................. 125

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Preparing the part for Machining ................................................................ 126

Setup Tab ........................................................................................... 126
Create Stock Geometry ......................................................................... 128
Align Part and Stock ............................................................................. 130
Set Machine Coordinate System (MCS) .................................................... 131
Create Tools ........................................................................................... 133
Setting Feeds and Speeds ...................................................................... 134
Create Machining Operations ..................................................................... 135
V-Carving ............................................................................................... 135
Select Machining Features/Regions ......................................................... 136
Selecting the Tool ................................................................................. 138
Set Feeds and Speeds ........................................................................... 139
Clearance Control ................................................................................. 140
Specifying Cut Parameters ..................................................................... 141
Sorting ............................................................................................... 142
Simulate Toolpath ................................................................................ 143
Post Processing ....................................................................................... 145
Tutorial 5: Embossing .................................................................................. 146
Introduction ............................................................................................ 147
Strategy to Machine the part .................................................................. 147
Main Programming Steps ....................................................................... 147
Loading the Part Model .......................................................................... 148
Loading the VisualMILL Browser.............................................................. 148
Preparing the part for Machining ................................................................ 149
Setup Tab ........................................................................................... 149
Create Stock Geometry ......................................................................... 151
Align Part and Stock ............................................................................. 153
Set Machine Coordinate System (MCS) .................................................... 154
Create Tools ........................................................................................... 156
Setting Feeds and Speeds ...................................................................... 157
Create Machining Operations ..................................................................... 160
V-Carving Roughing ................................................................................. 160
Select Machining Features/Regions ......................................................... 161
Selecting the Tool ................................................................................. 163
Set Feeds and Speeds ........................................................................... 164
Clearance Control ................................................................................. 165
Specifying Cut Parameters ..................................................................... 166
Simulate Toolpath ................................................................................ 168
V-Carving ............................................................................................... 169
Select Machining Features/Regions ......................................................... 169
Selecting the Tool ................................................................................. 170
Set Feeds and Speeds ........................................................................... 171
Clearance Control ................................................................................. 172
Specifying Cut Parameters ..................................................................... 173
Sorting ............................................................................................... 174
Simulate Toolpath ................................................................................ 175
Post Processing ....................................................................................... 176
Tutorial 6: Chamfering ................................................................................. 178
Introduction ............................................................................................ 179
Strategy to Machine the part .................................................................. 179
Main Programming Steps ....................................................................... 179
Loading the Part Model .......................................................................... 179

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Loading the VisualMILL Browser.............................................................. 180

Preparing the part for Machining ................................................................ 180
Setup Tab ........................................................................................... 181
Create Tools ........................................................................................... 182
Setting Feeds and Speeds ...................................................................... 183
Create Machining Operations ..................................................................... 184
Chamfering ............................................................................................. 184
Select Machining Features/Regions ......................................................... 185
Selecting the Tool ................................................................................. 186
Set Feeds and Speeds ........................................................................... 187
Clearance Control ................................................................................. 188
Specifying Cut Parameters ..................................................................... 189
Reorder a Machining Operation ............................................................... 190
Simulate Toolpath ................................................................................ 191
Post Processing ....................................................................................... 193
Tutorial 7: 3 Axis Milling............................................................................... 194
Introduction ............................................................................................ 195
Strategy to Machine the mold ................................................................. 195
Main Programming Steps ....................................................................... 195
Loading the Part Model .......................................................................... 195
Loading the VisualMILL Browser.............................................................. 196
Setup Tab ........................................................................................... 197
Create Stock Geometry ......................................................................... 199
Align Part and Stock ............................................................................. 201
Set Machine Coordinate System (MCS) .................................................... 202
Create Tools ........................................................................................... 204
Setting Feeds and Speeds ...................................................................... 205
Create Machining Operations ..................................................................... 207
3 axis Horizontal Roughing ........................................................................ 207
Specify Cut Parameters ......................................................................... 211
3 axis Parallel Finishing ............................................................................ 214
Specify Cut Parameters ......................................................................... 215
3 axis Horizontal Finishing......................................................................... 217
Select Machining Features/Regions ......................................................... 218
Specify Cut Parameters ......................................................................... 220
Post Processing ....................................................................................... 223
Tutorial 8: Profiling with Bridges (Tabs) .......................................................... 224
Introduction ............................................................................................ 225
Strategy to Machine the part .................................................................. 225
Main Programming Steps ....................................................................... 225
Loading the Part Model .......................................................................... 225
Loading the VisualMILL Browser.............................................................. 226
Preparing the part for Machining ................................................................ 227
Setup Tab ........................................................................................... 227
Create Stock Geometry ......................................................................... 229
Align Part and Stock ............................................................................. 231
Set Machine Coordinate System (MCS) .................................................... 232
Create Tools ........................................................................................... 234
Setting Feeds and Speeds ...................................................................... 234
Create Machining Operations ..................................................................... 236
2 ½ Axis Profiling..................................................................................... 236
Select Machining Features/Regions ......................................................... 237

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Selecting the Tool ................................................................................. 239

Set Feeds and Speeds ........................................................................... 240
Clearance Control ................................................................................. 241
Specifying Cut Parameters ..................................................................... 242
Entry/Exit ............................................................................................ 244
Advanced Cut Parameters ...................................................................... 245
Sorting ............................................................................................... 246
Simulate Toolpath ................................................................................ 248
Post Processing ....................................................................................... 251
Tutorial 9: Hole Making ................................................................................ 252
Introduction ............................................................................................ 253
Strategy to Machine the part .................................................................. 253
Main Programming Steps ....................................................................... 253
Loading the Part Model .......................................................................... 253
Loading the VisualMILL Browser.............................................................. 254
Preparing the part for Machining ................................................................ 254
Setup Tab ........................................................................................... 255
Create Stock Geometry ......................................................................... 257
Align Part and Stock ............................................................................. 259
Set Machine Coordinate System (MCS) .................................................... 260
Create Tools ........................................................................................... 262
Setting Feeds and Speeds ...................................................................... 263
Create Machining Operations ..................................................................... 264
Hole Machining ........................................................................................ 264
Select Hole Features ............................................................................. 265
Selecting the Tool ................................................................................. 267
Set Feeds and Speeds ........................................................................... 268
Clearance Control ................................................................................. 269
Specifying Cut Parameters ..................................................................... 270
Sorting ............................................................................................... 271
Simulate Toolpath ................................................................................ 273
Creating the Drill operation for the 0.25” Holes ............................................ 274
Post Processing ....................................................................................... 277
Tutorial 10: Re-Machining a 3D Mold.............................................................. 278
Introduction ............................................................................................ 279
Strategy to Machine the mold ................................................................. 279
Main Programming Steps ....................................................................... 279
Loading the Part Model .......................................................................... 279
Loading the VisualMILL Browser.............................................................. 280
Create Machining Operations ..................................................................... 280
3 axis Pencil Tracing................................................................................. 281
Specify Cut Parameters ......................................................................... 285
Advanced Cut parameters ...................................................................... 286
Entry/Exit ............................................................................................ 287
3 axis Valley Re-Machining ........................................................................ 288
Specify Cut Control ............................................................................... 289
Specify Cutting Parameters .................................................................... 291
Post Processing ....................................................................................... 293
Tutorial 11: Machining a Ring ....................................................................... 294
Introduction ............................................................................................ 295
Strategy to Machine the ring .................................................................. 295
Main Programming Steps ....................................................................... 295

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Loading the Part Model .......................................................................... 295

Loading the VisualMILL Browser.............................................................. 296
Preparing the part for Machining ................................................................ 296
Setup Tab ........................................................................................... 297
Create Stock Geometry ......................................................................... 299
Align Part and Stock ............................................................................. 302
Set Machine Coordinate System (MCS) .................................................... 303
Specify Rotary Center ........................................................................... 305
Create Tools ........................................................................................... 307
Setting Feeds and Speeds ...................................................................... 308
Create Machining Operations ..................................................................... 309
4 axis Roughing ....................................................................................... 309
Specify Cut Parameters ......................................................................... 314
Step Down Control ............................................................................... 315
4 axis Finishing ....................................................................................... 317
Specify Cut Parameters ......................................................................... 319
4th Axis Finishing Operation #2 .................................................................. 320
Copying a MOp..................................................................................... 320
Specify Cut Parameters ......................................................................... 322
Post Processing ....................................................................................... 324
Tutorial 12: Engraving on a Cylinder .............................................................. 325
Introduction ............................................................................................ 326
Strategy to engrave text on a cylinder ..................................................... 326
Main Programming Steps ....................................................................... 326
Loading the Part Model .......................................................................... 326
Loading the VisualMILL Browser.............................................................. 327
Preparing the part for Machining ................................................................ 327
Setup Tab ........................................................................................... 328
Create Stock Geometry ......................................................................... 330
Align Part and Stock ............................................................................. 333
Set Machine Coordinate System (MCS) .................................................... 334
Specify Rotary Center ........................................................................... 336
Create Tools ........................................................................................... 338
Setting Feeds and Speeds ...................................................................... 339
Create Machining Operations ..................................................................... 340
4 Axis Engraving...................................................................................... 340
Select Machining Features/Regions ......................................................... 341
Specify Cut Parameters ......................................................................... 346
Post Processing ....................................................................................... 348
Tutorial 13: Pocketing and Drilling on a Ring ................................................... 349
Introduction ............................................................................................ 350
Strategy to machine the part ................................................................. 350
Main Programming Steps ....................................................................... 350
Loading the Part Model .......................................................................... 350
Loading the VisualMILL Browser.............................................................. 351
Preparing the part for Machining ................................................................ 352
Setup Tab ........................................................................................... 352
Create Stock Geometry ......................................................................... 354
Align Part and Stock ............................................................................. 357
Set Machine Coordinate System (MCS) .................................................... 358
Specify Rotary Center ........................................................................... 360
Create Tools ........................................................................................... 362

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Setting Feeds and Speeds ...................................................................... 363

Create Machining Operations ..................................................................... 364
4 Axis Drilling .......................................................................................... 364
Select Hole Features ............................................................................. 366
Specify Cut Parameters ......................................................................... 371
Sorting ............................................................................................... 372
4 axis Pocketing ...................................................................................... 374
Select Machining Features/Regions ......................................................... 375
Specify Cut Parameters ......................................................................... 378
Sorting ............................................................................................... 380
Post Processing ....................................................................................... 382

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Welcome to VisualMILL 6.0 for SolidWorks Getting Started

Guide

Welcome to VisualMILL and thank you for choosing one of most powerful and easy to
use complete CAD/CAM packages on the market today.

VisualMILL is a unique CAM product plug-in that runs inside of SolidWorks. Plug-ins
can be considered as independent applications that can be loaded and unloaded on
demand from the host program, which in this case is SolidWorks. This fully
integrated VisualMILL plug-in seamlessly integrates SolidWorks CAD functionality
with toolpath generation and cutting simulation/verification, in one package that is
both easy and fun to use.

You can work with the native SolidWorks design data as well as use any of the data
types that can be imported into Solids such as solids and surfaces. Then you can
use VisualMILL with its wide selection of tools and toolpath strategies to create
machining operations and associated toolpaths. These toolpaths can then be
simulated and verified, and finally post-processed to the controller of your choice.

About this Guide

Welcome to the VisualMILL getting started guide. This file contains various tutorials
to help you get started with learning VisualMILL. Each tutorial lesson has two
associated SolidWorks files that you can find located in the Tutorials folder under
the installation folder of VisualMILL. The first file is a completed file that contains all
of the completed toolpaths and machining operations and represents the file that you
should end up with after working through the tutorial. The other file is a starter file
that contains only the geometry. Use the completed file as a reference. Copy the
starter file and use this file to begin each tutorial.

Good luck and have fun!

Where to go for more help

Apart from the on-line help system you can download tutorials and projects from
MecSoft Corporation's web site at www.mecsoft.com. This will help you get started
with using VisualMILL.

If you need additional help, or if you have any questions regarding VisualMILL, you
may contact us via e-mail at [email protected]

MecSoft offers Online training as well as personalized full day training sessions.
Please look up our website or email us at [email protected] for further details

Please do continue to visit our home page to learn about the latest updates to
VisualMILL and any other help material.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Tutorial 1: Machining a Gasket

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Introduction

This tutorial will illustrate machining of a simple prismatic part such as this gasket
using 2-1/2 milling operations. Even though we have created a 3-D representation of
the gasket, it will be seen later on that we can machine this using just 2-D Sketches.
The reason we are able to do this is because of the prismatic nature of this model.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the Gasket

• We will machine the Gasket by using a 2-½ axis machining operation called
Profiling.
• The part will be machined out of a 8 ½ x 5 x ¼ inch poplar wood sheet using
a ½ inch Flat End Mill.
• The wooden sheet will be held to the machine table or the spoil sheet on the
table using double-sided tape.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:
• Create the Stock geometry
• Set the Machine zero point 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

2. From the Open dialog box, select the Gasket.sldprt file from the Tutorials
folder in the VisualMILL 6.0 installation folder. (C:\Program Files\MecSoft
Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

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VisualMILL 6.0 for SolidWorks Getting Started Guide

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 3 axis

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VisualMILL 6.0 for SolidWorks Getting Started Guide

4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select
Haas as the post processor for this exercise. Set the posted file extension
type to .nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Box Stock

2. This brings up the Box Stock parameters. Set the Length (L) = 8.50,
Width W = 5.00 and Height (H) = 0.125. Leave the other parameters as
default and Click OK.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

The stock geometry is now created, and a semi-transparent stock box is displayed on
top of the part geometry.

Note: If the stock geometry is not visible, click Stock Visibility located on the status
bar in the MOPs browser.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

3. The setup tab now displays the following information: Machine Type, Post
Processor, and Stock type as show below.

Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Top and XY alignment to Center. (This would align the
stock to the top of the part in Z and center in XY)

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

The MCS is represented as a triad with 3 arrows, the Green arrow indicating X axis,
Blue the Y axis and Red the Z axis. It is always a good practice to set the machine
zero before generating a toolpath.

1. Select Set MCS from the Setup tab

2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face
to Highest Z, and Zero Position to South West corner. This sets the

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VisualMILL 6.0 for SolidWorks Getting Started Guide

machine home to the top of the stock material and the southwest corner
of the part geometry.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

(This sets the machine home to Southwest corner and top of the stock material).

Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Click Save As to save the work and specify a file name as Gasket-Rev1.

Create Tools

To machine the above part we will now create a ½ inch (0.5”) Flat End Mill.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-

MOps browser and select Create/Edit Tools. Select the Tool Type to Flat
End Mill.

2. Set the tool name as FlatMill-0.5, Tool Diameter = 0.5, Under the
Properties tab set Tool Number = 1.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

5. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

The created tools are now listed under the VisualMILL-Tools browser.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Create Machining Operations

In this process we will create a 2.5 axis profiling operation.

1. Switch to the Create Operations tab in VisualMILL-Mops browser.

2 ½ Axis Profiling

1. Select 2 ½ Axis Milling and choose Profiling

This brings up the 2 ½ Axis Profiling Operations dialog. We will go over the steps for
creating the profile operations for the inner features of the Gasket.

Select Machining Features/Regions

2. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Profiling operation dialog is now minimized and allows
selection of the sketch geometry.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

We will not select the sketch to machine the 3 inner circles on the part.

3. Switch to Feature Manager Design tree and select Sketch2 located under
Extrude2.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

4. Click the cancel button to terminate the selection.

The 2 ½ Axis Profiling operation dialog comes back up displaying the selected
regions (sketch entities). The selected regions are also highlighted on the part.

You can click on the Region list and corresponding sketch entities are highlighted on
the part.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Selecting the Tool

5. Switch to the Tools tab inside the 2 ½ Axis Profiling operation.

6. Select the FlatMill-0.5. The 0.5” Flat End mill is now selected as the active
tool and the Tool parameters are displayed to the right of the Tools window.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Set Feeds and Speeds

7. Click on the Feeds and Speeds tab.

8. Select Load From Tool. VisualMILL will now get the feeds and speeds
information that was set when the tool was defined.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Clearance Control

9. Switch to Clearance Tab.

10. Set the Clearance Plane Definition to Automatic and Cut Transfer Method to
Clearance Plane.

VisualMILL will determine a safe Z height for the Entry & Exit when set to automatic.
Setting Cut Transfer to Clearance Plane would apply the automatic Z clearance
between transfers when the tool moves from a machining region to another.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Specifying Cut Parameters

11. Switch to Cut Parameters tab

12. Set the Stock = 0 and under cut start Side check Use Outside/Inside for
Closed Curves and select Inside. Alternatively you can also use Determine
using 3D model.

13. Select the Cut Levels Tab. Set Location of Cut Geometry At Top (the
selected sketch is located at the top of the gasket) and specify the Total Cut
Depth = 0.125. The cut depth is always set as an absolute value.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Entry/Exit

14. Switch to Entry/Exit Tab and Set the Entry and Exit Type to None.

15. Click Generate. The 2½ Axis Profile toolpath is now generated and the
Operation is listed under the VisualMILL-MOps browser.

Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the
MOps browser.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Simulate Toolpath

The generated toolpath can now be simulated.

1. Switch to the Simulate tab in the VisualMILL-MOps browser.

2. Select the 2 ½ Axis Profiling Operation and click to Simulate.

The simulated part is as shown below.

Note: You can adjust the simulation speed by selecting Simulation Preferences that is
located to the bottom right corner of the VisualMILL-MOps browser.

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To exit the Simulation mode, pause the Simulation.

Creating a 2 ½ Axis Profile for the Outer Region

1. Switch to the Create Operation tab.

2. Select Profiling from the 2 ½ Axis operations menu.

3. Under Machining Features/ Regions, select Remove All.

4. Now click on Select Curves as Regions and select Sketch1 by switching

over to the Feature Manager Tree Outer profile of the Gasket as the region.

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5. Click the cancel button to terminate the selection.

6. Switch to Tools tab and select FlatMill-0.5 as the active tool.

7. Under Feeds/Speeds select Load from Tool.

8. Set the Clearance control to Automatic.

9. Switch to Cut Parameters tab, check Use Outside/Inside for Closed

Curves, and set the Cut Start Side to Outside

10. Go over to Cut Levels and set the Total Cut Depth = 0.125.

11. Click Generate to Create the 2 ½ Axis Profile Toolpath.

The 2 ½ Axis Profile Operation is now created and is listed in the MOps Browser.

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12. Switch to Simulate Tab, select 2 ½ Axis Profiling, and click to simulate
toolpath.

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Reports

1. Switch to Create Operations Tab.

2. Select the MOp Set1 and right click and select Information.

This provides the estimated machining time for the operations created under MOp
Set1.

Note: You can also go over to Machining Operations and right click and select
information determine the estimated machining time for all the MOp Sets.

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Shop Docs

Shop documentation can be generated selecting Machining Operations under the

Create Operations tab. Right mouse click and Shop Documentation.
User can select from one of the 2 templates and generate shop documentation. This
is saved as an html file and can be printed and handed over to the operator in
preparation for the part to be machined on the CNC.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as Gasket.nc and click Save.

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The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 1!

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Tutorial 2: Machining a Slotted Gear

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Introduction

This tutorial will introduce the usage of 2 ½ axis profiling and Engraving Machining
Operations of VisualMILL. We will be using the Gear.sldprt part file.
It should be noted that, even though the part file contains a 3-D geometry
representing the part, we could machine this entirely by using just 2D Sketches due
to the prismatic nature of this model.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the Slotted Gear

• We will machine the gear completely using 2 ½ axis-machining operations.

• We will use the Profiling operation to cut the outer shape of the gear and the
Engraving operation to cut the slots. The engraving option is preferred in
situations where the cutter can be driven to create a slot that conforms to the
shape of the tool trajectory. This is because of the computational efficiency as
well as the accuracy of this method.
• The part itself will be machined out of a 3 inch x 3 inch x ½ inch poplar wood
sheet.
• The wooden sheet will be held to the machine table or the spoil sheet on the
table using double-sided tape.
• The part will be machined using a single ¼ inch flat end mill.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Stock geometry

• Set the Machine zero point 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

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To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

2. From the Open dialog box, select the Gear.sldprt file from the Tutorials
folder in the VisualMILL 6.0 installation folder. (C:\Program Files\MecSoft
Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

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3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

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Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 3 axis

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4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Part Box Stock

2. This brings up the Part Box Stock Parameters.

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The system calculates the bounding box of the part model as the XYZ extents of
geometry of the part model. The user can then define offsets in any of the three
coordinate directions to apply to the computed bounding box.

3. Set the offsets for X, Y and Z =0 and click OK.

The stock geometry is now created, and a semi-transparent stock box is displayed on
top of the part geometry.

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4. The setup tab now displays the following information: Machine Type, Post
Processor, and Stock type as show below.

Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

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2. Set Z alignment to Top and XY alignment to Center. (This would align the
stock to the top of the part in Z and center in XY)

Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

The MCS is represented as a triad with 3 arrows, the Green arrow indicating X axis,
Blue the Y axis and Red the Z axis. It is always a good practice to set the machine
zero before generating a toolpath.

1. Select Set MCS from the Setup tab

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2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Highest Z, and Zero Position to South West corner. This sets the machine
home to the top of the stock material and the southwest corner of the part
geometry.

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(This sets the machine home to Southwest corner and top of the stock material).

Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Click Save As to save the work and specify a file name as Gear-Rev1.

Create Tools

To machine the above part we will now create a ¼ inch (0.25”) Flat End Mill.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to Flat End Mill.

2. Set the tool name as FlatMill-0.25, Tool Diameter = 0.25. Under the
Properties tab, set Tool Number = 1.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

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5. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

The created tool is now listed under the VisualMILL-Tools browser.

Create Machining Operations

In this process we will create a 2.5 axis profiling operation.

1. Switch to the Create Operations tab in VisualMILL-Mops browser.

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2 ½ Axis Profiling

2. Select 2 ½ Axis Milling and choose Profiling

This brings up the 2 ½ Axis Profiling Operations dialog. We will go over the steps for
creating the profile operations.

Select Machining Features/Regions

3. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Profiling operation dialog is now minimized and allows
selection of the sketch geometry.

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We will now select the inner circle first and then the outer circle.

4. Switch to Feature Manager Design tree and select Sketch2 located under
Extrude2. This selects the inner circle.

5. Hold the Ctrl key and select Sketch5. This selects the outer circle.

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6. Click the cancel button to terminate the selection.

The 2 ½ Axis Profiling operation dialog comes back up displaying the selected
regions (sketch entities). The selected regions are also highlighted on the part.

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Selecting the Tool

7. Switch to the Tools tab inside the 2 ½ Axis Profiling operation.

8. Select the FlatMill-0.25. The 0.25” Flat End mill is now selected as the active
tool, and the Tool parameters are displayed to the right of the Tools window.

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Set Feeds and Speeds

9. Click on the Feeds and Speeds tab.

10. Select Load From Tool. VisualMILL will now get the feeds and speeds
information that was set when the tool was defined.

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Clearance Control

11. Switch to Clearance Tab.

12. Set the Clearance Plane Definition to Automatic and Cut Transfer Method to
Clearance Plane.

VisualMILL will determine a safe Z height for the Entry & Exit when set to automatic.
Setting Cut Transfer to Clearance Plane would apply the automatic Z clearance
between transfers when the tool moves from a machining region to another.

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Specifying Cut Parameters

13. Switch to Cut Parameters tab.

14. Set the Stock = 0, cut start Side as Right.

15. Select the Cut Levels Tab and specify the Total Cut Depth = 0.25, Rough
Depth/Cut = 0.125. This would cut the profile in 2 cuts of each 0.125”. Make
sure the cut level ordering is set to Depth First. This would profile the inner
circle and then the outer profile.

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Entry/Exit

16. Switch to Entry/Exit Tab, and Set the Entry and Exit Type to None.

17. Click Generate. The 2½ Axis Profile toolpath is now generated, and the
Operation is listed under the VisualMILL-MOps browser.

Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the
MOps browser.

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Simulate Toolpath

The generated toolpath can now be simulated.

1. Switch to the Simulate tab in the VisualMILL-MOps browser.

2. Select the 2 ½ Axis Profiling Operation and click to Simulate.

The simulated part is as shown below.

Note: You can adjust the simulation speed by selecting Simulation Preferences that is
located to the bottom right corner of the VisualMILL-MOps browser.

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To exit the Simulation mode, pause the Simulation.

Creating an Engraving Operation

Now we will use engraving operation to cut the slots of the gear by driving the 0.25”
tool in the slot. As already mentioned, the most efficient way of machining slots is to
use the Engraving option and drive the cutter along the center of the slot.

1. Switch to the Create Operation tab.

2. Select Engraving from the 2 ½ Axis operations menu.

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Select Machining Regions

1. Under Machining Features/ Regions click on Remove All to deselect any

regions that could have been selected from the previous machining operation.

2. Now click on Select Curves as Regions and select Sketch3 from Feature
Manager Design tree. This will select the 6 line segments on the slotted gear
as shown below.

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3. Click the cancel button to terminate the selection.

The 2 ½ Axis Engraving operation dialog comes back up displaying the selected
regions (sketch entities). The selected regions are also highlighted on the part.

Select Tool

4. Switch to Tools tab and select FlatMill-0.25 as the active tool.

5. Under Feeds/Speeds, select Load from Tool.

6. Set the Clearance control to Automatic.

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Specify Engraving Cut Parameters

7. Switch to Cut Parameters tab. Under Cut Depth Control, set the Total Cut
Depth = 0.25, Rough Depth = 0.25, and Rough Depth/Cut = 0.125, Cut
Traversal between cut levels = ZigZag.

8. Click Generate to Create the Engraving Toolpath.

9. The Engraving Operation is now created and is listed in the MOps Browser.

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Simulate Toolpath

1. Switch to Simulate Tab, select Engraving, and click to simulate toolpath.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as Gear.nc and click Save.

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The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 2!

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Tutorial 3: Machining a Shaft Base

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Introduction

This tutorial will illustrate machining of a prismatic part such as this Shaft Base using
2-1/2 milling operations. Even though we have created a 3-D representation of the
part, it will be seen later on that we can machine this using just 2D Sketches. The
reason we are able to do this is because of the prismatic nature of this model. This
tutorial will introduce the usage of 2 ½ axis machining for a simple one sided part.
We will use profiling, pocketing and hole pocketing operations.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the Shaft Base

• We will machine the shaft base completely using 2 ½ axis-machining

operations.
• The starting material for the Shaft Base is soft wood and the size is 5.5 x 3.25
x 0.75 inches.
• The wooden sheet will be held to the machine table or the spoil sheet on the
table using double-sided tape.
• The part will be machined using a single ¼ inch flat end mill.
• Determining the sequence of machining operations
o As the part thickness is 0.625” thick and the available stock is 0.75”
the first operation would involve reducing the thickness of the stock
over the entire area from 0.75 to 0.625. To carry out this operation we
will use the 2 ½ axis Facing Operation as the toolpath extends past the
region.
o The next step would involve machining the areas around and inside
the boss. As the thickness of material to be removed is not the same
for both the areas we would have to use 2 separate operations to clear
the material. We will use 2 ½ axis Pocketing Operation which is ideal
removing material inside a specified region.
o We are now down to the level where the step holes need to be
machined. As the holes are circular we will use 2 ½ axis Hole
Pocketing operation to machine the holes to its depth in 2 separate
operations.
o The 2 inner holes can be drilled using an engraving operation to its
depth.
o Finally we will cut out the shape of the part from the rectangular using
a contour toolpath. This is accomplished using a 2 ½ axis Profiling
Operation which separates the finished part from the stock material.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

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• Create the Stock geometry

• Set the Machine zero point 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

2. From the Open dialog box, select the ShaftBase.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

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2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

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Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 3 axis

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4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Box Stock

2. This brings up the Box Stock parameters. Set the Length (L) = 5.50, Width
W = 3.25, and Height (H) = 0.75. Leave the other parameters as default, and
click OK.

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3. The stock geometry is now created, and a semi-transparent stock box is

displayed on top of the part geometry.

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4. The setup tab now displays the following information: Machine Type, Post
Processor, and Stock type as show below.

Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Bottom and XY alignment to Center. (This would align

the stock to the bottom of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

1. Select Set MCS from the Setup tab

2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Highest Z, and Zero Position to South West corner. This sets the machine
home to the top of the stock material and the southwest corner of the part
geometry.

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(This sets the machine home to Southwest corner and top of the stock material).

Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Click Save As to save the work and specify a file name as ShaftBase-Rev1.

Create Tools

To machine the above part we will now create a ¼ inch (0.25”) Flat End Mill.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to Flat End Mill.

2. Set the tool name as FlatMill-0.25, Tool Diameter = 0.25. Under the
Properties tab, set Tool Number = 1.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

6. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

7. Use the following settings for feeds and speeds.

8. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

The created tool is now listed under the VisualMILL-Tools browser.

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Create Machining Operations

We will machine the Shaft Base using 4 different machining operations – Facing,
Pocketing, Hole Pocketing and Engraving.

The stock geometry has a thickness of 0.75” and the finished part is 0.625”. We will
create a 2.5 axis facing operation to mill the 0.125” thickness of material from the
stock geometry.

1. Switch to the Create Operations tab in VisualMILL-Mops browser.

2 ½ Axis Facing

1. Select 2.5 Axis Milling and choose Facing.

2. This brings up the 2 ½ Axis Facing Operation Dialog. We will now go over the
steps for creating the toolpath.

Select Machining Features/Regions

3. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Facing operation dialog is now minimized and allows selection
of the sketch geometry.

4. Switch to Feature Manager Design tree and select Sketch7. This selects the
outside rectangle.

5. Click the cancel button to terminate the selection.

The 2 ½ Axis Facing operation dialog comes back up displaying the selected regions
(sketch entities). The selected regions are also highlighted on the part.

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6. Switch to the Tools tab inside the 2 ½ Axis Facing operation and select
FlatMill-0.25.

7. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

8. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

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Specify Cut Parameters

9. Click on the Roughing tab.

10. Set the Tolerance to 0.01, Stock to leave to 0, Cut Pattern to Island Offset
Cuts, and Step Distance to 50 (% Tool Diameter).

11. Switch to the Cut Levels Tab.

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12. Use the Following Settings.

a. Pick Top = 0 (As the selected region at Z = -0.125”, we would need to

start the first cut from Z =0).
b. Total Cut Depth = 0.125, Rough Depth = 0.125, and Rough
Depth/Cut = 0.0625.

13. Switch to the Entry/Exit tab and set the Entry and Exit parameters to none.

14. Click Generate. The 2½ Axis Facing toolpath is now generated, and the
Operation is listed under the VisualMILL-MOps browser.

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15. Switch to Simulate tab, Select 2 ½ Axis Facing, and click Simulate to run the
simulation.

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2 ½ Axis Pocketing
We will now use 2½ axis Pocketing operation to machine the area inside the boss.

Creating the Pocketing Operation #1

1. From the Create Operations tab, select 2½ axis Milling and Pocketing.

This brings up the 2 ½ Axis Pocketing Operations dialog. We will go over the steps
for creating the pocketing operation.

2. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Pocketing operation dialog is now minimized and allows
selection of the sketch geometry.

3. Switch to Feature Manager Design tree and select Sketch3 located under
Extrude3.

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4. Click the cancel button to terminate the selection.

The 2 ½ Axis Pocketing operation dialog comes back up displaying the selected
regions (sketch entities). The selected regions are also highlighted on the part.

5. Switch to the Tools tab inside the 2½ Axis Pocketing operation and select
FlatMill-0.25.

6. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

7. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

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Specify Cut Parameters

1. Click on the Cut Parameters tab.

2. Set the Tolerance to 0.001, Stock to leave to 0, Cut Pattern to Offset Cuts,
and Step over distance to 25 (% Tool Diameter).

3. Switch to the Cut Levels Tab.

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4. Use the Following Settings.

a. Location of Cut Geometry at Top.

We will determine the Total Cut Depth from the 3D model by snapping
at 2 points.

b. Select the Depth measuring tool located to the right of Total Cut
Depth. This will minimize the Pocketing Operation parameters
dialog.

c. Pick the top edge of the boss as the start point of axis vector and
the bottom edge of the boss as the end point as shown below.

d. The pocketing operation dialog shows up and determines Total Cut

Depth = 0.25.
e. Set the Rough Depth = 0.25 and Rough Depth/Cut = 0.05.

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This would machine the pocket in steps of 0.05 resulting in 5 cut levels.

Note: You can also specify the Total Cut Depth by entering the depth values under
Total Cut Depth.

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5. Switch to the Entry/Exit tab.

6. Use the following settings for Entry/Exit. Make sure to check Apply Entry/Exit
at all cut levels.

7. Click Generate. The 2½ Axis Pocketing toolpath is now generated and the
Operation is listed under the 2 ½ Axis Facing Operation in the VisualMILL-
MOps browser.

Note: You can rearrange the operations in the MOps browser by selecting the
operation and dragging and dropping.

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8. Switch to Simulate tab, select 2 ½ Axis Pocketing, and click Simulate to run
the simulation.

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Creating the Pocketing Operation #2

We will now create a 2nd pocketing operation for machining the region around the
boss.
1. Switch to the Create Operations tab.

Copying a MOp

2. Select the 2 ½ axis Pocketing Operation created from the previous step, right
mouse click, and select Copy.

3. Right click and select Paste.

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4. This would create a copy of the 2 ½ axis Pocketing Operation listed below the
first pocketing operation as show below.

5. Expand the 2 ½ Axis Pocketing-1 folder and double click on Machining

Features.

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6. Click Remove All under Machining Features and click Select Curves as
Regions.

7. Select Sketch7 and Sketch2 from the Feature Manager design area by
holding the Ctrl key down.

8. Click the cancel button to terminate the selection.

9. Regions are now listed under Machining Features/Regions.

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10. Switch to the Cut Levels Tab.

11. Use the Following Settings.

a. Location of Cut Geometry – Select Pick at Top = – 0.125
b. Total Cut Depth – Set this to 0.375
c. Set the Rough Depth = 0.375 and Rough Depth /Cut = 0.05
d. Switch to the Entry/Exit tab and set the Retract Motion to Linear,
Length = 0.1 and Angle = 0
e. Click Generate.

12. The pocketing toolpath is now created and displayed in the MOps browser.

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13. Switch to Simulate tab, select 2 ½ Axis Pocketing-1, and click Simulate to run
the simulation.

Note: To turn on/off the toolpath and stock model visibilities use the controls located
at the bottom of the MOps Browser.

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Hole Pocketing Operation

In order to machine the 6 holes, we will now use 2 ½ axis hole pocketing operation.

Creating the Hole Pocketing Operation #1

1. Select 2 ½ Axis Milling and Hole Pocketing.

2. Go to the Machining Features/ Regions tab and click Select Curves as

Regions.

3. Switch to Feature Manager Design tree and select Sketch4 located under
Extrude4. This selects the 6 holes.

4. Click the cancel button to terminate the selection.

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5. Switch to the Tools tab inside the Hole Pocketing operation and select FlatMill-
0.25.

6. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

7. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

Specify Cut Parameters

1. Click on the Cut Parameters tab.

2. Use the following Settings

a. Tolerance to 0.001,

b. Hole Depth (H) =0.0625, Uncheck Use 3D model to Detect Depth,

c. Hole Diameter (D) = 0.5, Check Cleanup pass at each Z level

d. Step over distance = 25 (% Tool Diameter),

e. Step Down Control (dZ) = 50 (% Tool Diameter),

f. Cut Direction = Climb (Down Cutting).

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3. Switch to the Entry Exit Tab and set the Helix Diameter = 0.25.

4. Check Create full (360 degree) helixes only and output each helix individually.

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5. Click Generate. The Hole Pocketing operation is now created and is listed
under the MOps browser.

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6. Switch to the Simulate tab, select Hole Pocketing, and click Simulate to run
the simulation.

7. The simulated part is shown below.

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Creating the Hole Pocketing Operation #2

1. Switch to the Create Operations tab.

Creating the Hole Pocketing Operation

2. Select the Hole Pocketing Operation created from the previous step, right
mouse click, and select Copy.

3. Right click and select Paste.

4. This would create a copy of the Hole Pocketing Operation listed below the first
Hole Pocketing operation as show below.

5. Expand the Hole Pocketing-1 folder and double click on Machining Features.

6. Click Remove All under Machining Features and click Select Curves as
Regions.

7. Switch to Feature Manager Design tree and select Sketch5 located under
Extrude5.

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8. Click the cancel button to terminate the selection.

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9. Switch to Cut Parameters tab and set the Hole Depth = 0.1875, Hole
Diameter = 0.315.

10. Switch to the Entry/Exit tab and set the Helix Diameter to 0.09.

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11. Click Generate. The Hole Pocketing Operation for the inner holes is now
created.

12. Switch to the Simulate tab, select Hole Pocketing-1, and click Simulate to run
the simulation.

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2 ½ Axis Engraving Operation

Now we will use engraving operation to drill the 2 holes. This can also be
accomplished by using a drilling operation that is available under Hole Machining.

Creating the Engraving Toolpath

1. From the Create Operations tab, select 2 ½ Axis Milling and Engraving.

2. Go to the Machining Features/ Regions tab, click Remove All under Machining
Features, and click Select Curves as Regions.

3. Switch to Feature Manager Design tree and select Sketch8. The 2 points are
now selected as Machining Regions.

4. Click the cancel button to terminate the selection.

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5. Switch to the Tools tab inside the Engraving operation and select FlatMill-
0.25.

6. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

7. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

8. Switch to the Cut Parameters tab and use the following parameters -
Tolerance = 0.001, Location of Cut Geometry At Top, Total Cut Depth =
0.375, Rough Depth = 0.375 and Rough Depth/Cut = 0.05. Leave the Cut
Traversal between cut levels at ZigZag.

9. Set the Entry and Exit to None under the Entry/Exit tab.

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10. Click Generate. The Engraving operation is now created.

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11. Switch to Simulate tab, select Engraving, and click Simulate to run the
simulation.

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2 ½ Axis Profiling

1. Switch to the Create Operations tab and select 2.5 Axis Milling and choose
Profiling.

2. Go to the Machining Features/ Regions tab, click Remove All under

Machining Features, and click Select Curves as Regions.

3. Switch to Feature Manager Design tree and select Sketch1 located under
Extrude1.

4. Click the cancel button to terminate the selection.

5. The selected region is now displayed under Machining Features/Regions.

6. Switch to the Tools tab inside 2 ½ Axis Profiling operation and Select the
FlatMill-0.25.

7. Click on the Feeds and Speeds tab. And select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

8. Switch to Clearance Tab. Set the Clearance Plane Definition to Automatic and
Cut Transfer Method to Clearance Plane.

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Specifying Cut Parameters

1. Switch to Cut Parameters tab and use the following Settings

a. Tolerance = 0.001,
b. Stock = 0,
c. Cut Start Side- Check Use Outside/Inside for closed curves and pick
Outside.

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2. Select the Cut Levels Tab and specify Location of Cut Geometry At Bottom,
Total Cut Depth = 0.25, Rough Depth/Cut = 0.05.

3. Switch to Entry/Exit Tab and Set the Entry and Exit Type to None.

4. Click Generate. The 2½ Axis Profile toolpath is now generated and the
Operation is listed under the VisualMILL-MOps browser.

Toolpath display can be turned on/off by selecting Toolpath Visibility under the MOps
browser.

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5. Switch to the Simulate tab in the VisualMILL-MOps browser. Select the 2 ½

Axis Profiling Operation and click to Simulate.

6. The simulated part is as shown below.

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Note: You can adjust the simulation speed by selecting Simulation Preferences that is
located to the bottom right corner of the VisualMILL-MOps browser.

To exit the Simulation mode, pause the Simulation.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as Shaftbase.nc and click save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 3!

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Tutorial 4: Simple V-Carving

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Introduction

This tutorial will illustrate machining a Sign using 2-1/2 axis-engraving operations.
We can engrave the sign using 2-D Sketches. This tutorial will introduce the usage of
2-½ axis simple V Carving using V bit.

V carving refers to a cutting strategy employed by sign makers to create sharp

corners. V carving is performed using a tapered bit or conical tool (as shown below)
usually known in the industry as a V Bit.

The V-bit is made to rise from the cutting depth to the top of the surface at the
corners in such a way that the tapered sides of the cutter are always in contact with
the corners. When the cutter finally reaches the top surface, only the bottom tip of
the tool will be in contact with the corners, thereby creating clean and crisp cuts at
the corners.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the part

• V carving is performed using the 2 ½ axis Machining Operation.

• The part itself will be machined out of a 10.75 inch x 4 inch x ½ inch poplar
wood sheet
• The part would be machined using a single V-Groove bit.
• The wooden sheet will be held to the machine table or the spoil sheet on the
table using double-sided tape.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Stock geometry

• Set the Machine zero point with respect to the machine coordinates

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• 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

2. From the Open dialog box, select the V-Carve1.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

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2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

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3. Set the Machine type to 3 axis

4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

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C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts

The program to send the posted output is set to notepad. This would output the G
code to a notepad.

Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Box Stock

2. This brings up the Box Stock parameters. Set the Length (L) = 10.75, Width
W = 4.00 and Height (H) = 0.5. Make sure to set the corner position to
Southwest corner Top of Stock as shown below.

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3. The stock geometry is now created, and a semi-transparent stock box is

displayed on top of the part geometry.

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4. The setup tab now displays the following information: Machine Type, Post
Processor, and Stock type as show below.

Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Top and XY alignment to Center. (This would align the
stock to the top of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

1. Select Set MCS from the Setup tab

2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Highest Z, and Zero Position to South West corner. This sets the machine
home to the top of the stock material and the southwest corner of the part
geometry.

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(This sets the machine home to Southwest corner and top of the stock material).

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Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Click Save As to save the work and specify a file name as V-Carve1-Rev1.

Create Tools

To machine the above part, we will now create a 60-degree Taper Tool.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to VeeMill.

2. Set the tool name as VeeMill1, Taper Angle = 30, Flute Length = 0.4, Tool
Length = 2. Under the Properties tab set Tool Number = 1.

Note: Taper Angle represents the included angle for a taper tool. For example a 60-
degree taper tool would have a included angle of 30 degrees. If you have a taper
tool with a diameter select Chamfer Mill or Taper Mill under Create/Select Tool.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

5. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

The created tools are now listed under the VisualMILL-Tools browser.

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Create Machining Operations

In this process we will create a 2.5 axis V-Carve operation.

1. Switch to the Create Operations tab in VisualMILL-Mops browser.

V-Carving

2. Select 2.5 Axis Mill and choose V-Carving.

This brings up the V-Carving Operations dialog. We will go over the steps for creating
the toolpath.

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Select Machining Features/Regions

3. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Profiling operation dialog is now minimized and allows
selection of the sketch geometry.

4. Switch to Feature Manager Design tree and select Sketch3. This will select
the text.

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5. Click the cancel button to terminate the selection.

6. V-Carve operation dialog comes back up displaying the selected regions

(sketch entities). The selected regions are also highlighted on the part

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Selecting the Tool

7. Switch to the Tools tab inside the V-Carving operation.

8. Select VeeMill1. VeeMill1 is now selected as the active tool and the Tool
parameters are displayed to the right of the Tools window.

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Set Feeds and Speeds

9. Click on the Feeds and Speeds tab.

10. Select Load From Tool. VisualMILL will now get the feeds and speeds
information that was set when the tool was defined.

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Clearance Control

11. Switch to Clearance Tab.

12. Set the Clearance Plane Definition to Absolute Z Value = 0.25 and Cut
Transfer Method to Clearance Plane.

Setting Cut Transfer to Clearance Plane would apply the Absolute Z value
clearance between transfers when the tool moves from a machining region to
another.

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Specifying Cut Parameters

13. Switch to Cut Parameters tab.

14. Set the Tolerance = 0.001, Cut Side = Inside, Location of Cut Geometry =
At Top, Total Cut Depth = 0.2, Rough Depth = 0.2 and Rough Depth/Cut =
0.05.

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Sorting

15. Select the Sorting Tab.

16. Use Minimum Distance Sort & set Start Point as Lower Left.

This will sort based on the minimum distance between 2 text based on their start
points.

17. Click Generate. The V-Carving toolpath is now generated and the Operation
is listed under the VisualMILL-MOps browser.

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Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the
MOps browser.

Simulate Toolpath

The generated toolpath can now be simulated.

1. Switch to the Simulate tab in the VisualMILL-MOps browser.

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2. Select the V-Carving Operation and click to Simulate.

3. The simulated part is as shown below.

Note: You can adjust the simulation speed by selecting Simulation Preferences that is
located to the bottom right corner of the VisualMILL-MOps browser.

To exit the Simulation mode, pause the Simulation.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as V-Carve.nc and click Save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 4!

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Tutorial 5: Embossing

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Introduction

This tutorial will illustrate machining a Sign using 2-1/2 axis-engraving operations.
We can engrave the sign using 2-D curves. This tutorial will introduce the usage of 2-
½ axis V Carve Roughing with a Flat End Mill and V Carving using V bit.

V carving refers to a cutting strategy employed by sign makers to create sharp

corners. V carving is performed using a tapered bit or conical tool (as shown below)
usually known in the industry as a V Bit.

The V-bit is made to rise from the cutting depth to the top of the surface at the
corners in such a way that the tapered sides of the cutter are always in contact with
the corners. When the cutter finally reaches the top surface, only the bottom tip of
the tool will be in contact with the corners, thereby creating clean and crisp cuts at
the corners.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the part

• Embossing is performed using the 2 ½ axis Machining Operations.

• The part itself will be machined out of a 20 inch x 4 inch x 1 inch poplar wood
sheet
• The part would be machined using a Flat End Mill and a V-Groove bit.
• The wooden sheet will be held to the machine table or the spoil sheet on the
table using double-sided tape.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Part

• Create the Stock geometry
• Set the Machine zero point with respect to the machine coordinates

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• 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

2. From the Open dialog box, select the Embossing1.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

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3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

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3. Set the Machine type to 3 axis

4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Box Stock

2. This brings up the Box Stock parameters and set the Length (L) = 20.00,
Width W = 4.00 and Height (H) = 1.0. Make sure to set the corner position to
Southwest corner Top of Stock as shown below.

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3. The stock geometry is now created, and a semi-transparent stock box is

displayed on top of the part geometry.

4. The setup tab now displays the following information: Machine Type, Post
Processor and Stock type as show below.

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Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Top and XY alignment to Center. (This would align the
stock to the top of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

1. Select Set MCS from the Setup tab

2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Highest Z, and Zero Position to South West corner. This sets the machine
home to the top of the stock material and the southwest corner of the part
geometry.

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(This sets the machine home to Southwest corner and top of the stock material).

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Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Click Save As to save the work and specify a file name as Embossing1-Rev1.

Create Tools

To machine the above part, we will now create a 1/8th inch (0.125”) Flat End Mill for
the V Carve Roughing operation and a VeeMill for the V Carve (finishing) operation.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to Flat End Mill.

2. Set the tool name as FlatMill-0.125 and the Tool Diameter = 0.125. Under
the Properties tab, set Tool Number = 1.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

1. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

2. Use the following settings for feeds and speeds.

3. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

The created tools are now listed under the VisualMILL-Tools browser.

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4. Create a 2nd tool of type VeeMill.

5. Set the tool name as VeeMill1, Taper Angle = 30, Flute Length = 0.4, and
Tool Length = 2. Under the Properties tab, set Tool Number = 2.

Note: Taper Angle represents the included angle for a taper tool. For example a 60-
degree taper tool would have a included angle of 30 degrees. If you have a taper
tool with a diameter select Chamfer Mill or Taper Mill under Create/Select Tool.

6. Switch to the Feeds & Speeds tab inside the create/select tool dialog and use
the following settings for Feeds/Speeds for the VeeMill1.

7. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

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Create Machining Operations

In this process we will create a 2.5 axis V-Carve operation.

1. Switch to the Create Operations tab in VisualMILL-Mops browser.

V-Carving Roughing

2. Select 2.5 Axis Mill and choose V-Carve Roughing.

This brings up the V-Carve Roughing dialog. We will go over the steps for
creating the toolpath.

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Select Machining Features/Regions

1. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Profiling operation dialog is now minimized and allows
selection of the sketch geometry.

2. Switch to Feature Manager Design tree and select Sketch2 and Sketch3 by
holding the Ctrl key. This will select the text and the inner rectangle.

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3. Click the cancel button to terminate the selection.

4. V-Carve Roughing operation dialog comes back up displaying the selected

regions (sketch entities). The selected regions are also highlighted on the part

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Selecting the Tool

5. Switch to the Tools tab inside the V-Carve Roughing operation.

6. Select FlatMill-0.125. FlatMill-0.125 is now selected as the active tool and the
Tool parameters are displayed to the right of the Tools window.

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Set Feeds and Speeds

7. Click on the Feeds and Speeds tab.

8. Select Load From Tool. VisualMILL will now get the feeds and speeds
information that was set when the tool was defined.

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Clearance Control

9. Switch to Clearance Tab.

10. Set the Clearance Plane Definition to Absolute Z Value = 0.25 and Cut
Transfer Method to Clearance Plane.

Setting Cut Transfer to Clearance Plane would apply the Absolute Z value clearance
between transfers when the tool moves from a machining region to another.

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Specifying Cut Parameters

11. Switch to Cut Parameters tab.

12. Set the Tolerance = 0.001, Stock = 0, V-Carving Finish Tool Taper Angle =
30, Cut Type = Offset, and Cut Direction = Mixed. Check the Corner
Cleanup option.

Note: V-Carve Finishing Tool Taper Angle represents the included angle of the Vbit
that would be used after the V-Carve Roughing Operation. If you have a 60 degree
V-Bit, the Taper Angle would be 30 degrees.

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13. Switch to the Cut Levels tab and use the following settings.

14. Specify Location of Cut Geometry = At Top, Total Cut Depth = 0.25, Rough
Depth = 0.25, and Rough Depth/Cut = 0.125. Click Generate. The V-Carve
Roughing toolpath is now generated and the Operation is listed under the
VisualMILL-MOps browser.

Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the
MOps browser.

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Simulate Toolpath

The generated toolpath can now be simulated.

1. Switch to the Simulate tab in the VisualMILL-MOps browser.

2. Select the V-Carve Roughing Operation and click to Simulate.

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The simulated part is as shown below.

Note: You can adjust the simulation speed by selecting Simulation Preferences that is
located to the bottom right corner of the VisualMILL-MOps browser.

To exit the Simulation mode, pause the Simulation.

We will now generate V Carve Finishing to finish the sign with a Taper Tool.

V-Carving

1. Switch to Create tab, select 2.5 Axis Mill and choose V-Carving.

This brings up the V-Carving Operations dialog. We will go over the steps for creating
the toolpath.

Select Machining Features/Regions

2. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Profiling operation dialog is now minimized and allows
selection of the sketch geometry.

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3. If the regions are not listed under Selected Machining regions, switch to
Feature Manager Design tree and select Sketch2 and Sketch3 by holding the
Ctrl key. This will select the text and the inner rectangle.

4. Click the cancel button to terminate the selection.

5. V-Carve operation dialog comes back up displaying the selected regions

(sketch entities). The selected regions are also highlighted on the part

Selecting the Tool

6. Switch to the Tools tab inside the V-Carve operation.

7. Select VeeMill1. VeeMill1 is now selected as the active tool and the Tool
parameters are displayed to the right of the Tools window.

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Set Feeds and Speeds

8. Click on the Feeds and Speeds tab.

9. Select Load From Tool. VisualMILL will now get the feeds and speeds
information that was set when the tool was defined.

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Clearance Control

10. Switch to Clearance Tab.

11. Set the Clearance Plane Definition to Absolute Z Value = 0.25 and Cut
Transfer Method to Clearance Plane.

Setting Cut Transfer to Clearance Plane would apply the Absolute Z value
clearance between transfers when the tool moves from a machining region to
another.

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Specifying Cut Parameters

12. Switch to Cut Parameters tab.

13. Set the Tolerance = 0.001, Cut Side = Inside, Location of Cut Geometry =
At Top, Total Cut Depth = 0.25, Rough Depth = 0.25, and Rough Depth/Cut
= 0.25.

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Sorting

14. Select the Sorting Tab.

15. Use Minimum Distance Sort & set Start Point as Lower Left.

16. Click Generate. The V-Carving toolpath is now generated and the Operation
is listed under the VisualMILL-MOps browser.

Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the
MOps browser.

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Simulate Toolpath

The generated toolpath can now be simulated.

1. Switch to the Simulate tab in the VisualMILL-MOps browser and Select the V-
Carving Operation and click to Simulate.

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The Simulated part is as shown below.

Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

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2. Specify the File Name as Embossing.nc and click Save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 5!

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Tutorial 6: Chamfering

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Introduction

This tutorial is intended to show an easy way to chamfer and smooth sharp corners
by using 2 ½ axis Chamfering operation. A tapered tool is suitable for this purpose.

We plan to chamfer the edges of the part using a 30 degree taper tool that has 0
radius at the tip.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the part

• Chamfering is performed using the 2 ½ axis Chamfer Machining Operation.

• The part would be machined using a single V-Groove bit.
• The wooden sheet will be held to the machine table or the spoil sheet on the
table using double-sided tape.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:
• Create the Stock geometry
• Set the Machine zero point 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

2. From the Open dialog box, select the Chamfer.sldprt file from the Tutorials
folder in the VisualMILL 6.0 installation folder. (C:\Program Files\MecSoft
Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

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The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

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Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab. The loaded
part has the stock model defined and includes a 2 ½ axis Facing Operation
with a 0.5” Flat End Mill. The Machining Operation information is listed in the
MOps browser as shown below.

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Create Tools

To machine the chamfer, we will now create a 60-degree Taper Tool.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps
browser and select Create/Edit Tools. Select the Tool Type to Chamfer.

2. Set the tool name as ChamferMill1, Taper Angle = 30, Flute Length = 1,
and Tool Length = 2. Under the Properties tab, set Tool Number = 2.

Note: Taper Angle represents the included angle for a taper tool. For example a 60-
degree taper tool would have a included angle of 30 degrees. If you have a taper
tool with a diameter select Chamfer Mill or Taper Mill under Create/Select Tool.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

5. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

The created tools are now listed under the Tools browser.

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Create Machining Operations

1. Switch to the Create Operations tab in VisualMILL-Mops browser.

Chamfering

2. Select 2.5 Axis Mill and choose Chamfering.

This brings up the Chamfering Operations dialog. We will go over the steps for
creating the toolpath.

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Select Machining Features/Regions

3. Go to the Machining Features/ Regions tab and click remove all if any
Machining regions are listed.

4. Click Select Curves as Regions.

5. Switch to Feature Manager Design tree and select Sketch1 located under
Extrude1.

6. Click the cancel button to terminate the selection.

7. The selected regions are now displayed under Machining Regions.

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Selecting the Tool

8. Switch to the Tools tab inside the Chamfering operation.

9. Select ChamferMill1. ChamferMill1 is now selected as the active tool, and the
Tool parameters are displayed to the right of the Tools window.

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Set Feeds and Speeds

10. Click on the Feeds and Speeds tab.

11. Select Load From Tool. VisualMILL will now get the feeds and speeds
information that was set when the tool was defined.

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Clearance Control

12. Switch to Clearance Tab.

13. Set the Clearance Plane Definition to Absolute Z Value = 0.25 and Cut
Transfer Method to Clearance Plane.

Setting Cut Transfer to Clearance Plane would apply the Absolute Z value clearance
between transfers when the tool moves from a machining region to another.

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Specifying Cut Parameters

14. Switch to Cut Parameters tab.

15. Set the Tolerance = 0.001, Stock = 0, Chamfer Parameters use Chamfer
Width = 0.05, Cut Side = Outside. Click Generate. The Chamfering toolpath
is now generated and the Operation is listed under the VisualMILL-MOps
browser.

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Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the
MOps browser.

Reorder a Machining Operation

If the chamfer operation is created above the 2 ½ axis Facing operation, you can
reorder the MOp using the steps below.

1. Minimize all MOps inside the Mop Set1.

2. Select the Chamfering MOp and drag it over the 2 ½ axis Facing MOp. This
would move the Chamfer MOp below the Facing MOp.

Chamfer toolpath is now generated and is displayed below.

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Simulate Toolpath

The generated toolpath can now be simulated.

1. Switch to the Simulate tab in the VisualMILL-MOps browser.

2. Select the 2 ½ Axis Facing Operation and click to Simulate.

3. Once the Facing operation is simulated, select the Chamfering Operation and
click Simulate to run the simulation.

4. The simulated part is as shown below.

Note: You can adjust the simulation speed by selecting Simulation Preferences that is
located to the bottom right corner of the VisualMILL-MOps browser.

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To exit the Simulation mode, pause the Simulation.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as Chamfering.nc and click Save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 6!

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Tutorial 7: 3 Axis Milling

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Introduction

This tutorial will illustrate machining this Mold using 3 axis-milling operations.
This tutorial will introduce the usage of several 3-axis operations such as horizontal
roughing, parallel finishing, and horizontal finishing.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the mold

• We will machine the mold completely using 3 axis-machining operations.

• The part itself will be machined out of a 5.5 x 6.5 inch x 1.25-inch wood
block.
• The stock may be held to the machine table or the spoil sheet on the table
using double-sided tape or by clamps.
• The part will be machined using 0.5” flat end mill, 0.25” & 0.125” ball end
mills.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Stock geometry

• Set the Machine zero point 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

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2. From the Open dialog box, select the 3Axis-Example1.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

You can toggle between the MOPs browser and the Feature Manager from the tabs
located at the top of the window. You can also resize it by dragging one of its sides.

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Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 3 axis

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4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Box Stock

2. This brings up the Box Stock parameters. Set the Length (L) = 5.50, Width W
= 6.5 and Height (H) = 1.25. Leave the other parameters as default and Click
OK. Set Corner coordinates for Xc, Yc and Zc = 0.

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The stock geometry is now created, and a semi-transparent stock box is displayed on
top of the part geometry.

3. The setup tab now displays the following information: Machine Type, Post
Processor, and Stock type as show below.

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Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Bottom and XY alignment to Center. (This would align

the stock to the bottom of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

3. Select Set MCS from the Setup tab

4. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Highest Z, and Zero Position to South West corner. This sets the machine
home to the top of the stock material and the southwest corner of the part
geometry.

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(This sets the machine home to Southwest corner and top of the stock material).

Click Save As to save the work and specify a file name as 3Axis-Example1-Rev1.

Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Create Tools

To machine the above part we will now create a ½ inch (0.5”) Flat End Mill.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to Flat End Mill.

2. Set the tool name as FlatMill-0.5, Tool Diameter = 0.5, Under the Properties
tab set Tool Number = 1.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

5. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

6. Create a Ball End Mill with the following parameters.

a. Tool Name: BallMill-0.25, Tool Number = 2.
b. Switch to Feeds & Speeds tab set Spindle Speed = 5000 rpm, plunge &
approach feed = 35 ipm, approach feed = 40 ipm, cut feed = 45 ipm,
retract and departure feeds = 50 ipm. Set the Transfer Feedrate to
Use Rapid.
c. Click Save as New Tool.

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7. Create another Ball End Mill with the following parameters.

a. Tool Name: BallMill-0.125, Tool Number = 3.
b. Switch to Feeds & Speeds tab set Spindle Speed = 5000 rpm, plunge &
approach feed = 35 ipm, approach feed = 40 ipm, cut feed = 45 ipm,
retract and departure feeds = 50 ipm. Set the Transfer Feedrate to
Use Rapid.
c. Click Save as New Tool.

The created tools are now listed under the VisualMILL-Tools browser.

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Create Machining Operations

We will machine the mold using 3 different machining operations – Horizontal

Roughing, Parallel Finishing, and Horizontal Finishing.

The first step in machining the mold will be a roughing operation. This type of
machining is very efficient for removing large volumes of material and is typically
performed with a large tool. Roughing is typically followed by semi-finishing or
finishing toolpaths.

Switch to the Create Operations tab in VisualMILL-Mops browser.

3 axis Horizontal Roughing

1. Select 3 Axis Milling and choose Horizontal Roughing.

2. This brings up the 3 Axis Horizontal Roughing Operation Dialog. We will now
go over the steps for creating the toolpath.

3. Switch to the Tools tab inside the 3 axis Horizontal Roughing operation and
select FlatMill-0.5.

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4. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

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5. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

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Specify Cut Parameters

6. Click on the Cut Parameters tab.

7. Set the Intol and Outol = 0.01, Stock to leave =0.025, Cut Pattern to Stock
Offset, Cut Direction = Mixed, Step over distance = 40 (% Tool Diameter).

8. Switch to the Cut Levels Tab.

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9. Use the Following Settings.

a. Step Down Control (dZ) = 50 (% Tool Diameter).

b. Check Clear Flats under Cut Levels.

10. Switch to the Engage/Retract tab and leave the entry/exit parameters as
default.

11. Click Generate. The 3 axis Roughing toolpath is now generated, and the
Operation is listed under the VisualMILL-MOps browser.

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12. Switch to Simulate tab, select Horizontal Roughing, and click Simulate to run
the simulation.

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3 axis Parallel Finishing

We will now use 3 axis Parallel Finishing operation to pre-finish the part using a
0.25” Ball End Mill.

This is an efficient method of finishing or pre-finishing, typically used when part

surfaces are relatively flat. A 2D linear zigzag pattern is generated on the XY plane
above the part geometry. The tool moves along this cut pattern, following the
contours of the part geometry below.

1. From the Create Operations tab, select 3 axis Milling and Parallel Finishing.

This brings up the Parallel Finishing Operations dialog. We will go over the steps for
creating the pocketing operation.

2. Switch to the Tools tab inside the Parallel Finishing operation and select
BallMill-0.25.

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3. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

4. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

Specify Cut Parameters

5. Click on the Cut Parameters tab.

6. Set the Tolerance to 0.001, Stock to leave =0, Cut Direction = Mixed, Step
over distance = 15 (% Tool Diameter).

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7. Click Generate. The Parallel Finishing toolpath is now generated, and the
Operation is listed under the 3 Axis Horizontal Roughing Operation in the
VisualMILL-MOps browser.

8. Switch to Simulate tab, select Parallel Finishing, and click Simulate to run the
simulation.

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3 axis Horizontal Finishing

We will now create a Horizontal Finishing operation for machining steep area regions.
This method is used for pre-finishing or finishing in constant Z levels, typically used
when the part has large vertical surfaces and when Parallel Finishing will not yield
satisfactory results.

1. Switch to the Create Operations tab.

2. Select 3 axis Milling and Horizontal Finishing.

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Select Machining Features/Regions

1. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Horizontal Finishing operation dialog is now minimized and
allows selection of the sketch geometry.

2. Switch to Feature Manager Design tree and select Sketch1 located under
Extrude1.

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3. Click the cancel button to terminate the selection.

The 3 Axis Horizontal Finishing operation dialog comes back up displaying the
selected regions (sketch entities). The selected regions are also highlighted on the
part.

4. Switch to the Tools tab inside Horizontal Finishing operation and select
BallMill-0.125.

5. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

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6. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

Specify Cut Parameters

7. Click on the Cut Parameters tab.

8. Set Intol, Outol = 0.001, Cut Direction = Climb/Conventional.

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9. Switch to the Cut Levels tab.

10. Set the Step Down Control (dZ) = 15 (% Tool Diameter).

11. Leave the entry/exit parameters at default.

12. Click Generate. The Horizontal Finishing operation is now created and is
listed under the MOps browser.

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13. Switch to the Simulate tab, select Horizontal Finishing, and click Simulate to
run the simulation.

14. The simulated part is shown below.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as 3axisMold.nc and click save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 7!

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Tutorial 8: Profiling with Bridges (Tabs)

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Introduction

This tutorial will illustrate machining of multiple parts on a single sheet of stock using
2-1/2 milling operations.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the part

• We will machine the part using a 2-½ axis profiling operation.

• We will define bridges so that the parts do not fall off the sheet once its cut to
its full depth.
• The part will be machined out of a 36 x 24 x ½ inch poplar wood sheet using
a 0.25 inch Flat End Mill.
• The wooden sheet will be held to the machine table or the spoil sheet on the
table using fixtures/clamps.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Load part geometry

• Create the Stock geometry
• Set the Machine zero point 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

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2. From the Open dialog box, select the Profile_Tabs.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

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4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 3 axis

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4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Box Stock

2. This brings up the Box Stock parameters. Set the Length (L) = 36, Width W
= 24, and Height (H) = 0. 5. Make sure to set the corner position to
Southwest corner Top of Stock as shown below.

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3. The stock geometry is now created, and a semi-transparent stock box is

displayed on top of the part geometry.

4. The setup tab now displays the following information: Machine Type, Post
Processor, and Stock type as show below.

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Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Top and XY alignment to Center. (This would align the
stock to the top of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

1. Select Set MCS from the Setup tab

2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Highest Z, and Zero Position to South West corner. This sets the machine
home to the top of the stock material and the southwest corner of the part
geometry.

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Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

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Create Tools

To machine the above part we will now create a ¼ inch (0.25”) Flat End Mill.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to Flat End Mill.

2. Set the tool name as FlatMill-0.25, Tool Diameter = 0.25. Under the
Properties tab, set Tool Number = 1.

Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

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5. Click Save as New Tool. The tool is now created and listed under Tools in
Library. Click OK to close the dialog.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

The created tool is now listed under the VisualMILL-Tools browser.

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Create Machining Operations

In this process we will create a 2.5 axis profiling operation.

1. Switch to the Create Operations tab in VisualMILL-Mops browser.

2 ½ Axis Profiling

2. Select 2 ½ Axis Milling and choose Profiling

This brings up the 2 ½ Axis Profiling Operations dialog. We will go over the steps for
creating the profile operations.

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Select Machining Features/Regions

1. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The Profiling operation dialog is now minimized and allows
selection of the sketch geometry.

2. Switch to Feature Manager Design tree and select Sketch2. This will select all
the rounded rectangles.

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3. Click the cancel button to terminate the selection.

The 2 ½ Axis Profiling operation dialog comes back up displaying the selected
regions (sketch entities). The selected regions are also highlighted on the part.

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Selecting the Tool

4. Switch to the Tools tab inside the 2 ½ Axis Profiling operation.

5. Select the FlatMill-0.25. The 0.25” Flat End mill is now selected as the active
tool and the Tool parameters are displayed to the right of the Tools window.

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Set Feeds and Speeds

6. Click on the Feeds and Speeds tab.

7. Select Load From Tool. VisualMILL will now get the feeds and speeds
information that was set when the tool was defined.

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Clearance Control

8. Switch to Clearance Tab.

9. Set the Clearance Plane Definition to Automatic and Cut Transfer Method to
Clearance Plane.

VisualMILL will determine a safe Z height for the Entry & Exit when set to
automatic. Setting Cut Transfer to Clearance Plane would apply the automatic
Z clearance between transfers when the tool moves from a machining region to
another.

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Specifying Cut Parameters

10. Switch to Cut Parameters tab.

11. Set the Stock = 0. Under Cut Start Side, check Use Outside/Inside for
Closed Curves and select Outside.

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12. Select the Cut Levels Tab and specify the Total Cut Depth = 0.51, Rough
Depth = 0.5, Rough Depth/Cut = 0.125. The cut depth is always set as an
absolute value.

Note: The stock material is 0.5” in thickness. We will generate the toolpath to cut to
a depth of 0.51to ensure that the part is cut to its full depth.

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Entry/Exit

13. Switch to Entry/Exit Tab and set the entry and exit type to None.

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Advanced Cut Parameters

14. Switch to Advanced Cut parameters tab and check Use Bridges/Tabs.

15. Specify bridge height = 0.1, bridge length = 0.6, and # of Bridges on each
part = 4.

In the next step, we will sort the order of machining the parts.

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Sorting

16. Switch to the Sorting tab and use Directional Sort.

17. Set Start Angle = 0 and traverse pattern to ZigZag. This would sort the
toolpaths along X and then along Y.

18. Click Generate. The 2½ Axis Profile toolpath is now generated and the
Operation is listed under the VisualMILL-MOps browser.

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Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the
MOps browser.

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Simulate Toolpath

The generated toolpath can now be simulated.

1. Switch to the Simulate tab in the VisualMILL-MOps browser.

2. Select the 2 ½ Axis Profiling Operation and click to Simulate.

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The simulated part is as shown below.

Note: You can adjust the simulation speed by selecting Simulation Preferences that is
located to the bottom right corner of the VisualMILL-MOps browser.

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To exit the Simulation mode, pause the Simulation.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as Profile_Tabs.nc and click Save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 8!

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Tutorial 9: Hole Making

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Introduction

This tutorial will illustrate machining holes using Drilling operations. Even though we
have created a 3-D representation of the part, it will be seen later on that we can
machine this using just 2D Sketches.

The reason we are able to do this is because of the prismatic nature of this model.
The stepped instructions are accompanied by explanatory and introductory text.
Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the part

• We will machine part by using a Hole machining operation called Drilling.

• The part will be machined out of a 7.25 x 8.5 x 0.75 inch poplar wood sheet
using a 0.5” and 0.25” Standard Drill bit.
• The wooden sheet will be held to the machine table or the spoil sheet on the
table using clamps.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Stock geometry

• Set the Machine zero point 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

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2. From the Open dialog box, select the Bitholder.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

Preparing the part for Machining

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The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 3 axis

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4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Part Box Stock

2. This brings up the Part Box Stock Parameters.

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The system calculates the bounding box of the part model as the XYZ extents of
geometry of the part model. The user can then define offsets in any of the three
coordinate directions to apply to the computed bounding box.

3. Set the offsets for X, Y and Z =0 and click OK.

The stock geometry is now created, and a semi-transparent stock box is displayed on
top of the part geometry.

4. The setup tab now displays the following information: Machine Type, Post
Processor, and Stock type as show below.

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Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Top and XY alignment to Center. (This would align the
stock to the top of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

1. Select Set MCS from the Setup tab

2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Highest Z, and Zero Position to South West corner. This sets the machine
home to the top of the stock material and the southwest corner of the part
geometry.

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(This sets the machine home to Southwest corner and top of the stock material).

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Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Click Save As to save the work and specify a file name as Bitholder-Rev1.

Create Tools

To machine the above part, we will now create 2 tools.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to Drill Tool.

2. Set the tool name as Drill-0.5 and Tool Diameter = 0.5. Under the Properties
tab, set Tool Number = 1.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

5. Click Save as New Tool. The tool is now created and listed under Tools in
Library.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

6. Create a second tool of type Drill. Set the Tool Name as Drill-0.25, Tool
Number = 2. Use the same settings for the other parameters and click Save
as New Tool. Click OK to close the dialog.

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The created tools are now listed under the VisualMILL-Tools browser.

Create Machining Operations

In this process, we will create a 2.5 axis profiling operation.

3. Switch to the Create Operations tab in VisualMILL-Mops browser.

Hole Machining

4. Select Hole Machining and choose Drilling.

This brings up the Drilling Operations dialog. We will go over the steps for creating
the toolpath.

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Select Hole Features

5. Go to the Hole Features tab and click Select Drill Points/Circles. The
drilling operation dialog is now minimized and allows selection of the sketch
geometry.

6. Switch to Feature Manager Design tree and select Sketch3 located under
Extrude3. This selects the circles of diameter 0.5”

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7. Click the cancel button to terminate the selection.

The Drilling operation dialog comes back up displaying the selected regions (sketch
entities). The selected regions are also highlighted on the part.

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Selecting the Tool

8. Switch to the Tools tab inside the Drilling operation.

9. Select the Drill-0.5. The 0.5” Drill is now selected as the active tool and the
Tool parameters are displayed to the right of the Tools window.

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Set Feeds and Speeds

10. Click on the Feeds and Speeds tab.

11. Select Load From Tool. VisualMILL will now get the feeds and speeds
information that was set when the tool was defined.

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Clearance Control

12. Switch to Clearance Tab.

13. Set the Clearance Plane Definition to Automatic and Cut Transfer Method to
Clearance Plane.

VisualMILL will determine a safe Z height for the Entry & Exit when set to automatic.
Setting Cut Transfer to Clearance Plane would apply the automatic Z clearance
between transfers when the tool moves from a machining region to another.

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Specifying Cut Parameters

14. Switch to Cut Parameters tab.

15. Set the Drill Type to Standard Drill, Drill Depth = 0.75, Check Add Tool Tip
to Drill Depth, Location of Cut Geometry – At Top, and Approach Distance
= 0.1.

Note: Adding Tool Tip to Drill Depth adds the taper height of the drill tool to the drill
depth to make it a through hole.

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Sorting

16. Select the Sorting Tab. Use Directional Sort, leave the primary sort direction
Start Angle = 0, Secondary Sort direction (s) – Low to High and Traverse
Pattern to ZigZag.

The holes will now be sorted row first starting from the lowest point moving up in
Y in a ZigZag pattern.

17. Click Generate. The Drilling toolpath is now generated, and the Operation is
listed under the VisualMILL-MOps browser.

Note: Toolpath display can be turned on/off by selecting Toolpath Visibility under the
MOps browser.

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Simulate Toolpath

The generated toolpath can now be simulated.

1. Switch to the Simulate tab in the VisualMILL-MOps browser.

2. Select the Standard Drill Operation and click to Simulate.

The simulated part is as shown below.

Note: You can adjust the simulation speed by selecting Simulation Preferences that is
located to the bottom right corner of the VisualMILL-MOps browser.

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To exit the Simulation mode, pause the Simulation and click Exit Simulation. This
switches back to the Create Operations tab.

Creating the Drill operation for the 0.25” Holes

1. Switch to the Create operations tab

2. Select the Standard Drill Operation created from the previous step, right
mouse click, and select Copy.

3. Right click and select Paste.

4. This would create a copy of the Drilling Operation and lists below the first
pocketing operation as show below.

5. Double click on the Standard Drill-1 to edit the Hole Features.

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6. Click Remove All from the Hole Features Dialog to remove all the regions
from the list.

7. Now use Select Drill Points/Circles. The drilling operation dialog is now
minimized and allows selection of the sketch geometry.

8. Switch to Feature Manager Design tree and select Sketch2 located under
Extrude2.

9. Click the cancel button to terminate the selection.

10. Switch to the Tools tab under the Drilling Operations dialog and select Drill-
0.25.

11. Click Generate. The toolpath for Drill Operation-1 is now generated.

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12. Switch to Simulate tab and select Drill Operation- and click to simulate
toolpath.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as Drilling.nc and click Save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 9!

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Tutorial 10: Re-Machining a 3D Mold

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Introduction

This tutorial will illustrate machining this Mold using advanced 3 axis-milling
operations.

This tutorial will introduce the usage of advanced 3-axis operations such as pencil
tracing & valley remachining.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the mold

• We will machine the mold completely using 3 axis-machining operations.

• The part itself will be machined out of a 5.5 x 4.45 inch x 1.25-inch wood
block.
• The stock may be held to the machine table or the spoil sheet on the table
using double-sided tape or by clamps.
• The part will be machined using 0.5” flat end mill, 0.25” & 0.125” ball end
mills.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Stock geometry

• Set the Machine zero point 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

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2. From the Open dialog box, select the 3Axis-Example2.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

You can toggle between the MOPs browser and the Feature Manager from the tabs
located at the top of the window. You can also resize it by dragging one of its sides.

Create Machining Operations

Note: The part is pre-programmed with 2 machining operations. Horizontal Roughing

and Parallel Finishing.

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We will now use remachining to finish the mold using 2 different machining
operations – Pencil Tracing and Valley Re-Machining.

Switch to the Create Operations tab in VisualMILL-Mops browser.

3 axis Pencil Tracing

1. Highlight the Parallel Finishing operation in the Create operations tab. This
would ensure the next machining operation created would below the Parallel
Finishing toolpath.

2. Select 3 Axis Milling and choose Pencil Tracing.

3. This brings up the 3 Axis Pencil Tracing Operation Dialog. We will now go over
the steps for creating the toolpath.

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4. Switch to the Tools tab inside the Pencil Tracing operation and select BallMill-
0.125.

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5. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

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6. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

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Specify Cut Parameters

7. Click on the Cut Parameters tab.

8. Set the Intol and Outol = 0.001, Stock to leave =0.0, Cut Direction to
Climb, Select Do multiple cuts and set Number of Cuts = 2 and Step over
control = 20 (% Tool Diameter).

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Advanced Cut parameters

9. Switch to the advanced cut parameters Tab.

10. Use the Following Settings.

a. Limiting Steep Angle = 90 and Maximum included angle =180.

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Entry/Exit

11. Switch to the Entry/Exit tab and use the following settings.

12. Switch to the Exit Tab and set the Retract motion length = 0.025 and Angle =
10.

13. Click Generate. The 3-axis Pencil Tracing toolpath is now generated, and the
Operation is listed under the VisualMILL-MOps browser.

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14. Switch to Simulate tab, select Pencil Trace, and click Simulate to run the
simulation.

3 axis Valley Re-Machining

We will now use 3 axis Valley Re-Machining operation to finish the part using a
0.125” Ball End Mill.

1. From the Create Operations tab, select 3 axis Milling and Valley Re-Machining.

2. This brings up the Valley Re-Machining Operations dialog. We will go over the
steps for creating the pocketing operation.

3. Switch to the Tools tab inside the Parallel Finishing operation and select
BallMill-0.125.

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4. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

5. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

6. Click on the Cut control tab.

Specify Cut Control

7. Click on the cut control tab.

8. Set the Tolerance to 0.001, Stock to leave =0, Under Reference Tool
Parameters set Tool Diameter (D) = 0.25 (This is the diameter of the tool that
was used for parallel finishing).

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Specify Cutting Parameters

9. Click on the Cutting Parameters tab.

10. Use Split Cuts under slope Control. Specify the Cuts Split Angle (A) = 10

11. Select Output Flat and Steep Cuts.

12. Select Flat Cut Parameters.

13. Select Cut Pattern as Along, Cut Direction as Along, Cut Direction as Mixed
and specify Step Over control = 20 (% tool diameter).

14. Select Steep Cut Parameters.

15. Select Cut Pattern as Across, Cut Direction as Along, Cut Direction as Mixed
and specify Step Over control = 20 (% tool diameter).

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16. Click Generate. The Valley Remachining toolpath is now generated, and the
Operation is listed in the VisualMILL-MOps browser.

17. Switch to Simulate tab, select Valley Remachining, and click Simulate to run
the simulation.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as 3axisMold2.nc and click save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 10!

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Tutorial 11: Machining a Ring

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Introduction

This tutorial will illustrate machining this Ring using 4 axis-milling operations.
This tutorial will introduce the usage of several 4-axis operations such as 4 axis
roughing and finishing.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to Machine the ring

• We will machine the ring completely using 4 axis-machining operations.

• The part itself will be machined out of a cylindrical blank.
• The stock will be held to the machine table using a rotary chuck.
• The part will be machined using 0.125”, 0.0625”, and 0.03125” ball end mills.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Stock geometry

• Set the Machine zero point respect to the machine coordinates.
• Set the rotary axis and rotary center.
• 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 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

2. From the Open dialog box, select the RingExample_1.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

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Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

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Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 4 Axis and Rotary Axis to X Axis. For most
controllers rotation along X represents A axis and rotation along Y represents
B axis. We will set the Rotary Center once we determine the Machine Zero.

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4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Cylinder Stock.

2. This brings up the Cylinder Stock parameters. Set the Axis (rotary) = X,
Radius = 0.52” and Length (L) = 0.6. Leave the other parameters as default
and click OK.

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3. The stock geometry is now created, and a semi-transparent stock is displayed

on top of the part geometry.

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4. You must switch the simulation model to Polygonal model to run 4 axis
simulations. Select Preferences->Simulation Preferences from the Setup Tab
and switch the simulation model to Polygonal if set to Voxel.

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The setup tab now displays the following information: Machine Type, Post Processor,
and Stock type as show below.

Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Center and XY alignment to Center. (This would align the
stock to the top of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

The MCS is represented as a triad with 3 arrows, the Green arrow indicating X axis,
Blue the Y axis and Red the Z axis. It is always a good practice to set the machine
zero before generating a toolpath.

3. Select Set MCS from the Setup tab

4. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Highest Z, and Zero Position to East corner. This sets the machine home to
the top of the stock material and the right most edge of the part geometry.

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Click Save As to save the work and specify a file name as RingExample_1-Rev1.

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Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Specify Rotary Center

In this step we will determine the rotary center for the part geometry. The rotary
center must pass thro’ the entire part geometry. VisualMILL will not compute a
toolpath if the part/feature is below the rotary center as this is considered as an
undercuts in the part.

1. Select Machine Setup from the setup tab.

2. Set the rotary center in X =0, Y = 0 and Z = -0.54 which is the center of the
stock geometry.

The rotary center is represented by an arrow and displayed on the part geometry
when the Machine Setup Dialog is invoked.

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Create Tools

To machine the above part, we will now create a 0.125”, 0.0625” and 0.03125” Ball
End Mills.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to Ball End Mill.

2. Set the tool name as BallMill-0.125 and Tool Diameter = 0.125. Under the
Properties tab, set Tool Number = 1.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

5. Click Save as New Tool. The tool is now created and listed under Tools in
Library.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

6. Create a 2nd Ball End Mill with the following parameters.

a. Tool Name: BallMill-0.0625, Tool Number = 2.

b. Switch to Feeds & Speeds tab set Spindle Speed = 5000 rpm, plunge,
approach & engage feed = 20 ipm, cut feed = 30 ipm, retract and
departure feeds = 20 ipm. Set the Transfer Feedrate to Use Rapid.

c. Click Save as New Tool.

7. Create a 3rd Ball End Mill with the following parameters

a. Tool Name: BallMill-0.03125, Tool Number = 3.

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b. Switch to Feeds & Speeds tab set Spindle Speed = 5000 rpm, plunge,
approach & engage feed = 20 ipm, cut feed = 30 ipm, retract and
departure feeds = 20 ipm. Set the Transfer Feedrate to Use Rapid.

The created tools are now listed under the VisualMILL-Tools browser.

Create Machining Operations

We will machine the ring using 2 different machining operations – 4 axis Roughing
and Finishing.

The first step in machining the ring will be a roughing operation. In this cut method,
the tool cuts the stock in successive levels. The spacing between these levels are
specified by the user. This type of machining is very efficient for removing large
volumes of material and is typically performed with a large tool. Roughing is typically
followed by semi-finishing or finishing toolpaths.

Switch to the Create Operations tab in VisualMILL-Mops browser.

4 axis Roughing

1. Select 4 Axis Milling and choose Roughing.

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If the rotary center is not set to the same location as the Machine Zero, a warning
message dialog would be displayed at all times when a 4 axis machining operation is
selected. Users can override this message by clicking OK in the dialog.

Note: You can check Do no show this dialog again to stop the warning message
appearing again when you create/edit a 4 axis machining operation.

2. This brings up the 4 Axis Roughing Operation Dialog. We will now go over the
steps for creating the toolpath.

3. Switch to the Tools tab inside the 4th axis Roughing operation and select
BallMill-0.125.

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4. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

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5. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

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Specify Cut Parameters

6. Click on the Cut Parameters tab.

7. Set the Intol and Outol = 0.001, Stock to leave =0.005, Cut Pattern to
Across Axis, Zig Zag and Low to High, Cut Containment Low Value = -0.6,
High Value = 0 (as the machine zero is set to the right edge of the stock/
part), Step over distance = 25 (% Tool Diameter).

8. Switch to the Step Down Control Tab.

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Step Down Control

9. Use the Following Settings.

a. Cut Levels, Check Top (T) and specify Top (T) = 0.53 (radius of stock
material)
b. Step Down Control (dR) = 75 (% Tool Diameter).

10. Click Generate. The 4th axis Roughing toolpath is now generated, and the
Operation is listed under the VisualMILL-MOps browser.

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11. Switch to Simulate tab, select 4 Axis Roughing, and click Simulate to run the
simulation.

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4 axis Finishing

We will now use 4th Axis Finishing operation to finish the part using a 0.0625” Ball
End Mill.

In this method, the tool is always normal to the axis of table rotation (continuous
mode). The tool motions can be parallel to or normal to the rotation axis.

1. From the Create Operations tab, select 4 axis Milling and 4 Axis Finishing.

This brings up the Finishing Operations dialog. We will go over the steps for creating
the pocketing operation.

2. Switch to the Tools tab inside the 4 Axis Finishing operation dialog and select
BallMill-0.0625.

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3. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

4. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

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Specify Cut Parameters

1. Click on the Cut Parameters tab.

2. Set the Tolerance to 0.001, Stock to leave =0, Cut Pattern = Along Axis,
Zig Zag, Low to High, Set Cut Containment Low Value = -0.5, High Value = -
0.1, Step over distance = 5 (% Tool Diameter).

3. Click Generate. The Finishing toolpath is now generated, and the Operation
is listed under the 4th Axis Roughing Operation in the VisualMILL-MOps
browser.

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4. Switch to Simulate tab, select 4 Axis Finishing, and click Simulate to run the
simulation.

4th Axis Finishing Operation #2

We will now create a second 4 Axis finish operation to machine the prongs and
pocket areas around the ring by limiting the toolpath using start, end angle cut
containments.

Copying a MOp

1. Switch to the Create Operations tab in the Mops Browser.

2. Select the 4 Axis Parallel Finishing, right click copy.

3. Now right click on 4 Axis Parallel Finishing and select paste.

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4. A copy of the finish operation is created below the 4th Axis Finishing
operation. The operation name is labeled 4th Axis Parallel Finishing-1 and is
as shown below.

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Specify Cut Parameters

5. Double click on 4th Axis Parallel Finishing-1 to edit the operation.

6. Switch to the tools tab and select BallMill-0.03125.

7. Switch to the Cut parameters tab and use the following parameters.

8. Click Generate. The 4th Axis Parallel Finishing-1 toolpath is now generated,
and the Operation is listed under the MOps browser.

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9. Switch to Simulate tab, select 4th Axis Parallel Finishing-1, and click Simulate
to run the simulation.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as Ring.nc and click save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 11!

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Tutorial 12: Engraving on a Cylinder

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Introduction

This tutorial will illustrate engraving text on a cylinder using a 4 Axis Engraving
operation.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to engrave text on a cylinder

• We will machine the ring completely using 4 axis-machining operations.

• The part itself will be machined out of a cylindrical blank.
• The stock will be held to the machine table using a rotary chuck.
• The part will be machined using 15deg V-Bit.

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Stock geometry

• Set the Machine zero point with respect to the machine coordinates.
• Set the rotary axis and rotary center.
• 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 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the standard
toolbar.

2. From the Open dialog box, select the 4Axis_Engrave.sldprt file from the
Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

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Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from the
tabs located at the top of the window. You can also resize it by dragging one
of its sides.

Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

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Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 4 Axis and Rotary Axis to X Axis. For most
controllers rotation along X represents A axis and rotation along Y represents
B axis. We will set the Rotary Center once we determine the Machine Zero.

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4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select Haas
as the post processor for this exercise. Set the posted file extension type to
.nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Cylinder Stock.

2. This brings up the Cylinder Stock parameters. Set the Axis (rotary) = X,
Radius = 1” and Length (L) = 8”. Leave the other parameters as default and
click OK.

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The stock geometry is now created, and a semi-transparent stock is displayed on top
of the part geometry.

3. You must switch the simulation model to Polygonal model to run 4 axis
simulations. Select Preferences->Simulation Preferences from the Setup Tab
and switch the simulation model to Polygonal if set to Voxel.

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The setup tab now displays the following information: Machine Type, Post Processor,
and Stock type as show below.

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Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Center and XY alignment to Center. (This would align the
stock to the top of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

The MCS is represented as a triad with 3 arrows, the Green arrow indicating X axis,
Blue the Y axis and Red the Z axis. It is always a good practice to set the machine
zero before generating a toolpath.

1. Select Set MCS from the Setup tab

2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face to
Mid Z, and Zero Position to West corner. This sets the machine home to the
center of the stock material and the left most edge of the part geometry.

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Click Save As to save the work and specify a file name as 4Axis_Engrave-Rev1.

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Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Specify Rotary Center

In this step we will determine the rotary center for the part geometry. The rotary
center must pass thro’ the entire part geometry. VisualMILL will not compute a
toolpath if the part/feature is below the rotary center as this is considered as an
undercuts in the part.

1. Select Machine Setup from the setup tab.

2. Set the rotary center in X, Y and Z = 0 which is the center of the stock
geometry.

In this tutorial both the Machine Zero and the Rotary center are at the same
location.

The rotary center is represented by an arrow and displayed on the part geometry
when the Machine Setup Dialog is invoked.

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Create Tools

To machine the above part, we will now create a 15 deg V-Bit.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to VeeMill.

2. Set the tool name as VeeMill1, Taper Angle = 7.5, Flute Length = 0.5, Tool
Length = 1. Under the Properties tab set Tool Number = 1.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

5. Click Save as New Tool. The tool is now created and listed under Tools in
Library.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

The created tool is now listed under the VisualMILL-Tools browser.

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Create Machining Operations

We will engrave the text on the cylinder using 4 Axis Engraving.

This method machines text or logos by following the contours of the selected regions
by projecting the text onto the cylinder.

1. Switch to the Create Operations tab in VisualMILL-Mops browser.

4 Axis Engraving

2. Select 4 Axis Milling and choose Engraving.

If the rotary center is not set to the same location as the Machine Zero, a warning
message dialog would be displayed at all times when a 4 axis machining operation is
selected. Users can override this message by clicking OK in the dialog.

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Note: You can check Do no show this dialog again to stop the warning message
appearing again when you create/edit a 4 axis machining operation.

3. This brings up the 4 Axis Engraving Operation Dialog. We will now go over the
steps for creating the toolpath.

Select Machining Features/Regions

4. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The 4th Axis Engraving operation dialog is now minimized and
allows selection of the sketch geometry

5. Switch to Feature Manager Design tree and select Sketch2.

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6. Click the cancel button to terminate the selection.

The 4 Axis Engraving operation dialog comes back up displaying the selected regions
(sketch entities). The selected regions are also highlighted on the part.

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7. Switch to the Tools tab inside the 4th Axis Engraving operation and select
VeeMill1.

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8. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

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9. Switch to the Clearance Tab and set the Clearance Plane Definition to
Automatic and Cut Transfer Method to Clearance Plane.

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Specify Cut Parameters

10. Click on the Cut Parameters tab.

11. Set the Tolerance = 0.001, Check Project Curve(s) to Model, Check
Finishing Passes and set # of finishing passes = 2, and R Depth (Rf) = 0.05
(this is the depth/pass. Total depth = 0.1”).

12. Click Generate. The 4th Axis Engraving toolpath is now generated, and the
Operation is listed under the VisualMILL-MOps browser.

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13. Switch to Simulate tab, select 4 Axis Engraving, and click Simulate to run the
simulation.

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Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as 4AxisEngrave.nc and click save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 12!

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Tutorial 13: Pocketing and Drilling on a Ring

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Introduction

This tutorial is intended to describe the 4 axis pocketing and hole making operations.
Pocketing machines closed regions as if they were pockets - completely enclosed by
inner and outer regions. The tool cannot go beyond the outer region, and cannot go
within inner regions. This is unlike Facing, in which the outermost region is
considered to enclose material to be removed. Hole making operations are used to
create holes in a part; the hole types varying from simple drill holes, counter sunk
holes, through holes to tapped and bored holes. Here you will learn to drill simple
holes.

The stepped instructions are accompanied by explanatory and introductory text.

Reading this text will help you understand the tutorial methodology and provide
information about additional options available.

Don’t forget to save your work periodically! You may want to save the file under a
different name so that the original file will be preserved.

Strategy to machine the part

• We will machine the ring completely using 4 axis-machining operations.

• The part itself will be machined out of a cylindrical blank.
• The stock will be held to the machine table using a rotary chuck.
• The part will be machined using a 0.0625” Flat End Mill and 0.125”
Standard Drill

Main Programming Steps

In creating programs for each setup, the following steps will be followed:

• Create the Stock geometry

• Set the Machine zero point with respect to the machine coordinates.
• Set the rotary axis and rotary center.
• 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 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.

Loading the Part Model

“Part” refers to the geometry that represents the final manufactured product. Typical
you would create this in SolidWorks.

To load a part:
1. Select File / Open from the Menu, or click the Open icon from the
standard toolbar.

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2. From the Open dialog box, select the 4AxisPocketing_1.sldprt file from
the Tutorials folder in the VisualMILL 6.0 installation folder. (C:\Program
Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Tutorials)

The imported part appears as shown below

Loading the VisualMILL Browser

1. Select VisualMILL 6.0 from the menu bar and click Show MOPs Browser

2. The VisualMILL browser is now loaded and appears next to the Feature
Manager Tree area.

3. Click on the VisualMILL tab in the Feature Manger Tree area to switch to the
VisualMILL MOPs and Tools Browser.

4. You can toggle between the MOPs browser and the Feature Manager from
the tabs located at the top of the window. You can also resize it by dragging
one of its sides.

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Preparing the part for Machining

The Setup tab allows the user to specify Machine Setup, Select Post Processor, Stock
Geometry, Machine Coordinate System (Machine Zero) & Preferences.

Setup Tab

1. Go to the VisualMILL- MOps browser and click on the Setup tab

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 4 Axis and Rotary Axis to X Axis. For most
controllers rotation along X represents A axis and rotation along Y
represents B axis. We will set the Rotary Center once we determine the
Machine Zero.

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4. Select Post from the setup tab to specify the post processor options

5. Set the current post processor that is on your controller. We will select
Haas as the post processor for this exercise. Set the posted file extension
type to .nc

Note: By default post processor files are located under

C:\Program Files\MecSoft Corporation\VisualMILL 6.0 for SolidWorks\Posts
The program to send the posted output is set to notepad. This would output the G
code to a notepad.

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Create Stock Geometry

1. Select Create/Load stock from the setup tab and create a Cylinder Stock.

2. This brings up the Cylinder Stock parameters. Set the Axis (rotary) = X,
Radius = 2” and Length (L) = 1”. Leave the other parameters as default
and click OK.

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The stock geometry is now created, and a semi-transparent stock is displayed on top
of the part geometry.

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3. You must switch the simulation model to Polygonal model to run 4 axis
simulations. Select Preferences->Simulation Preferences from the Setup
Tab and switch the simulation model to Polygonal if set to Voxel.

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The setup tab now displays the following information: Machine Type, Post Processor,
and Stock type as show below.

Align Part and Stock

Once the stock model is created, user can move the stock geometry relative to the
part geometry and use the stock box to specify the machine zero (home position).

1. Select Align Part and Stock from the Setup tab

2. Set Z alignment to Center and XY alignment to Center. (This would align

the stock to the top of the part in Z and center in XY)

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Set Machine Coordinate System (MCS)

The steps below help you determine the machine home (also know as machine zero
or tool touch off point) for the part/stock geometry.

The MCS is represented as a triad with 3 arrows, the Green arrow indicating X axis,
Blue the Y axis and Red the Z axis. It is always a good practice to set the machine
zero before generating a toolpath.

1. Select Set MCS from the Setup tab

2. Switch to SetMCS Origin tab and choose Set to Stock Box, the Zero Face
to Mid Z, and Zero Position to West corner. This sets the machine home to

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the center of the stock material and the left most edge of the part
geometry.

Click Save As to save the work and specify a file name as 4AxisPocketing_1-
Rev1.

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Note: You can change the stock model transparency under standard mode by
selecting Simulation Preferences that is located at the bottom of the MOps browser.

Specify Rotary Center

In this step we will determine the rotary center for the part geometry. The rotary
center must pass thro’ the entire part geometry. VisualMILL will not compute a
toolpath if the part/feature is below the rotary center as this is considered as an
undercuts in the part.

1. Select Machine Setup from the setup tab.

2. Set the rotary center in X, Y and Z = 0 which is the center of the stock
geometry.

In this tutorial both the Machine Zero and the Rotary center are at the same
location.

The rotary center is represented by an arrow and displayed on the part geometry
when the Machine Setup Dialog is invoked.

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Create Tools

To machine the above part, we will now create a 0.125” Drill (Standard Drill) and a
0.0625” Flat End Mill.

1. Go to the VisualMILL-Tools browser that is located below the VisualMILL-MOps

browser and select Create/Edit Tools. Select the Tool Type to Drill.

2. Set the tool name as Drill-0.125, Tool Diameter = 0.125, Tip Angle = 120.
Under the Properties tab set Tool Number = 1.

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Setting Feeds and Speeds

You can assign Feeds & Speeds to a tool or you can load from a table. In this
exercise, we will assign feeds and speeds to the tool.

3. Switch to the Feeds & Speeds tab inside the create/select tool dialog.

4. Use the following settings for feeds and speeds.

Click Save as New Tool. The tool is now created and listed under Tools in Library.

Note: You can edit the tool properties and click Save Edits to Tool to save the
changes. You can create additional tools by assigning a different name and specify
the tool parameters.

5. Create a 2nd tool, a Flat End Mill with the following parameters.
a. Tool Name: FlatMill-0.0625, Tool Diameter = 0.0625, Flute Length =
1,Tool Length = 1.5, Tool Number = 2.

b. Switch to Feeds & Speeds tab set Spindle Speed = 5000 rpm, plunge,
approach & engage feed = 20 ipm, cut feed = 30 ipm, retract and
departure feeds = 20 ipm. Set the Transfer Feedrate to Use Rapid.

c. Click Save as New Tool.

The created tools are now listed under the VisualMILL-Tools browser.

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Create Machining Operations

First we will drill the holes on the cylinder using 4 Axis Drilling.

As in any other 4 axis operations, the tool is positioned normal (perpendicular) to

the rotary axis. Once the holes (regions) are selected, the dialog boxes are similar to
the 3 axis hole making operations. Sorting of holes is also possible to optimize the
tool motion.

Switch to the Create Operations tab in VisualMILL-Mops browser.

4 Axis Drilling

1. Select Holes and choose 4 Axis Drilling.

If the rotary center is not set to the same location as the Machine Zero, a warning
message dialog would be displayed at all times when a 4 axis machining operation is
selected. Users can override this message by clicking OK in the dialog.

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Note: You can check Do no show this dialog again to stop the warning message
appearing again when you create/edit a 4 axis machining operation.

This brings up the 4 Axis Drilling Operation Dialog. We will now go over the steps for
creating the toolpath.

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Select Hole Features

2. Go to the Hole Features tab and click Select Drill Points/Circles. The
drilling operation dialog is now minimized and allows selection of the sketch
geometry.

3. Switch to Feature Manager Design tree and select 3Dsketch1.

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4. Click the cancel button to terminate the selection.

The Drilling operation dialog comes back up displaying the selected regions (sketch
entities). The selected regions are also highlighted on the part.

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5. Switch to the Tools tab inside the 4 Axis Drilling operation and select Drill-
0.125.

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6. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

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7. Switch to Clearance tab and set the Clearance Plane Definition to Stock Max R
+ Dist = 0.25. Set the cut transfer method to Clearance Plane.

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Specify Cut Parameters

8. Click on the Cut Parameters tab.

9. Set the Drill Type = Standard Drill, Drill Depth = 0.1, Check Add Tool tip to
Drill Depth and Approach Distance = 0.1

10. Switch to Sorting tab in the 4 Axis Drilling dialog.

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Sorting

11. Use Minimum Distance Sort and specify the Start Point as Lower Left

12. Click Generate. The 4 Axis Drilling toolpath is now generated, and the
Operation is listed under the VisualMILL-MOps browser.

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13. Switch to Simulate tab, select 4 Axis Drilling, and click Simulate to run the
simulation.

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4 axis Pocketing

1. Select 4 Axis from the Create operations tab and choose 4 Axis Pocketing

If the rotary center is not set to the same location as the Machine Zero, a warning
message dialog would be displayed at all times when a 4 axis machining operation is
selected. Users can override this message by clicking OK in the dialog.

Note: You can check Do no show this dialog again to stop the warning message
appearing again when you create/edit a 4 axis machining operation.

This brings up the 4 Axis Pocketing Operation Dialog. We will now go over the steps
for creating the toolpath.

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Select Machining Features/Regions

2. Go to the Machining Features/ Regions tab and click Select Curves as

Regions. The 4th Axis Engraving operation dialog is now minimized and
allows selection of the sketch geometry.

3. Switch to Feature Manager Design tree and select 3DSketch2.

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4. Click the cancel button to terminate the selection.

The 4 Axis Pocketing operation dialog comes back up displaying the selected regions
(sketch entities). The selected regions are also highlighted on the part.

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5. Switch to the Tools tab inside the 4 axis pocketing operation and select
FlatMill-0.0625.

6. Click on the Feeds and Speeds tab and select Load From Tool. VisualMILL will
now get the feeds and speeds information that was set when the tool was
defined.

7. Switch to the Clearance Tab and set the Clearance Plane Definition to Stock
Max Z + Dist = 0.25 and Cut Transfer Method to Clearance Plane.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Specify Cut Parameters

8. Click on the Cut Parameters tab.

9. Set Tolerance = 0.001, Stock = 0, Cut Pattern = Offset Cuts, Cut Direction
= Mixed, Start Point = Inside, Step Distance = 25% (Tool Diameter),
Check Corner Cleanup.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

10. Switch to Cut Levels Tab.

11. Use the following Settings

a. Location of Cut Geometry – At Top.
b. Total Cut Depth = 0.1, Rough Depth = 0.1
c. Rough Depth/Cut = 0.025.
d. Cut Level Ordering = Depth First.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Sorting

12. Switch to Sorting tab and use Minimum Distance Sort and select Lower Left as
Start Point

13. Click Generate. The 4 Axis Pocketing toolpath is now generated, and the
Operation is listed under the VisualMILL-MOps browser.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

14. Switch to Simulate tab, select 4 Axis Engraving, and click Simulate to run
the simulation.

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VisualMILL 6.0 for SolidWorks Getting Started Guide

Post Processing

1. Select Machining Operations from the Create Operations tab and right click
and select post process.

2. Specify the File Name as 4AxisPocketing.nc and click save.

The post by default is set to Haas as specified under the Post processor setup. You
can change the post processor by selecting a different one from the drop down menu
in the list. The posted g code by default will be saved to the folder where the part file
is located.

End of Tutorial 13!

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