SOLIDS MACHINING

TUTORIAL

TekSoft, Inc.
An Company
www.teksoft.com
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PC25c February, 2003
Table of Contents
CHAPTER 1 LEARNING 2 AXIS MILL BASICS 1-1
2 Axis Mill 1..........................................................................................................1-2
What You'll Learn............................................................................................1-2
Steps to Generate Mill Toolpaths and NC Code ........................................1-2
Step 1: Create Solid Model Part and Import into ProCAM.......................1-3
Step 2: Change to Solids Machining Feature tree .....................................1-3
Step 3: Define the Machine .......................................................................1-5
Step 4: Define the Workpiece....................................................................1-8
Step 5: Define Machinable Features..........................................................1-9
Step 6: Generate Operation Plan .............................................................1-13
Step 7: Adjust Machining Parameters .....................................................1-14
Step 8: Generate Toolpaths .....................................................................1-15
Step 9: Post Process Toolpaths................................................................1-17
2 Axis Mill 2........................................................................................................1-19
What You'll Learn..........................................................................................1-19
Extracting and Working With Machinable Features ................................1-19
2 Axis Mill 3........................................................................................................1-27
What You'll Learn..........................................................................................1-27
Defining the Workpiece From a Bounding Box.......................................1-27
Extracting Machinable Features ...............................................................1-28
Inserting Additional Part Setups...............................................................1-29
Reorganizing Machinable Features ..........................................................1-30
Suppressing Machinable Features ............................................................1-30
Inserting 2.5 Axis Features.......................................................................1-31
Combining Machinable Features..............................................................1-33
2 Axis Mill 4........................................................................................................1-36
What You'll Learn..........................................................................................1-36
Inserting Cross Section Entities................................................................1-36
Defining the Workpiece from a Cross Section Entity ..............................1-38
Extracting Machinable Features ...............................................................1-39
Defining Additional Features ...................................................................1-40
Generating Operations..............................................................................1-42
Adjusting Machining Parameters .............................................................1-42
Deleting an Operation...............................................................................1-43
Inserting an Operation ..............................................................................1-43
Defining Program Zero.............................................................................1-45
Sorting Operations....................................................................................1-46

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CHAPTER 2 LEARNING MORE 2 AXIS MILL 2-1

2 Axis Mill 5..........................................................................................................2-2
What You'll Learn............................................................................................2-2
Setting Attributes and Generating Operations............................................2-3
Sorting and Sequencing Operations ...........................................................2-3
Machining Island Tops ...............................................................................2-4
Changing the Part Setup Origin..................................................................2-5
Combining Operations................................................................................2-6
2 Axis Mill 6..........................................................................................................2-8
What You'll Learn............................................................................................2-8
Inserting 2.5 Axis Features.........................................................................2-9
Inserting Operations .................................................................................2-11
Defining Avoid Areas for Clamps............................................................2-12
Changing Machining Parameters and Generating Toolpaths...................2-12
Inserting a Part Setup and Adding a Facing Cut ......................................2-14
Customizing Toolpaths.............................................................................2-15
2 Axis Mill 7........................................................................................................2-17
What You'll Learn..........................................................................................2-17
Extracting Machinable Features and Generating Operations...................2-17
Creating an Entry Drill Operation and Generating Toolpaths..................2-17
Specifying a Tool Overlap on Open Air Segments ..................................2-18
Using an Avoid Area ................................................................................2-19
Defining Rapid and Clearance Planes ......................................................2-20
For More Practice ................................................................................................2-22
Part1 ...............................................................................................................2-22
Part2 ...............................................................................................................2-23
CHAPTER 3 LEARNING 3 AXIS MILL 3-1
3 Axis Mill 1..........................................................................................................3-2
What You'll Learn............................................................................................3-2
Defining the Machine, Workpiece and Machining Direction ....................3-2
Creating a 3 Axis Feature ...........................................................................3-3
Generating an Operation Plan ....................................................................3-4
Generating Toolpaths and Post Processing ................................................3-6
3 Axis Mill 2..........................................................................................................3-7
What You'll Learn............................................................................................3-7
Inserting a Part Setup and Creating a 3 Axis Feature.................................3-7
Generating Z-level Rough and Finish toolpaths.........................................3-8
Changing Machining Depths for 3 Axis Rough Toolpaths ........................3-9
Generating Core Toolpaths for Finish and Rough Operations.................3-10

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3 Axis Mill 3........................................................................................................3-12

What You'll Learn..........................................................................................3-12
Using AFR to Identify 2 Axis Features....................................................3-12
Creating 3 Axis Features ..........................................................................3-13
Changing 3 Axis Roughing and Finishing Strategies...............................3-16
3 Axis Mill 4........................................................................................................3-19
What You'll Learn..........................................................................................3-19
Defining the Machine and Machining Direction......................................3-19
Creating a 3 Axis Feature .........................................................................3-20
Defining Program Zero.............................................................................3-20
Adjusting Machining Parameters and Generating Toolpaths...................3-21
Simulating Toolpaths................................................................................3-22
Generating Finish Toolpaths Using the Lace Strategy.............................3-22
Inserting a Pencil Mill Operation .............................................................3-24
3 Axis Mill 5........................................................................................................3-26
What You'll Learn..........................................................................................3-26
Generating Finish Toolpaths Using the Flowline Pattern ........................3-27
Defining Contain and Avoid Areas to Modify Toolpaths ........................3-28
3 Axis Mill 6........................................................................................................3-30
What You'll Learn..........................................................................................3-30
Generating Finish Toolpaths Using the UV Pattern.................................3-31
Generating Finish Toolpaths Using the Radial Pattern ............................3-32
Generating Finish Toolpaths Using the Spiral Pattern .............................3-33
Generating Finish Toolpaths Using the Offset Pattern.............................3-33
CHAPTER 4 LEARNING 2 AXIS TURN 4-1
Turn 1 ....................................................................................................................4-2
What You'll Learn............................................................................................4-2
Steps to Generate Turn Toolpaths and NC Code .......................................4-2
Step 1: Open the Solid Model Part ............................................................4-3
Step 2: Change to Solids Machining Feature Tree....................................4-3
Step 3: Define the Machine .......................................................................4-5
Step 4: Edit the Workpiece Definition ......................................................4-8
Step 5: Define Machinable Features..........................................................4-9
Step 6: Generate Operation Plan and Adjust Machining Parameters......4-13
Step 7: Generate Toolpaths .....................................................................4-15
Step 8: Post Process Toolpaths................................................................4-17
Turn 2 ..................................................................................................................4-19
What You'll Learn..........................................................................................4-19
Extracting and Working With Machinable Features ................................4-19

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Turn 3 ..................................................................................................................4-25
What You'll Learn..........................................................................................4-25
Inserting an OD Profile for Threading .....................................................4-26
Reorganizing Machinable Features ..........................................................4-27
Suppressing Machinable Features ............................................................4-27
Generating an Operation Plan and Toolpaths...........................................4-27
Post Processing Toolpaths........................................................................4-29
Turn 4 ..................................................................................................................4-30
What You'll Learn..........................................................................................4-30
Defining the Workpiece as a Forging or Casting .....................................4-30
Defining Additional Turn Features ..........................................................4-33
Deleting an Operation...............................................................................4-34
Adjusting Machining Parameters .............................................................4-34
Defining Program Zero.............................................................................4-35
Turn 5 ..................................................................................................................4-37
What You'll Learn..........................................................................................4-37
Adding an ID Groove Feature ..................................................................4-38
Adding OD Thread and ID Thread Features ............................................4-39
Generating Operations and Modifying Machining Parameters................4-41
Defining the Machining Sequence and Generating Toolpaths.................4-43
Displaying Locating Symbols and Defining the Chuck ...........................4-43
Turn 6 ..................................................................................................................4-46
What You'll Learn..........................................................................................4-46
Defining the Workpiece from a Sketch for Double Chucking .................4-46
Establishing Part Zero ..............................................................................4-47
Defining Machinable Features .................................................................4-47
Changing the Origin Machining Direction and Generating Toolpaths ....4-48
Defining the Chuck Location and Simulating Toolpaths .........................4-50
Turn 7 ..................................................................................................................4-52
What You'll Learn..........................................................................................4-52
Using the Generation 1 Method to Extract Machinable Features ............4-53
CHAPTER 5 LEARNING 4 AXIS TURN 5-1
4 Axis Turn 1.........................................................................................................5-2
What You'll Learn............................................................................................5-2
Defining Machinable Features Automatically and Interactively................5-3
Editing Machinable Features......................................................................5-3
Generating Operations and Adjusting Parameters for Front Turret ...........5-4
Defining the Chuck Location for Setup1....................................................5-5
Defining the Chuck Location for Setup2....................................................5-6
Simulating the Toolpaths for Turn Setup1 and Setup2 ..............................5-6

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CHAPTER 6 LEARNING THE TECHDB 6-1

TechDB 1...............................................................................................................6-2
What You'll Learn............................................................................................6-2
Adding and Editing Mill Machines ............................................................6-2
TechDB 2...............................................................................................................6-5
What You'll Learn............................................................................................6-5
Adding Tools to the Tools Library.............................................................6-5
TechDB 3...............................................................................................................6-8
What You'll Learn............................................................................................6-8
Using Tool Cribs ........................................................................................6-8
Tech DB 4............................................................................................................6-11
What You'll Learn..........................................................................................6-11
Feature and Operation Basics...................................................................6-11
TechDB 5.............................................................................................................6-15
What You'll Learn..........................................................................................6-15
Creating an Attribute and Associating a Machining Sequence ................6-15
Applying the Attribute in Solids Machining ............................................6-21
TechDB 6.............................................................................................................6-23
What You'll Learn..........................................................................................6-23
Understanding Threading Parameters ......................................................6-23
TechDB 7.............................................................................................................6-26
What You'll Learn..........................................................................................6-26
Defining an Attribute in the Technology Database..................................6-26
Inserting a 2 Axis Feature and Applying the T-slot Attribute..................6-30
Generating Operations and Toolpaths ......................................................6-32
INDEX

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Chapter 1 Learning 2 Axis Mill Basics

This chapter provides an opportunity to learn 2 Axis Mill through a step by step hands-on
tour of the features and functions.
The exercises in this chapter are intended to show you how to use ProCAM and may not
correspond to actual machining practices.

IMPORTANT! Solids Machining uses a set of knowledge-based rules to assign machining

operations to features. The Technology Database contains the data for the machining
process plans and can be customized for your facility's machining methodology. When you
do these exercises, your results may not be the same as described in the steps and illustrated
in the figures. This is because the machining sequences and operations data in your
Technology Database may be different from the database used to produce the
documentation.

Learning 2 Axis Mill Basics 1-1

2 Axis Mill 1

2 Axis Mill 1
What You'll Learn
Steps to Generate Mill Toolpaths and NC Code
The following steps are used to generate Mill toolpaths and NC code:
1. Create the solid model in a solid model design program and save the file in
one of these formats: Parasolid ASCII (x_t) or Binary (x_b), ACIS ASCII (sat)
or Binary (sab), AutoCAD DWG (dwg) or DXF (dxf).
2. In ProCAM, set the Units Type in the Units dialog box.
3. Open the solid model file in ProCAM: make sure you select the applicable file
type (x_t, x_b, sat, sab, dwg or dxf) in the Files of type list and check the
Solids option in the Open dialog box.
4. Start Solids Machining and change to the Solids Machining Feature tree.
5. Define the Machine and modify the controller parameters.
6. Define the Workpiece.
7. Define machinable features.
8. Generate the operation plan.
9. Adjust machining parameters.
10. Generate toolpaths.
11. Post process the toolpaths.

START Adjust machining

parameters as Generate toolpaths
needed

Open solid model

file in ProCAM
Post process
Generate
operation plan
Start Solids &
change to Solids Transmit file into
Feature tree Define machinable CNC
features

Define machine
& change controller Define Workpiece END
parameters

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 2 Axis Mill 1

The next series of exercises show you how to generate finish toolpaths on a solid model.
When you define the operations and toolpaths, you will follow steps that are not explained in
depth. This is done to show you the basics of generating toolpaths from start to finish
without getting into the details at this time. Sample parts are provided for the exercises in
this manual. When you install ProCAM, these files are installed automatically in the
\pcii\learn\solid folder. The default path is \program files\procad\pcii\learn\solid.
Step 1: Create Solid Model Part and Import into ProCAM
In order for Solids Machining to generate mill toolpaths and NC code, the part must be a
solid model created in a solid model design system that supports exporting to Parasolid,
ACIS, DXF or DWG format.
EXERCISE 1. Select Setup on the menu bar, then select the Units command or press CTRL + U.
Before opening the solid model file in ProCAM, you must make sure the units are set
correctly in ProCAM. You cannot change the units after a solid model file is opened. The
file used in this exercise was saved in Parasolid format. Since Parasolid uses the metric
system of measurement, when you save a solid model in Parasolid format, the file is
always saved in meters.
2. In the Units dialog box, make sure the Units Type is set to Metric Decimal, then click
OK.
Metric units are used in this exercise. If the Units Type were set to English Decimal, the
part would be converted to inches when it is opened.
3. Click the Open button on the File toolbar.
4. In the Open dialog box, change the Files of type to Parasolid ASCII (*.x_t).
5. Make sure the Solids option is checked.
This option allows you to choose the type of machining you want to use to cut the part:
− If the Solids option is checked, the part is opened as a solid that must be cut using
Solids Machining.
− If the Solids option is not checked, the part is opened as surfaces that must be cut
using Surface Machining.
6. Open the \procad\pcii\learn\solid folder and double-click part file Mill2Ax_1.x_t.
Step 2: Change to Solids Machining Feature tree
EXERCISE 1. Click the Solids Machining button on the CAD/CAM toolbar.
The Solids Machining Feature and Operation Tree tabs display at the bottom of the Part
Manager.
If the Solids tabs are not visible, you can expand the size of the Part Manager. Position
the cursor on the line that divides the Part Manager from the graphics area. When the
cursor changes to a bar, drag the bar to the right until the tabs display.
2. Click the Solids Machining Feature Tree tab. The Feature tree
displays. Initially, the tree lists the Workpiece, Machine and
Recycle Bin items.

Learning 2 Axis Mill Basics 1-3

2 Axis Mill 1

Solids toolbar Solids menu

Feature tree

Graphics area
Feature
Tree tab
Operation Tree tab
Part model

Solids Machining Trees

The Solids Machining trees provide an outline view of the machining information for the
model. Initially, the Feature tree shows only the NC Manager, Workpiece, Machine and
Recycle Bin items. As you follow the steps to generate an NC program, this tree expands to
include Part Setups and machinable features. The tabs at the bottom are for moving between
the Solids trees.
• Workpiece
The workpiece is the stock from which the part will be machined. You can define the
workpiece as a rectangular shape or as a rectangular or circular extruded sketch. You can
also specify the type of material.
• Machine
The Machine item defines the machine tool that the part will be machined on. The
machine definition includes the type of machine (i.e., mill or turn), tool definitions and
the machine controller (post processor). The machines are set up in the Technology
Database.
• Recycle Bin
The Recycle Bin in the Feature tree is used to store machinable features that you do not
intend to machine.

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 2 Axis Mill 1

Solids Menu
The Solids menu lists the Solids commands. In addition to the Solids menu, right-mouse
shortcut menus provide quick access to frequently used commands.
Solids Toolbar
The Solids toolbar provides access to the main Solids commands found on the Solids menu.
Clicking a toolbar button is the same as selecting a command from the NC Manager level,
regardless of the active item in the tree. The Options dialog box contains a tab that allows
you to select the buttons that display on the toolbar.
Step 3: Define the Machine
The machine includes information that identifies what to machine, how to machine it, and
the format of the NC output. Important parameters of the machine definition include:
• Machine type – mill or turn: The machine type defines the machinable feature set that
can be recognized automatically and defined interactively.
The icons that display in the tree identify the current machine as either mill or turn:
Mill Machine Turn Machine
An alternative machine can be selected at any time to output different G-code programs
for alternative machine tools. If the machine type changes, then all features and
operations will be deleted.
• Tool crib: A subset of tools from the tool library that are commonly loaded into or used
with the current machine.
• Controller: Also called a post processor. This post processor identifies the format of the
NC G-code output.
EXERCISE Define the machine:

1. Right click the Machine in the Feature tree.

The shortcut menu displays. Right-mouse shortcut menus
provide quick access to commands that are appropriate for
whatever is highlighted in the tree.
2. Select Parameters on the shortcut menu.

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2 Axis Mill 1

The Machine dialog box displays the

Machine tab. The default selected machine
is specified in the Technology Database
(TechDB). Mill machine mm is the default
machine used for metric parts in this
manual. When you use ProCAM to machine
your own parts, select the machine tool you
want to use to machine the part.
Machine tools are set up in the TechDB.
Before using ProCAM to machine your
parts, make sure you define the machine
tools available in your facility. For more
information, see the Solids online Help.
3. In the Available machines list, highlight
Mill machine –mm and click the Select
button.

Click the Tool crib tab and make sure

Tool Crib 1 (metric) is selected.
The Tool crib page allows you to
choose a Tool Crib or set of tools that
are used with the machine you have
chosen. These are not all the tools that
are available, but a subset that you can
modify to represent the actual set of
tools that the machine has loaded.
Tool Crib 1 (metric) is a default tool
crib that has been set up the sample
Mill machine. When you define your
machine tools in the TechDB, you can
set up your own tool cribs.

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4. Click the Controller tab.

The Controller tab allows you to select the
post processor from a list of available
controllers. The list that displays depends
on the post processors that are installed on
your system. By default, ProCAM is
supplied with several default post
processors that may or may not be suitable
for your needs. Contact your TekSoft
reseller for information on making changes
to these post processors or for other post
processors.
If the controllers do not display, use the
Browse button to locate the folder
containing the controller files (*.ctl).
If FANTUTM (the tutorial post processor)
is not highlighted, highlight it in the list and
click the Select button. In the exercises in
this manual, when you choose a controller
type, select FANTUTM. This is a sample
post processor and is not intended for
production use. When you create your own
parts, pick the post processor that will be
used to cut the part.
The Current information area displays information about the FANTUTM controller. A
short description displays in the window below the Current information. This window
contains information only if an optional file has been created for the post processor.
5. Click the More button.
A longer description displays. The More button is activated only if a second optional file
has been created.
6. Click the Parameters tab.
The parameters on this page are used for the following:
− To provide information required to generate the NC program. The parameters are
machine-dependent and different parameters may display for your controller. The
value for a parameter is output in the NC code if the machine requires it.
− To provide information for the Setup Sheet file that is created when the NC program
file is generated. All of the Controller parameters are included in the Setup Sheet.

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2 Axis Mill 1

7. Type 1001 for the Program Number and press the down
arrow.
8. Type Stainless for the Material and press the down arrow.
9. Type 40 for the Part Thickness and click OK.
Step 4: Define the Workpiece
The workpiece is the stock from which the part will be machined. The default workpiece is
the smallest cube (bounding box) that the part will fit into. Typically, this is not the size of
the stock you will be using. You can change the workpiece definition either by offsetting the
bounding box from the part or by defining the workpiece from a cross section entity and a
height. Currently, the cross section entity can be a rectangle or a circle.

EXERCISE In this exercise, you define the workpiece as a box offset from the part.
1. Right click Workpiece in the Feature tree and select Edit
Definition on the shortcut menu.
A message window indicates that there are no valid
sketches for defining the workpiece.
2. Click OK to continue.
The Define Workpiece dialog box displays.
3. Change the Bounding box
Offset to 1.0000mm and
press Enter.
4. Click the Material button.
The Workpiece Material
dialog box displays.

5. Click the Common Name down

arrow and select 304L.

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 2 Axis Mill 1

6. Click OK to close the Workpiece

Material dialog box.
7. Click OK to exit the Define
Workpiece dialog box.
The workpiece is updated in the
graphics area.

Step 5: Define Machinable Features

Machining can be done only on machinable features. You use the following two methods to
define machinable features:
• Automatic Feature Recognition (AFR)
Automatic Feature Recognition analyzes the part shape and attempts to define most
common machinable features such as pockets, holes, slots and bosses. Depending on the
complexity of the part, AFR can save considerable time in defining two-dimensional
prismatic features.
• Interactively created features
If AFR does not recognize a feature you want to machine, you need to define the feature
using the Insert 2.5 Axis Feature command. If you have 3 Axis Milling, multi-surface
features can be defined using the Insert 3 Axis Feature command.
Automatic Feature Recognition is one of the most powerful features of Solids Machining.
The idea of AFR is to analyze the part for features that can be machined. This process is
much the same as what you would do if you were to pick up a part that you had to machine.
You would look it over, take measurements, and begin deciding how to define areas or
features to machine and what machining processes you would need to create the part.
Using Automatic Feature Recognition (AFR)
EXERCISE Define machinable features automatically:
1. Select one of the following methods to extract features:
Click the Extract Machinable Features button on the
Solids toolbar.
or
Right click NC Manager in the tree and select Extract
Machinable Features on the shortcut menu.

Learning 2 Axis Mill Basics 1-9

2 Axis Mill 1

The Solids Machining Message Window

displays. This window displays automatically
to report the progress and status of the current
process. Generating Part Setups is always the
last item. When you see it, you know the
process is almost complete.
You can control whether this window
displays temporarily or permanently by selecting the Options command on the Solids
menu and checking the Message Window option on the General tab.
ProCAM generates the Part Setup and machinable features. The items display in the
Feature tree.
The Part Setup is the 2 axis plane that the tool movement will be based on. It has an
origin location, and X, Y, and Z direction vectors. The Part Setup is created
automatically; however, you can move the origin, and change the direction and angles of
the X and Y axes.
A Part Setup is created for each different tool orientation. There is only one Part Setup
for this part because all features can be machined using a single tool orientation. For each
Part Setup, the machinable features are listed in the
order in which they were recognized.
The Feature tree allows you to:
− Copy, rename, suppress, delete and combine
machinable features
− Change machinable feature parameters
− Change the order in which the features are
machined
− Insert 2.5 Axis and 3 Axis features
− Search for a feature based on item name
− Hide or show feature display in graphics area
− Generate an Operation Plan and find the first operation for a feature
Most feature parameters are fixed; however, some parameters can be changed using the
Parameters command on the feature shortcut menu.
2. Right click Hole Pattern1 in the tree and select Parameters on the shortcut menu.
The Hole Parameters dialog box displays the number of components and the hole
parameters. Since there is no physical information about the type of hole, ProCAM
allows you to define an attribute for the hole (Drill, Bore, Ream, Thread or a user-defined
attribute).
3. Click the down arrow next to Drill to see the choices.
4. Click Thread in the list.
The figure changes to reflect your choice and the Thread parameters are enabled.

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5. Click the down arrow next to Thread and select Drill again, then
click OK to exit the dialog box.
6. Click the + next to Hole Pattern1 in the Feature tree.
The tree expands to display each individual hole.
7. Click the - next to Hole Pattern1.
Save the part with the machinable feature data:
8. Click the Options button the Solids toolbar.
Note that you can also click Solids on the menu bar or right click NC Manager in the tree
and select the Options command.
9. If the Save/Restore part command on the General tab does not have a check mark next to
it, click in the check box to select it, then click OK.
If this option is checked, when you save and close a part document, the machining data is
saved. When the part document is opened again, the machining data is restored along
with the part design information.
If this option is not checked, when you save and close a part document that contains at
least one Part Setup, a message indicates that Save/Restore is disabled. If you click Yes,
ProCAM saves all machining data before closing the file. If you click No, ProCAM
closes the part and discards any new machining data since the last save.
10. Click Save As on the File menu.
The Save As dialog box displays.
11. Open the \procad\pcii\learn\solid folder.
12. Type Solids1 and click the Save button.
The part model file is saved in ProCAM format (.pcii).
SAVE FREQUENTLY!
− When you open a file, you are actually working on a copy of the file. The original is
still stored on disk. Periodically saving your file ensures that your latest work is
retained. Frequent saves prevent having to redo a time-consuming model or CAM
operation. If a power failure occurs, you will lose your current work.
− ProCAM provides an Auto save option on the General tab in the Options dialog box
for automatically saving your Solids Machining data.
Defining Features Interactively
Automatic Feature Recognition can save a significant amount of time; however, AFR does
have limitations. AFR cannot recognize every feature on complex parts and does not
recognize some typical types of features such as the top or outside profile of a part. To
machine these areas, you need to define machinable features interactively using the Insert 2.5
Axis Feature command.
EXERCISE In this exercise, you insert a Face Feature so that you can face the top of the part. In order to
define a Face Feature, you select a face on the solid part that is at the depth you want to face
the part to. In this example, the entire top of the part is the same height, so you can select any
of the topmost faces.

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2 Axis Mill 1

1. Right click Part Setup1 in the Feature tree and select Insert 2.5 Axis Feature on the
shortcut menu.
The 2.5 Axis Feature Wizard: Feature & Cross Section Definition dialog box displays.
2. Click the down arrow next to the Type
list box and select Face Feature.
3. Click the main face.
The outline of the face is highlighted on
the part and Face <1> displays in the
Entities selected list.
4. Make sure the Edge selection is set to
Open chain.
5. If the Check for tapers & fillets option
is checked, remove the check mark.
If the feature you are defining does
not contain any fillets at the base of
the feature, you can disable this option
to improve the performance of the
wizard.
6. Click the Next button.
The 2.5 Axis Feature Wizard: End
Conditions dialog box displays.
This dialog box also allows you to
determine how ProCAM calculates
the depth of the feature and selects an
attribute that defines a unique
machining sequence.
7. Leave the End condition set to Upto
Workpiece.
8. Leave the Attribute set to Coarse.
9. If the Edit feature profiles option is
checked, remove the checkmark.
When this option is checked and you
click the Next button, a dialog box
displays that allows you to pick the
open air edges. An open air edge
specifies that the tool can machine
past the edge by a user specified
percentage of the tool diameter. For
edges that are not open, the toolpath
will remain contained inside the edge.
For this Face Feature, there are no
open edges.

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10. Click Finish.

11. Click Close to close the 2.5 Axis Feature Wizard:
Feature & Cross Section Definition dialog box.
Face Feature1 displays in the Feature tree.
You have now defined all the machinable features in
this part and you are ready to generate the Operation
Plan.

Step 6: Generate Operation Plan

An Operation Plan contains information on how each machinable feature is to be machined
and how the NC code will be output. When Generate Operation Plan is run, operations for
each machinable feature are created automatically based on information in the TechDB. In
some situations, the operations defined for a feature in the TechDB may not be sufficient and
additional operations may be required. You can insert operations manually using the Insert
Operation or Insert Hole Operation commands.
EXERCISE 1. Select one of the following methods to generate an operation plan:
Right click Part Setup1 in the Feature tree and click Generate Operation Plan on the
shortcut menu.
or
Click the Generate Operation Plan button on the Solids
toolbar. Clicking this toolbar button is the same as
selecting the command from the NC Manager level, regardless of the active item in the
tree.
ProCAM generates the operation plan for all the machinable features in Part Setup1. The
operations are listed in the Operation tree, which is accessed by clicking the Solids
Machining Operation Tree tab.
2. Click the Solids Machining Operation Tree tab at the bottom of
the tree.
The Operation tree displays.

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2 Axis Mill 1

This tree provides an outline view of the operations for the machinable features.
Operations are listed under the Part Setup in the same order as the machinable features.
At the top of the tree is the NC Manager. The Workpiece and Machine items function the
same as in the Feature tree. You can change the workpiece size and shape and the
controller definition used by ProCAM to produce G-Code.
The Operation tree allows you to:
− Insert, rename, suppress and delete operations
− Change operation parameters
− Combine operations
− Sort operations
− Change the machining order
− Generate toolpaths
− Simulate toolpaths
− Post process the toolpaths
− Hide or show toolpath display
− Search based on item name
To the left of each toolpath operation is a plus sign (+).
Clicking a plus sign displays the name of the
Machinable Feature that this operation is going to
machine. These Machinable Feature items can be used to
view geometric information and to modify the machining depth of the feature.
Step 7: Adjust Machining Parameters
The operations that are generated by ProCAM are based on information stored in the
Technology Database (TechDB). These operations are intended to be used as a starting point.
Each operation contains machining parameters that affect how the toolpath is created and
specific parameters that will be output to the NC program. These parameters can be edited
before generating the toolpaths and post processing the part.
EXERCISE Edit operation parameters using the Parameters command on the shortcut menu:
1. Right click on Rough Mill5 (Irregular Pocket2) in the Operation tree.
2. Click the Parameters command on the shortcut menu.
The Machining Parameters dialog box displays. This dialog box gives you access to all
the parameters used to define the toolpath. General parameters for the type of toolpath
include the method of machining, depth of cut, step over, stock allowance, retract height,
speeds and feeds. This dialog box also gives you access to all the parameters for the tool
you are using. You can also change to a different tool.
3. Click the Roughing tab and change the Pocketing Method to Zigzag.
4. Click the Feature Options tab and change the Entry type to Entry Drill.
5. Click OK to exit.

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Step 8: Generate Toolpaths

EXERCISE ProCAM calculates toolpaths using the operation parameters and the feature's size and shape.
1. Select one of the following options to generate toolpaths:
Right click Part Setup1 in the Operation tree and click Generate Toolpath on the shortcut
menu.
or
Click the Generate Toolpath button on the Solids toolbar.
Clicking this toolbar button is the same as selecting the
command from the NC Manager level, regardless of the active item in the tree.
ProCAM calculates the toolpaths for each operation in the Part Setup.
You can also generate toolpaths for each operation individually by right clicking on an
operation (such as Rough Mill1) and clicking Generate Toolpath on the shortcut menu.
2. Highlight the first operation in the tree, hold down the Shift key, then highlight the last
operation.
The toolpaths for all the operations display on the part showing the centerline of the
toolpath.
3. Click an operation in the Operation tree.
− The toolpath for that operation displays.
− As you click each operation, the toolpaths for that
operation are displayed.
4. Click the Entry Drill operation.
− An Entry Drill operation was created automatically
for Rough Mill4 because you set the Entry Method to
Entry Drill.
− The Entry Drill displays as black circles on the
toolpath. The circle represents the diameter of the
drill. By default, the diameter of the drill used in the
Entry Drill is the same as the diameter of the mill
used in the roughing cycle. If a tool of the same size
is not available, a tool diameter of the next smallest
size is used.
− The depth of the drill cycle for blind features is .02"
or .5mm off the bottom of the feature. For through features, the depth of the drill is
the same as the feature.
− Entry Drill operation parameters can be edited and the operation can be renamed,
moved, suppressed, deleted, etc.
ProCAM provides the ability to simulate the toolpath showing the tool movement and the
resulting shape of the part.
5. Right click on Part Setup1 and select Simulate Toolpath.

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2 Axis Mill 1

The Simulate Toolpath toolbar displays. The

toolbar controls allow you to:
− Run the simulation in Tool or Turbo
mode.
− Display the simulated part, the design part
and a comparison of the two.
− In Tool mode, customize the display of the stock, tool and tool holder (wireframe,
translucent, shaded or no display).
− Run the simulation for all or selected operations.
− When simulating an operation, the simulation can be for the current operation or for
all previous operations up to the selected operation.
− Pause the simulation in either Tool or Turbo mode and dynamically change the
orientation of the part using zoom, pan, rotate, etc.
− Control the simulation by dragging the Simulation Speed Control slider up or down.
If you want to simulate only the toolpath for a given operation, right click that operation,
then select Simulate Toolpath.

6. Click the Run button.

The simulation runs in Tool mode with the tool displayed during simulation.
7. Click the X button in the upper right corner to cancel the simulation.
Solids Machining also provides the ability to step through the toolpath using the Step Thru
Toolpath command.
8. Right click an operation in the tree and select Step Thru Toolpath.
The Step Thru Toolpath toolbar displays.
Step increment

Forward one record Forward multiple records

9. Click the Forward one record button (single arrow) several times.
The active toolpath node is highlighted.
10. Set the multiple step increment to 5 and click the Forward Multiple Records button
(double arrow) several times.
11. Click the Goto End button. The toolpath is completed.
12. Click the X button in the upper right corner to remove the dialog box.

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Did You Know ...

ProCAM provides an option to display the XYZ position of the tool in the Message
Window during Simulation and Step Thru Toolpath. To activate this option, select the
Options command on the Solids menu or the NC Manager shortcut menu. On the
General tab, select the Message Window option. On the Simulation tab, select the
Display Coordinates option.

Step 9: Post Process Toolpaths

Post processing is the final step in generating the NC program file. This step translates
generalized toolpath and operation information into NC code for a specific machine tool
controller. ProCAM creates NC code for each toolpath in the order the operation appears in
the Operation tree. When you post process a part, ProCAM creates two files: the NC
program and the Setup Sheet. These are text files that you can read, edit and print using a
word processor or text editor.
EXERCISE In this exercise, you post process all the operations and generate the NC program:
1. Click the Post Process button on the Solids toolbar or right click NC Manager in the
Operation tree and click Post Process on the shortcut menu.
The Post Output File dialog box
displays so you can name and save
the NC program file.
If you are running Solids
Machining in Demo mode, the Post
Output File dialog box does not
display because you cannot save
NC code in Demo mode.
Typically, the NC program and
Setup Sheet files are stored in the
folder that contained the last part
that was opened. If you want these
files in another location, you can
change the folder.
If the Post Process command is grayed out on the Solids menu or on a shortcut menu,
make sure that you have selected a post processor and generated the toolpaths.
2. Click the down arrow to the right of the Save as type box.
ProCAM provides a list of commonly used extensions that you can select. For this
exercise, use FANTUTM (*.txt).
Did You Know ...
If you want to change the default extension from txt to one of the extensions in the list
or if you want a different extension for NC program files, you can edit or create a .pinf
file and specify a new extension. For more information on making these changes, see
the online Help.

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2 Axis Mill 1

3. If Solids1 is not in the File name text box, type Solids1, then click Save.
You do not have to type the extension if you are using the default .txt.
Naming the post output file the same as the part file is the most common way of saving
parts and NC programs. Both files can have the same name because they have different
extensions.
The Post Process Output dialog box
displays.
4. Click the Step button on the control bar
at the top.
ProCAM starts to generate the program Run
and the first line of NC code displays in
the Post Output view box. The output Step
mode is set to post process one line of
code at a time (Step mode).
5. Click the Step button.
The next line of NC code displays.
6. Click the Run button.
Post processing continues until it is
completed.
When the post processing is finished, you
can view the code using the vertical
scroll bar.
7. Click OK to close the Post Process Output dialog box.

More About Setup Sheets

The Setup Sheet is a printable file that contains information the machine tool operator can
use to set up the part and the tools required to produce a part. The information includes
the machine, the controller, estimated machine time, the part material, and the tooling
used to machine the part.
ProCAM provides two methods for creating Setup Sheets:
− During post processing, ProCAM automatically creates a simple text file with a .set
extension.
− The Setup Sheet command on the NC Manager shortcut menu allows you to generate
a Setup Sheet that is based on an Access database report template and store the
information in the Report Database to view at any time. ProCAM supplies several
report templates that can be used as is. You can also open the Report Database in
Access and create customized reports based on these templates or design your own
original reports.

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2 Axis Mill 2
What You'll Learn
Extracting and Working With Machinable Features
Solids Machining is a feature-based machining system. Feature-based machining provides
numerous benefits because the definition of the feature enables a higher level of automation
when creating machining operations and associated toolpaths. Adding to this benefit,
ProCAM provides both an automatic method of extracting features called Automatic Feature
Recognition (AFR), and an interactive method using the Insert 2.5 Axis Feature function. A
ProCAM Solids file can contain both types of features.
This exercise demonstrates some of the features that are identified automatically by the
Extract Machinable Features command.
EXERCISE 1. Open the part file Mill2ax_2.pcii in
the \procad\pcii\learn\solid folder.
In the Open dialog box, make sure
the Files of type option is set to
ProCAM Files (*.pcii).
This part was originally a Parasolid
(x_t) file that was opened in
ProCAM and saved in ProCAM
(pcii) format.
2. Click the Solids Machining
button on the CAD/CAM toolbar.
3. Click the Solids Machining Feature
Tree tab at the bottom of the Part Manager.
4. Right click the Machine in the Feature tree
and select the Parameters command on the shortcut menu.
The Machine dialog box displays the Machine tab. This dialog box allows you to select a
machine definition, tool crib and control.
On the Machine tab, Mill machine – Inch is the Active machine. This machine definition
has been created for the Solids Machining exercises. When you use ProCAM to machine
your own parts, select the machine tool you want to use to machine the part.
5. Click the Tool crib tab.

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2 Axis Mill 2

The Tool Crib page allows you to

choose a tool crib or set of tools that are
used with the machine you have
chosen. These are not all the tools that
are available, but a subset that you can
modify to represent the actual set of
tools that the machine has loaded.
If you select the Tool crib priority
option, tool selection rules are modified
to place a higher priority on selecting
tools from the tool crib. This results in
fewer tools being added to the tool list
from the tool library. The online help
explains the rules that are observed
when this option is used.
6. Click the Select button to make sure
Crib 1 is the Active tool set.
From this page you can add, remove
and edit tools in the Tool Crib.
7. Select a tool from the Active tool crib
list and click the Edit button.
The Edit Tool Parameters dialog
box displays.
This dialog box allows you to
change the parameters for the
selected tool. The changes you
make in this dialog box affect
only the tool crib for the current
part. To change the tool
definition for all future jobs, edit
the tool crib definition in the
Technology Database.
8. Click OK or Cancel to close the
Edit Tool Parameters dialog
box.

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9. Click the Add button at the bottom of the

Tool crib tab in the Machine dialog box.
The Tool Select Filter dialog box
displays. This dialog box allows you to
set filters for displaying and selecting
tools.

10. Click OK.

The Tools Database form
displays. This form allows
you to add an existing tool
in the TechDB to the Tool
Crib for the current part.
The list contains all the
tools that have been
entered into the
Technology Database.
Note that you cannot use
the form to add new tools
to the TechDB.
11. Click OK to exit the Tools
Database without adding a
tool to the active tool set.
12. In the Machine dialog box,
click the Controller tab and make sure FANTUTM (the tutorial post processor) is
selected.
FANTUTM is the controller used for the exercises in this manual. When you use
ProCAM to machine your own parts, select your machine controller or post processor.
13. Click the Parameters tab.
These parameters provide information required to generate the NC program. When you
use ProCAM to machine your own parts, change these parameters as required.
14. Click OK.
15. Right click the Workpiece in the Feature tree and select Edit Definition on the
shortcut menu.
16. Click OK to close the message window.
17. Change the bounding box offset to .10" and press Enter.
18. Click OK.

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Extract machinable features:

1. Click the Extract Machinable Features button on the Solids toolbar or right click NC
Manager in the tree and select Extract Machinable Features on the shortcut menu.
The Solids Machining Message Window displays.
This window reports the process status and shows
the progress of the process.
When AFR is finished, the Feature tree displays the
machinable features.
From the Feature tree, you can reorder features
using drag and drop, change feature names and
suppress features.

2. Click each machinable feature in the Feature tree.

As you pick each machinable feature, the geometry
for that feature highlights on the part

Rectangular Pocket

Rectangular Boss Rectangular Slot

Obround Boss
Irregular Slot 2.5 Axis Pocket
Multi-stepped Hole Counterbore
Hole
Rectangular
Corner Slot Countersunk
Hole
Hole

Circular Boss Irregular Corner Slot

Obround Pocket
Irregular Pocket
Irregular Boss

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3. Notice that an Open Pocket feature was

created.
When ProCAM creates a Part Setup, an
Open Pocket feature is created
automatically if AFR finds a boss
feature and the Setup is parallel to one
of the sides of the workpiece. The
bottom of the Open Pocket is the
bottom of the Boss feature and the boss
becomes an island in the Open Pocket.

ProCAM allows you to control the types of 2.5 and 3 axis features that are created by AFR.
1. Click the Options button on the Solids toolbar or select Options on the Solids menu.
2. Click the Features tab in the Options dialog box.
3. Notice that the defaults are set for ProCAM to create hole, non-hole and boss features.
4. In the Feature types section, check the Face option.
If the Face option is checked, when ProCAM creates a Part Setup, a face feature is
created automatically if the top most face is parallel to the Setup and the Setup is parallel
to one of the sides of the workpiece.
5. Check the Tapered & filleted option.
When ProCAM extracted features, the 2.5 Axis pocket was not found. If you check this
option, ProCAM can automatically create features that meet the definition of filleted and
tapered features as created interactively using the Insert 2.5 Axis Feature command:
− The top and bottom of the feature are flat and parallel to the Part Setup direction.
− The side wall can be vertical or a constant taper with a top or bottom fillet and/or a
top of bottom chamfer.
− Corner fillets must be conical as defined by the taper angle of the feature.
6. Remove the check mark from the Boss option and check the Remove on Rebuild option,
then click OK.
If you were machining this part, you would not want to generate operations for the Boss
features that were found by AFR. You can delete the features or you can Rebuild the
features without the bosses as shown in this exercise.

Rebuild the features:

7. Click the Extract Machinable Features button on the Solids toolbar.
ProCAM rebuilds the feature list and removes the boss features.

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2 Axis Mill 2

Notice that AFR created a Face feature and a Rectangular Pocket feature for the tapered
pocket.

Machinable features are recognized based on the part's geometry (the shape of a feature) and
topology (how the features are related to one another). However, not all attributes of a
feature can be determined from the geometry and topology. For example, AFR cannot
determine that a hole has been threaded, reamed or bored. ProCAM allows you to specify
additional attributes to a feature so that appropriate operations can be can be created.
EXERCISE 1. Right click Hole1 in the
Feature tree and select
Parameters.
The Parameters dialog box
displays. This dialog box
provides a geometric and
dimensional report on the
feature and allows you to
assign additional information
to the feature. In the case of
holes, you can identify that
the hole is to be drilled,
bored, reamed or threaded.
Depending on the attribute, a
different machining process
can be assigned. You can
change how each feature is
processed by defining the
sequence in the Technology
Database.
2. Click OK or Cancel.
3. Review the parameters of
other machinable features to
understand more about the features.

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EXERCISE Notice that feature recognition also created Part Setup1. The Part Setup defines the tool
direction necessary to machine these features.
1. Click Part Setup1 in the tree.
A triad displays on the part. One arrow indicates the
machining direction. The other two arrows represent the
machining X and Y axes. The X machining direction can be
changed if necessary. For more information, see the Solids
online Help.
The origin of the Part Setup is program zero for the Part Setup. By default, the origin is
set to a vertex or middle of the top most feature. In most situations, you will want to
change this. You learn how to change the Part Setup origin in Chapter 3.
If the triad does not display, click Redraw and select the Part Setup again.
When you select Generate Operation Plan, operations are created for every selected feature
based on the rules defined in the Technology Database (TechDB). Operations are not
generated for suppressed features and features in the Recycle Bin.
EXERCISE In this exercise, you create an operation plan for an individual machinable feature and then
for all machinable features in the Part Setup.
1. Right click Rectangular Pocket1 and select Parameters on the shortcut menu.
2. Click the down arrow to display the Attributes list and select Coarse.
This is a system attribute that has been defined in the TechDB to generate a Rough Mill
operation for a Rectangular Pocket feature. After you have learned how to use ProCAM,
you can modify system attributes to correspond to your requirements.
3. Click OK to exit the dialog box.
4. Right click Rectangular Pocket1 in the tree, select
Generate Operation Plan, then click the Solids
Machining Operation Tree tab at the bottom of the
tree.
The Operation tree lists a Rough Mill operation for the rectangular pocket.
5. Click the Solids Machining Feature Tree tab to return to the Feature tree.
6. Right click Rectangular Pocket1 and select Parameters on the shortcut menu.
7. Change the Attribute to Rough Finish in the Rectangular Pocket Parameters dialog box,
then click OK.
This attribute is a user-defined attribute that has been set up in the TechDB to generate
Rough Mill and Finish Mill operations for a Rectangular Pocket feature. After you have
learned how to use ProCAM, you can modify or delete the user-defined attributes and
you can define additional attributes to customize the TechDB.
8. Right click Rectangular Pocket1 in the tree, select Generate Operation Plan.

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If Generate Operation Plan has been run

once and you select the command again,
ProCAM displays a dialog box with the
following choices:
Update: Select this option to generate
operations for new features or for
features that you deleted all previously
generated operations. The operation list
will not be updated for features that have previously generated operations.
Regenerate: If you select this option, all previously generated operations are deleted and
new a new operation list is created. If you have modified any operations, these
modifications will be lost.
9. Click Regenerate to delete the previous Rough Mill operation and generate a new
operation list.
10. Click the Solids Machining Operation Tree tab.
The Operation tree lists Rough Mill and Finish Mill
operations for the rectangular pocket.
11. Click the Solids Machining Feature Tree tab.
12. Right click Part Setup1 in the Feature tree and select Generate Operation Plan on the
shortcut menu.
13. Click either Update or Regenerate in the Generate Operation Plan dialog box.
Since you have not changed any machining parameters for the Rough Mill and Finish
Mill operations that have already been generated, you could select either Regenerate or
Update. If you had modified these operations, you would want to select Update to
generate an operation list only for the features that do not have operations.
14. Click the Solids Machining Operation Tree tab at the bottom of the tree.
The Operation tree now contains operations for all machinable features in the selected
Part Setup.
15. Click the Solids Machining Feature Tree tab at the bottom of the tree.
16. Right click on MS Hole1 [MSH1(inch)] in the tree and select Go To First Operation on
the shortcut menu.
This command allows you to quickly locate the first operation that was generated for a
selected feature.
The Drill3 operation is highlighted in the Operation tree. In the TechDB, the attribute
[MSH1(inch)] has been defined to generate a single drill cycle for multi-stepped hole
features. Since multi-stepped holes can be any shape, you can define machining
sequences in the TechDB that are common for machining multi-stepped holes in your
facility.
To generate the NC code for this part, you would: adjust the machining parameters as
required for the operations, insert a series of operations for the multi-stepped hole, generate
toolpaths, and post process the part.

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2 Axis Mill 3
What You'll Learn
• Defining the Workpiece from a Bounding Box
• Inserting Additional Part Setups
• Creating a Face Feature
• Reorganizing Machinable Features
• Suppressing Machinable Features
• Inserting 2.5 Axis Features
• Combining Machinable Features
In this exercise, assume that the part starts out as a casting and machining is required only for
the holes and certain faces.
In the first clamping position or Part Setup, you will face the bottom of the part and drill the
large center hole and the three outside holes. In the second clamping position or Part Setup
you will machine off the top center face and the three ears.
EXERCISE 1. Open part file Mill2ax_3.pcii in the \procad\pcii\learn\solid folder.
This part was originally a Parasolid (x_t) file that was opened in ProCAM and saved in
ProCAM (pcii) format.
2. Click the Solids Machining button on
the CAD/CAM toolbar.

3. Click the Solids Machining Feature

Tree tab at the bottom of the Part Manager.
4. Right click Mill machine - Inch in the
Feature tree and select the Parameters
command on the shortcut menu.
− On the Machine tab, Mill machine –
Inch is the Active machine.
− Click the Tool Crib tab and make sure Crib 1 is the Active tool set.
− Click the Controller tab and make sure FANTUTM is selected, then click OK to exit
the Machine dialog box.
Defining the Workpiece From a Bounding Box
The workpiece size, shape and material type is defined next.
The workpiece definition serves several purposes:
• Defines the stock size and shape for simulation.
• Specifies the material type, which is used by the TechDB for feed/speed calculations.

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2 Axis Mill 3

By default, the workpiece shape is a cube whose dimensions enclose the part. For this
example, the part is machined from a casting that has .1" material to be removed from the top
and bottom surfaces.
Since ProCAM currently defines the workpiece as either a rectangle or a round bar stock,
you will use the default rectangle shape and offset the minimum workpiece size by .1".
EXERCISE 1. Right click Workpiece in the Feature tree and select Edit Definition on the shortcut
menu.
2. Change the Offset to .10" and press Enter.
3. Click OK.
Extracting Machinable Features
EXERCISE Before ProCAM extracts machinable features, you can customize AFR to eliminate Boss
features:
1. Click the Options button on the Solids toolbar or select Options on the Solids menu.
2. Click the Features tab in the Options dialog box.
3. Remove the check mark from the Boss option.
4. Make sure the Face option is not checked.
ProCAM can recognize some Face features automatically when you select the Face
option. However, for some parts you may need to define a Face Feature interactively as
explained in this exercise.
5. Click OK.
6. Click the Extract Machinable Features button on the Solids toolbar or right click NC
Manager in the tree and select Extract Machinable Features on the shortcut menu.
ProCAM creates the Part Setups necessary to machine
all of the machinable features that are recognized.
Other than drilling, the only additional operations
needed to machine this part are facing cycles.
Currently, faces are not recognized automatically as
machinable features, so you need to define Face
Features interactively.
ProCAM may not be able to find all features on a part.
On complex parts, AFR may not recognize all possible
features that you want to machine or AFR may
recognize a feature that might not be suitable for the
intended machining process. When this occurs, you
can define these features interactively.
For learning purposes, in this exercise you delete the Irregular Corner Slot features and
insert them interactively.
7. Hold down the Shift key on the keyboard and click each Irregular Corner Slot in the tree
to highlight the items, then right click and select Delete on the shortcut menu.

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8. Click Yes to confirm the deletion.

The features are moved to the Recycle Bin. When a feature is deleted, it is automatically
placed in the Recycle Bin, which is used to store machinable features that you do not
intend to machine.
9. Click the minus sign to the left of the Recycle Bin to collapse it.
10. Click Part Setup1 in the tree and notice the machining direction indicated by the triad that
displays on the part in the graphics area.
Inserting Additional Part Setups
Part Setup1 defines a tool direction pointing down from the top of the part. For this exercise,
you want to face the underside of the part first. Before you can machine the underside, you
must define a Part Setup for that tool direction. New Part Setups are inserted into the Feature
tree by selecting a part face that is normal to the tool axis of the Part Setup.
EXERCISE 1. Rotate the part so that the underside surface is visible.
2. Right click Part Setup1 in the Feature tree and select Insert Part Setup.
The Part Setup dialog box displays.
3. For the Reference plane, select Top
4. In the graphics area, pick the underside face.

5. Make sure the Face option is checked.

If this option is checked, when ProCAM creates a Part Setup, a face feature is created
automatically if the top most face is parallel to the Setup and the Setup is parallel to one
of the sides of the workpiece.
6. Click OK.
Part Setup2 is created with the tool direction shown in the figure above. The Face Feature
is created automatically and listed under the Part Setup.

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The names for Part Setup1 and Part Setup2 can be changed to Top and Bottom or some
other recognized convention.
7. Right click Part Setup2 and select Properties on the
shortcut menu.
8. Change the name to Bottom Part Setup, then click OK.
Notice that when you click a Part Setup in the tree, an
axis displays on the part to indicate the tool direction.
9. Right click Part Setup1 and select Properties.
10. Change the name to Top Part Setup, then click OK.

Reorganizing Machinable Features

You also want to drill the holes in the Bottom Part Setup. However, the hole features were
recognized in the Top Part Setup. With the mouse, you can drag the features in the Feature
tree from the Top Part Setup to the Bottom Part Setup.
EXERCISE 1. Hold down the left mouse button and drag Hole1 over
Bottom Part Setup, then release the button.
− Notice that as you drag the item, an arrow displays to
indicate where the item will be positioned.
− Hole1 is listed after Bottom Part Setup.
2. Hold down the left mouse button and drag Hole Pattern1
over Hole1, then release the button.
Hole Pattern1 is listed after Hole1.
Suppressing Machinable Features
You will now define features to machine the top of the part. The only machinable features
left in the Top Part Setup are the Open Pocket and the three irregular pockets. Since these
features will not be machined in this exercise, you can either delete or suppress them. The
steps below show you how to suppress these features.
EXERCISE 1. Click Open Pocket1 in the tree,
2. Hold down the Ctrl key and select Irregular Pocket1,
Irregular Pocket2 and Irregular Pocket3.
Make sure you select all 4 features.
3. Right click and select Suppress on the shortcut
menu.
The icons for the features display in gray instead of
yellow to indicate these features are suppressed.
4. Click Save As on the File menu.
5. Type Solids3 and click the Save button.

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Inserting 2.5 Axis Features

The top of the circular boss and the three ears need to be machined. Again, you use the Insert
2.5 Axis Feature command to define them.
EXERCISE 1. Rotate the part so the top face is visible.
2. Right click Top Part Setup in the Feature tree and select Insert 2.5 Axis Feature.
First, you define a Face Feature for the top of the boss.
3. Click the down arrow next to display the Feature Type list and select Face Feature.
4. Pick the top center face for the top of the
boss.
Face <1> displays in the Entities selected
list.
5. Click the Next button.
6. In the 2.5 Axis Feature Wizard: End
Conditions dialog box, click Finish to use
the defaults.
The 2.5 Axis Feature Wizard: Feature &
Cross Section Definition dialog box displays again and you can continue to define
features for the three ears.
7. Click the down arrow next to
display the Feature Type list and
select Corner Slot.
The ears are defined as Corner Slots
because more than one edge is open.
By defining it as a corner slot, the
tool will machine outside the ear on
the open air edges.
8. Select the Multiple option.
This option allows you to define
multiple similar features by
selecting multiple faces, sketches
and edges. A sketch (cross section
entities) representing multiple
features can also be selected. This
option can be selected for Pocket,
Slot, Corner Slot, Boss, Hole, and Open Profile feature types.

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2 Axis Mill 3

9. Pick each of the three ears on the part.

The Entities selected list shows Face <1>,
Face <2> and Face <3>.
10. Click Next.
The 2.5 Axis Feature Wizard: End
Conditions dialog box displays.

The depth of material to leave

for this feature will be from
the face of the ear to the face
immediately above the ear.
The depth can be specified
based on faces or vertex
points on the part. You can
either pick an end condition
from the End Condition
pulldown or select a face or
vertex and have ProCAM set
the depth automatically.
11. Leave the End condition set
to Blind and pick the face
above the ear.

The End condition is set to Upto Face and the Depth

parameter displays the distance as 0.140".

12. Make sure the Edit feature profiles option is checked.

13. Click Next.
The Edit Feature Profiles dialog box displays. When a Corner Slot is defined from a part
face, ProCAM determines the open air edges automatically. If necessary, you can change
the open air edges.
14. Select a segment in the Profile Segments list.
The corresponding edge is highlighted on Irregular Corner Slot(1). If ProCAM
determined that the edge is an open air edge, the Open air edge option is checked.
15. Select several segments in the Profile segments list to verify that the open air segments
are set correctly.
You do not need to change any segments.

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16. Click Next.

The 2.5 Axis Wizard: Island End Conditions dialog box displays. This dialog box
displays when you define a Pocket, Slot, Corner Slot, or Face Feature.
17. Make sure the Detect for all option is checked.
When you define multiple features and select this option, ProCAM attempts to find
islands for all features. If this option is not checked, ProCAM attempts to find islands
only for the current feature.
18. Click Autodetect.
There are no islands for the corner slots. If necessary,
you could click the Add button and interactively insert
islands.
19. Click Finish.
The Irregular Corner Slot features are listed in the tree.
All machinable features are now defined.
20. Click Close to exit the wizard.
Combining Machinable Features
Three Irregular Corner Slots were defined for the ears. If you were to generate an operation
plan now, separate operations would be created for each feature. For example, if the
Technology Database defines that an Irregular Corner Slot feature will be machined with a
rough and finish cycle, Generate Operation Plan would create three Rough Mill operations
and three Finish Mill operations for these features.
EXERCISE To make it easier to manage the machining parameters for these features, you can make a
single Pattern feature that contains all three features. As a Pattern feature, the three Irregular
Corner Slot features will be machined with one set of operations.
1. Right click the first Irregular Corner Slot in the
Feature tree and select Insert Pattern.
The Edit Pattern dialog box displays.

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2 Axis Mill 3

The Feature List on the right

displays the selected feature. The
Available Features list on the left
shows other features of the same
type and depth that can be added to
make the Pattern feature.
2. Pick Irregular Corner Slot5, then
hold down the CTRL key and pick
Irregular Corner Slot6.
3. Click Add.
The two features are added to the
Feature List on the right.
4. Click OK.
The three pockets are combined into a single
feature labeled Irregular Corner Slot Pattern2 in
the Feature tree.

EXERCISE Generate an operation plan for each Part Setup:

1. Click the Generate Operation Plan button

on the Solids toolbar or right click NC Manager in the Feature tree, select Generate
Operation Plan.
Operations are created for the machinable features in the Bottom and Top Part Setup.
2. Click the Solids Machining Operation Tree tab at the
bottom of the tree.
The operations are listed in the Operation tree.
3. Right click each operation and review the cutting
parameters.
Generate toolpaths and post process the part:
4. After you have verified that the parameters for each
operation are set the way you want them, right click
Bottom Part Setup in the Operation tree and select
Generate Toolpath.
5. Repeat step 1 for the operations in Top Part Setup.
6. Check the Solids Machining Message Window.
− The Message Window provides information you may find helpful. For example,
based on the information in this window, you may want to change a tool or insert a
finish operation in order to cut a machinable feature completely.
− If the Message Window is not displayed, select Options on the Solids menu and check
the Message Window check box on the General tab.

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− You can move the window and adjust the size of the window. To change the size,
point to a border or corner of the window (the pointer changes to a two-headed
arrow). Drag the corner or border until the window is the size you want, then release
the mouse button.
7. Experiment by changing parameters for the operations and regenerating the toolpaths.
ProCAM provides the ability to simulate toolpaths showing the tool movement and the
resulting shape of the part.
8. Right click NC Manager and select Simulate Toolpath.

9. Click the Run button.

10. Click the X button in the upper right corner of the Simulation toolbar to exit
Simulation mode.
11. Right click Bottom Part Setup in the Operation tree and select Post Process.
12. In the Save Post File dialog box, click Save to accept the default file name (Solids3.txt).
Note that if you are running Solids Machining in Demo mode, this dialog box does not
display.
13. In the Post Process Output dialog box, check the Display Centerline option so that the
toolpath will be highlighted as each line of code is produced.
14. Click the Run button (the double arrow).
NC code is created for the Bottom Part Setup.
15. After viewing the code, click Cancel.
16. Right click Top Part Setup in the Operation tree and select Post Process.
17. In the Save Post File dialog box, type Solids3top.txt.
18. In the Post Process Output dialog box, click the Run button (the double arrow).

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2 Axis Mill 4

2 Axis Mill 4
What You'll Learn
• Inserting Cross Section Entities
• Defining the Workpiece from a Cross Section Entity
• Defining Additional Machinable Features
• Adjusting Machining Parameters
• Deleting an Operation
• Inserting an Operation
• Defining Program Zero
• Sorting Operations
This lesson guides you through the steps for the sequence of machining the part shown
below. The bottom depressions of the part will not be machined in this exercise.
Sequence of machining:
Top Face
Drill two holes on each end of part
Face top of part
Face depression on left side of part
Finish profile the hole on the left
Rough and finish rectangular pocket
Finish machine three obround holes Left Depression
Rough and finish outside part shape from
stock.

EXERCISE 1. Open the part file Mill2ax_4.pcii in the \procad\pcii\learn\solid folder.

2. Click the Solids Machining button on the CAD/CAM toolbar.

3. Click the Solids Machining Feature Tree tab at the bottom of the Part Manager.
4. Right click Mill machine – Inch in the Feature tree and select Parameters.
− On the Machine tab, Mill machine – Inch is the Active machine.
− Click the Tool crib tab and make sure Crib 1 is the Active tool set.
− Click the Controller tab and make sure FANTUTM is selected, then click OK to exit
the Machine dialog box.
Inserting Cross Section Entities
Cross section entities are closed boundaries that can be used in Solids Machining to define
features, to define a location for the Part Setup origin, to represent a workpiece, and to
identify contain and avoid areas for machining. A cross section entity is automatically
assigned a unique identification number and is listed as a "sketch" in applicable dialog
boxes.

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This exercise explains how to insert and use cross section entities to represent the material
and to define the location for the Part Setup origin.

EXERCISE 1. Click the CAD button on the CAD/CAM toolbar.

2. Click the Polygon button on the CAD toolbar.
3. Click the Keyboard button on the Snap toolbar.
The prompt line reads: ENTER X coordinate for 1st location on box.
4. Type –1.0 for X Start and press ENTER.
5. Type -1.5 for Y Start and press ENTER.
6. Type .955 for Z Start and press ENTER.
The prompt line reads: ENTER X coordinate for 2nd location on box.
7. Type 6.6 and press ENTER.
8. For Y End, type 2.3 and press ENTER.
9. For Z End, type .955 and press ENTER.
The polygon is inserted. This is the geometry for the workpiece cross section entity.
10. Click the Circle button on the CAD toolbar.
11. Click the Radius modifier button.
12. For the Radius, type .2 and press ENTER.
13. Click the Endpoint button on the Snap toolbar.
14. Pick the end of one of the lines on the lower left side of the workpiece (see the figure).
15. With the mouse pointer in the graphics area, click BUTTON 2 (the middle button).

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Insert the cross section entities:

16. Click the Solids Machining button on the CAD/CAM toolbar.
17. Click the Cross Section Entity button on the Solids toolbar.
18. Make sure the Check Breaks/Sharp Corners modifier is not highlighted.
The prompt line reads: PICK
entity for cross section start. End Start

19. Pick the end of the line of the

rectangle shown in the figure.
The prompt line reads: PICK
next entity for cross section.
20. Pick the vertical line on the
left near the top of the line.
You can chain-select entities
by skipping several entities
and picking an entity further
along the path. The skipped
entities are picked automatically.
21. With the mouse pointer in the graphics area, click BUTTON 2 (the middle button).
The cross section entity is inserted to create a closed boundary.
22. Pick the circle and click BUTTON 2.
The cross section entity is inserted.
Defining the Workpiece from a Cross Section Entity
The workpiece is a block of material that does not have the same amount of material on all
sides. To represent the material, you inserted a rectangular cross section entity positioned
.05" above the top of the part.

EXERCISE 1. Click the Solids Machining Feature Tree tab at the bottom of the Part Manager.
2. Right click Workpiece in the Feature tree and select Edit Definition.
ProCAM automatically calculates the workpiece size and shape based on the smallest
block possible. You can change this definition by specifying a cross section entity and
depth.

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3. Select Sketch.
In the Sketch list box, select
sf000256.
Cross section entities are
identified in the dialog boxes
by sf000nnn where nnn is a
unique three digit number.
4. Set the Height to 1.00" and
press Enter.
5. Check the Reverse direction
option, then click OK.
An outline of the stock
displays in the graphics area.

Extracting Machinable Features

EXERCISE Define machinable features automatically:

1. Click the Options button on the Solids toolbar.

2. Click the Features tab in the Options dialog box.
3. Check the Face option in the Feature types section
and click OK.
4. Click the Extract Machinable Features button
on the Solids toolbar or right click NC Manager
and select Extract Machinable Features.
The recognized features include the face feature,
two holes, the rectangular pocket and the three
obround pockets, which are included in Obround Pocket
Pattern1.
5. Click Part Setup1 in the Feature tree and check the machining
direction that displays on the part.
Because all the features go through the part, AFR may
determine the machining direction is from the bottom.
Correct direction

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If the direction is from the bottom instead of from the top as shown on the right, right
click Part Setup1 and select Parameters. Click the Reverse Direction button, then click
OK.
Defining Additional Features
For this example, you interactively define three machinable features.
− Irregular Corner Slot (to machine the depression on the left side of the part)
− Open Pocket (defines the outside profile of the part so it can be machined from the
stock)
One of the features is created from part faces and the second from sketches.
EXERCISE First, you create a 2.5 Axis feature for the depression on the left side of the part. To
completely remove the material along the open edges, you need to define the feature as an
Irregular Corner Slot. By definition, an Irregular Corner Slot has two or more adjacent edges
that have open air edges.
1. Right click Part Setup1 and select Insert 2.5 Axis Feature on the shortcut menu.
The 2.5 Axis Feature Wizard: Feature &
Cross Section Definition dialog box displays.
2. Make sure Single is selected.
3. Select Corner Slot for the Feature Type and
pick the top face of the depression on the left
side of the part.
4. Click Next.
The 2.5 Axis Feature Wizard: End Conditions
dialog box displays.
5. Pick the topmost face on the right.
ProCAM automatically sets the End condition to Upto Face and the Depth to 0.0600".
6. Make sure the Edit feature profiles option is checked, then click Next.
The 2.5 Axis Feature Wizard: Edit Feature Profiles dialog box displays. When a Corner
Slot or Slot feature is defined from a part face, ProCAM automatically determines the
open air edges. If necessary, you can change the open air edges.
7. Click the segments in the Profile Segments list to view the open air edges selected by
ProCAM. You do not need to change any segments for this exercise.
8. Click Finish. Irregular Corner Slot1 is created and added to the Feature tree.
EXERCISE The second 2.5 Axis feature to add will be used to machine the perimeter of the part. For this
example, you rough the part from the workpiece, then finish machine the perimeter of the
part. In order to do this, you define the workpiece perimeter as an Open Pocket and the part
as an island in this pocket.
By defining this 2.5 Axis feature as an Open Pocket, the toolpath will extend beyond the
workpiece perimeter so that all of the material will be removed. In comparison, if the
workpiece perimeter were defined as a simple Pocket, the roughing toolpath would be
constrained within the perimeter of the workpiece leaving unmachined areas in the corners.

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1. In the 2.5 Axis Feature Wizard: Feature & Cross Section Definition dialog box, select
Open Pocket for the Type.
2. In the Available sketches list, select
sf000256 and click Next.
This is the cross section entity you
inserted to represent the workpiece.

3. In the 2.5 Axis Feature Wizard: End

Conditions dialog box, set the End
condition Type to Upto Workpiece.
4. Select the Through option.
With this option checked, the feature
will be machined slightly deeper
than the workpiece to remove all
material.
5. Click Next.
The 2.5 Axis Feature Wizard: Island
End Conditions dialog box displays.

6. Click the Autodetect button.

ProCAM considers a flat face that
is normal to the Part Setup as an
island. In this part, the top face of
the part and the left depression
face are both flat and normal to the
current Part Setup and will be
identified as islands automatically.
If necessary, you can define
islands interactively by clicking
the Add button and selecting faces,
edges loops and sketches.
7. Click Finish.

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The last 2.5 Axis feature is now complete and all

machinable features are listed in the Feature tree.
8. Click Close to exit the Wizard.

Generating Operations
EXERCISE Before the operation plan is generated, attributes can be assigned to features to affect the
operations that are created for each feature.
1. Right click Rectangular Pocket1 and select Parameters.
2. In the Rectangular Pocket Parameters dialog box, set the Attribute to Coarse, then click
OK.
This system attribute has been set up in the TechDB to
generate a Rough Mill operation for a Rectangular
Pocket feature.
3. Click the Generate Operation Plan button on the
Solids toolbar or right click Part Setup1 in the tree and
select Generate Operation Plan.
4. Click the Solids Machining Operation Tree tab at the
bottom of the tree.
The operations are listed in the Operation tree.
Adjusting Machining Parameters
The operations that are generated by ProCAM are based on information stored in the
TechDB. These operations are intended to be used as a starting point. Each operation
contains machining parameters that affect how the toolpath is created and specific
parameters that will be output to the NC program. These parameters can be edited before
generating the toolpaths and post processing the part.
EXERCISE 1. Click the + next to Finish Mill4 in the Operation tree.
The tree expands to identify the machinable feature the operation was generated for.
2. Right click Finish Mill4 and select Collapse Items on the shortcut menu.
You can use either the + and – symbols or the Expand and Collapse Items commands on
the shortcut menus to view items in the trees.
3. Right click Finish Mill4 again and select Parameters.

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4. In the Machining Parameters

dialog box, click the Tool
Crib tab.
5. Select a .1875in diameter
flat end mill.
If Flat End tools are not
listed, clear the check mark
to the left of the Filter button.
6. Click the <-- Select button,
then click Yes to replace the
corresponding holder.
7. Click the Finish tab.
8. In the Side parameters section, make sure the Allowance is set to 0.0.
This will cut the pockets to size.
9. Click OK to exit the Machining Parameters dialog box.
Deleting an Operation
In some cases, it may be desirable to delete operations that are created automatically. In this
example, Rough Mill and Finish Mill operations were created for the Obround Pocket
Pattern1 machinable feature. Based on the tool that is going to be used for the obround hole,
a Finish Mill operation is all that is needed. You can delete the Rough Mill operation.
1. In the Operation tree, right click Rough Mill5 (the roughing operation for the obround
slots) and select Delete on the shortcut menu.
2. Click Yes to confirm you want to delete the operation. The operation is removed from the
tree.
Inserting an Operation
The larger hole on the right has been drilled. In this
example, you also want to finish mill around the inside
of the hole. To do this, you need to add a Finish Mill
operation.
EXERCISE 1. Right click Drill1 in the Operation tree and select
Insert Hole Operation.
The Insert hole operation dialog box displays.

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2. Set the Type of operation to

Finish Mill.
3. Select Hole1 in the Features list
on the left and click Define.

The Hole Feature

Definition dialog box
displays. This dialog box
allows you to define the
top and bottom of the hole
and the hole diameter.
Since this hole contains
only a single diameter, the
start and end location of
the hole diameter are set
automatically to the
correct values.
4. Click OK.
The Insert Hole Operation
dialog box displays again.
5. Click Next.
The Mill Tool dialog box
displays.
6. If a .500" flat end mill is
not selected, click the
Tool Crib tab and select it
from the Tool Crib, then click the <-- Select button.
7. Click Finish.
8. Click Close to exit the Insert Hole Operation dialog box.
A finish operation is added after the Drill1 operation in the Operation tree.

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Defining Program Zero

The Part Setup defines the tool direction as well as program zero. Program zero can be
changed in the Part Setup by selecting a vertex or arc edge, typing in the origin relative to the
ProCAM origin (0,0,0), picking a cross section entity that is a single circle, or picking a
workpiece corner. When selecting a cross section entity, the center of the circle will be the
origin of the Part Setup and program zero. Each Part Setup can have a different origin. You
insert the cross section entity at the beginning of this exercise.
EXERCISE 1. Right click Part Setup1 in the tree and
select Parameters.
The Part Setup Parameters dialog box
displays.
2. On the Origin tab, select the Sketch
option.
Cross section entity sf000257 is listed.

The circle in the lower left corner of

the workpiece should be highlighted.
This indicates that the center of the
circle is now the Part Setup origin.
3. Click OK.

Did You Know ...

If you change the Part Setup origin after generating toolpaths, always regenerate all
toolpaths. Otherwise, the post processed output will not be relative to the origin.

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2 Axis Mill 4

EXERCISE Generate toolpaths, simulate toolpaths and post process the part:

1. Click the Generate Toolpath

button on the Solids toolbar or right
click Part Setup1 in the Operation tree
and select Generate Toolpath.
2. Click the first operation in the tree,
hold down the Shift key and click the
last operation in the tree.
The toolpaths that were generated for
all operations display.

3. Right click Part Setup1 and select Simulate Toolpath.

4. Click the Run button to simulate the

toolpaths.
5. Click the Cancel button to exit the
simulation.

Sorting Operations
When the Generate Operation Plan command is run, operations are created for each feature
in the order the features are listed in the tree. As shown above, operations can also be
inserted manually and deleted. After making these changes, it is possible that the machining
order is not in the most efficient sequence. Using drag and drop, operations can be reordered
into an optimized sequence; however, this could become time consuming for a part that
includes dozens of operations. To make the ordering task easier, ProCAM provides a Sort
command that sorts operations based on their type, depth and tool.
EXERCISE 1. Right click Part Setup1 in the tree and select Sort Operations on the shortcut menu.
The Sort Operations dialog box displays.
2. On the Process tab, remove the check mark from the Process complete feature option.
When this option is checked, all operations for a given feature will be sorted and grouped
together so that the entire feature is completed before processing other feature operations.
After all feature operations are grouped, the order the operations are processed will be
from highest Z face to lowest Z face.

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3. Select the Sort tab.

This page shows the order in which the operations will be sorted.
4. Click the Apply button.
Note that the operations have been sorted according to the specified operation sequence.
Within each type of operation, the operations with the highest Z face will be processed
first. If you do not like the order, you can select the Undo button and change the options
parameter, then select Apply again to see the results.
5. Click the OK button.
If required, the operations can still be reordered manually using drag and drop.
6. Right click Part Setup1 and select Simulate Toolpath.
7. Run the simulation and note the changes.
8. Save the part.
9. Right click Part Setup1 and select Post Process.
The Post Output File dialog box displays. If you are running Solids Machining in Demo
mode, this dialog box does not display.
10. Click Save to use the default name for the NC program file.
The Post Process Output dialog box displays.
11. Click the Run button.
ProCAM generates the NC program.
12. Use the vertical scroll bar to view the code.
13. Click Cancel to exit the Post Process Output dialog box.

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1-48 Learning 2 Axis Mill Basics

Chapter 2 Learning More 2 Axis Mill

This chapter provides an opportunity to learn more about Solids Machining 2 Axis Mill.
The exercises in this chapter are intended to show you how to use Solids Machining and may
not correspond to actual machining practices.
The part files used in these exercises were originally Parasolid (x_t) files that were opened in
ProCAM and saved in ProCAM (.pcii) format.

IMPORTANT! ProCAM uses a set of knowledge-based rules to assign machining

operations to features. The Technology Database contains the data for the machining
process plans and can be customized for your facility's machining methodology. When you
do these exercises, your results may not be the same as described in the steps and illustrated
in the figures. This is because the machining sequences and operations data in your
Technology Database may be different from the database used to produce the
documentation.

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2 Axis Mill 5

2 Axis Mill 5
What You'll Learn
• Setting Attributes and Generating Operations
• Sorting and Sequencing Operations
• Machining Island Tops
• Changing the Part Setup Origin
• Combining Operations
In this exercise, AFR finds all the features on a rectangular part except for the top face of the
part. You learn how to insert a 2.5 axis feature to machine the top face.
EXERCISE 1. Open the part file Mill2ax_5.pcii in the \procad\pcii\learn\solid folder.
Since this part is rectangular, you do not have to
machine the outside of the part. AFR will find
the holes, bosses, slot, and corner slots, but not
the face of the part.
2. Click the Solids Machining button on the
CAD/CAM toolbar.

3. Click the Solids Machining Feature Tree

tab.
4. Right click Mill machine – mm in the Solids
Feature tree and select Parameters.
− On the Machine tab, Mill machine – mm is
the Active machine.
− Click the Tool Crib tab and make sure Tool
Crib 1 (metric) is the Active tool set.
− Click the Controller tab and make sure FANTUTM is selected, then click OK.
5. Right click on the Workpiece
in the Feature tree and select
Edit Definition on the
shortcut menu. The Define
Workpiece dialog displays.
6. Change the Offset to
1.00mm and press Enter.
7. Click the Material button.
The Workpiece Material
dialog box displays.
8. Select a material in the
pulldown list, then click OK.

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9. Click OK to close the Define Workpiece dialog box.

10. Click the Options button on the Solids toolbar or select Options on the Solids menu.
11. Click the Features tab in the Options dialog box.
12. In the Feature types section, make sure the Face option is not checked and click OK.
13. Click the Extract Machinable Features button on the Solids toolbar or right click on
the NC Manager in the tree and select Extract Machinable Features.
Automatic Feature Recognition analyzes the model for features to machine. When AFR
is complete, the tree displays the list of Machinable Features that ProCAM has found.
− An Open Pocket feature was created with the
Obround Boss and the two Rectangular Bosses
as islands.
− The two rectangular bosses were extracted as a
Rectangular Boss Pattern.
− The Rectangular Corner Slots were not
extracted as a Pattern Feature because they are
different sizes.
Did You Know ...
The default machining sequence is based on the order that the machinable features
appear in the tree. Using drag and drop, you could rearrange the features in the tree
so that they are in the order that you would like them to be machined. However, the
Operation tree allows operations to be automatically sorted and interactively
sequenced so it is unnecessary to reorder the features manually.
Setting Attributes and Generating Operations
EXERCISE 1. Right click on the Hole Pattern in the Solids Feature tree and select Parameters.
2. In the Hole Parameters dialog box, change the Attribute to Ream, then click OK.
3. Click the Generate Operation Plan button on the Solids toolbar or right click Part
Setup1 in the Solids Feature tree and select Generate Operation Plan.
ProCAM creates the list of operations to machine the part.
4. Click the Solids Machining Operation Tree tab at the bottom of the tree.
All the operations for a given Feature are listed in order.
Sorting and Sequencing Operations
The machining sequence is based on the order of the operations in the tree. The Rough Mill
and Finish Mill operations for the Rectangular Corner Slot are listed at the bottom. You may
not want this order. For example, you may want all of the roughing done before the
finishing, and the hole making operations to be done last. ProCAM allows automatic and
interactive control over changing the machining sequence. Using drag and drop is suitable
when only several changes need to be made. However, when making numerous changes to
the order of the tree, the Sort Operations command provides an automatic approach.

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2 Axis Mill 5

EXERCISE 1. Right click Part Setup1 and select Sort Operations.

The Sort Operations dialog box displays.
2. Remove the check mark in the Process complete feature checkbox.
When checked, the operation sequence will be based on machining each feature
completely before machining the next feature. The features will be sorted from highest Z
to lowest Z.
3. Change to the Sort tab.
The Sort page allows operations to be sorted based on either one or two criteria. The Sort
by list shows the current order for sorting operations. The default order is defined in the
Technology Database and can be modified as required.
4. Click the Apply button to see the result of the current sorting rules.
Note that the operations in the tree are sorted according the order in the list.
5. Click the Undo button to return to the original order.
In this example, you want to sort by operation type where
Rough Mill cycles are first, Finish Mill cycles are second,
then hole making cycles. To do this, the operation order list
can be reordered using drag and drop.
6. Select the Rough Mill operation in the list and drag it to the
top. Note that the operation will be inserted before the
operation it is dropped on.
7. Select the Finish Mill operation and drag and drop it on the
Center Drill operation.
8. Click the Apply button.
The order in the tree changes to reflect the current operation
list.
9. Click OK.
The operation order in the tree can be further modified using
drag and drop if necessary.
Did You Know ...
Be careful when dragging and dropping the operations. Make sure you do not change
the order so that the tools will cause a crash. For example, you could drag the ream
operation in front of the drill operation. ProCAM assumes that you know what you are
doing and will process the toolpaths exactly the way you have them ordered.

Machining Island Tops

As in the previous exercises, the Machining Parameters dialog allows you access to all of the
parameters that will be used to machine a Feature. You can change as many parameters as
you like to customize the toolpath that ProCAM generates to suit your machining
requirements.

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The parameters that you change in the Machining Parameters dialog box are used only for
the operation you are editing. Other operations and other parts you do in the future will
revert to the default parameters that are defined in the TechDB.
EXERCISE 1. Right click the Rough Mill1 in the Operation tree and select Parameters.
2. Click the Roughing tab in the Machining Parameters dialog box.
3. Check the Machine Island Top option so that the islands on the top of the part are faced
off.
4. Change the Pocketing Pattern to Zigzag.
This option creates parallel lace cuts with the cuts alternating direction. Between each
lace cut, the tool stays down in the material.
5. Click OK.
Changing the Part Setup Origin
ProCAM creates Part Setups automatically with the Part Setup depth set to the highest face
on the recognized features and the Part Setup origin on the edge of the first recognized
feature on the top of the part. The Part Setup origin defines the G code program zero location
using the machine tool's fixture location, Work Coordinates and/or Sub Coordinate offsets.
The Part Setup origin position is based on the ProCAM origin. You can move the Part Setup
origin to a more useful location for machining.
EXERCISE 1. Left mouse click on Part Setup1 in the tree.
Notice where the origin is located on the part (shown below in the figure on the left).
2. Right click on Part Setup1 and select Parameters.
The Part Setup Parameters dialog box displays.
3. For the Origin, pick Workpiece vertex.
4. Pick the corner that corresponds to the location below shown in the figure, then click OK.
The origin location is moved on the part to the corner you selected.

New location

Original location

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2 Axis Mill 5

Did You Know ...

Based on the orientation of the part, selecting a corner in the dialog box may not appear
to be the same corner on the part. This is because the model can be rotated to any
position in space.

Combining Operations
Notice that several roughing and finishing operations use the same tool. Similar operation
types that use the same tool can be combined into one operation.
EXERCISE 1. Right click on Part Setup1 in the tree and select Combine Operations.
2. Select Finish Mill, then click OK.
ProCAM combines similar Finish Mill operations that use the same tool.
3. Click the + next to Finish Mill operations in the tree to expand the items.
Several of the operations were combined because they use the same size tool. Notice that
the order of the operations was maintained. The rough operations are first, followed by
the finish operations, and finally the hole operations.
Before Combining After Combining

Did You Know ...

If you combine operations and disable the Regenerate toolpaths option in the Combine
Operations dialog box, you must generate toolpaths again.

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4. Click the Generate Toolpath button on

the Solids toolbar or right click the Part
Setup in the tree and select Generate
Toolpath.
5. Highlight the first operation in the tree,
hold down the Shift key, then highlight the
last operation.
Your model should look similar to the
figure on the right.
6. Right click Part Setup1 in the tree and
select Simulate Toolpath.
The Simulate Toolpath toolbar displays.

7. Click the Run button to start the

simulation.
8. When the simulation is finished, rotate the
part to see how all the features were
machined.

9. Click the Return to start button.

10. Click the Turbo mode button, then

click Run.
The simulation does not update the
workpiece until the simulation is
completed. This is the fastest method for
simulation.
11. Click the X button in the upper right
corner of the Simulate Toolpath toolbar to
exit simulation mode.
12. Click the Post Process button on the Solids toolbar.
The Post Output File dialog box displays so you can name the NC program file.
13. Use either the default file name or type a different name and save the file.
14. Click the Run button in the Post Process Output dialog box to output the G-Code file.
Click OK to close the dialog box.

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2 Axis Mill 6

2 Axis Mill 6
What You'll Learn
• Interactively Inserting 2.5 Axis Features
• Inserting Operations
• Avoiding Clamps
• Changing Machining Parameters and Tools
• Inserting a Part Setup and Face Feature to Cut the Bottom of the Part
• Customizing Toolpaths
This exercise involves a non-rectangular part that requires a number of interactive tool paths.
Cross section entities have been created to represent the workpiece and the clamps. Cross
section entities are closed boundaries that can be used to define features, to define a location
for the Part Setup origin, to represent a workpiece, and to identify contain and avoid areas for
machining. The procedure to create cross section entities is explained in Chapter 1.
EXERCISE 1. Open the part file Mill2ax_6.pcii in the \procad\pcii\learn\solid folder.
Since this part is non-rectangular, the toolpaths to machine the outside of the part will
have to be added. In addition, two face cuts will be added. All machining will be from the
top of the part.
2. If necessary, rotate the part and
position it similar to the figure on
the right.
3. Click the Solids Machining
button on the CAD/CAM toolbar.

4. Click the Solids Machining

Feature Tree tab at the bottom of
the Part Manager.
5. Right click Mill machine – mm in
the Solids Feature tree and select Parameters.
− On the Machine tab, Mill machine – mm is the Active machine.
− Click the Tool Crib tab and make sure Tool Crib 1 (metric) is the Active tool set.
− Click the Controller and make sure FANTUTM is selected, then click OK.
6. Right click on the Workpiece and select Edit Definition.
7. Click the Sketch option button.
8. Select sf000148 from the Sketch pulldown list.

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When a cross section entity is

created, ProCAM automatically
assigns a unique identification
number that is listed as a "sketch"
in applicable dialog boxes.
9. Set the Height to 45.00mm and
press Enter.
10. Click the Reverse direction
option, then click OK.
11. Click the Extract Machinable
Features button on the Solids
toolbar or right click the NC Manager in the tree and select Extract Machinable Features.
Automatic Feature Recognition analyzes the model for
features to machine and the tree displays the list of
Machinable Features that ProCAM has found. Only the
large hole and the two internal pockets have been found.
Additional features will be defined interactively to
completely machine the part.
Inserting 2.5 Axis Features
You need to insert a 2.5 Axis Features to cut the outside of the part and the two faces.
EXERCISE Insert the first 2.5 Axis Feature to define the area to machine around the outside of the part.
1. Right click on Part Setup1 and select Insert 2.5 Axis Feature.
The 2.5 Axis Feature Wizard starts and the Feature & Cross Section Definition dialog
box displays.
2. Select Face Feature for the Feature Type.
3. Pick the top face of the part at the top of the hole.
The Entities selected list shows
Face<1>.
4. If the Check for tapers & fillets
option is selected, remove the check
mark.
5. Click Next.
The 2.5 Axis Feature Wizard: End
Conditions dialog box displays.
6. Make sure Use workpiece extents is
checked so that the entire top of the
material is faced off.
Click Finish to complete the feature.

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2 Axis Mill 6

The Feature & Cross Section Definition dialog box displays again so you can continue
inserting features.
EXERCISE Insert the 2.5 Axis Feature for the second face cut:
1. Make sure the Feature Type is set to
Face Feature, then pick the face at the
top of the pockets as shown in the
figure.
2. Click Next.
3. In the End Conditions dialog box, you
can use the defaults.
4. Click Finish to complete the feature.
EXERCISE The third 2.5 Axis Feature will be the area around the outside of the part. The workpiece was
defined so that the bottom of the part is 5mm off the bottom of the workpiece. If the feature
is defined as having a bottom depth equal to the bottom of the part, then a 5mm skin will
remain to hold the part to the clamp.
1. Rotate the part so that you can see the bottom face.
2. Make sure the Feature Type is set to Face Feature, then
pick the bottom face as the entity to be machined.
3. Click Next.
4. Rotate the part back to view the top.
5. Pick the face of the part at the top of the hole.

In the End Conditions dialog box, the

End condition Type changes to
UptoFace and the Depth is calculated
automatically.
6. Make sure that the Use workpiece
extents option is checked, then click
Finish.
7. Click Close to exit the Feature Wizard.
The Features are listed in the Solids Feature tree in the
order you added them with the last one first.
8. Drag and drop the features so that they are in the order
shown.

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Inserting Operations
EXERCISE 1. Click the Generate Operation Plan button on the Solids toolbar or right click on Part
Setup1 and select Generate Operation Plan, then click the Solids Operations tab at the
bottom of the tree.
The Operations list should look similar to the example
on the right. Note that the three Face Features are
machined only by a Rough Mill operation. This was
defined in the Technology Database. In the case of the
second and third face features, you also want finish
operations. In the next series of steps, you add
Operations to existing Operations.
2. Right mouse click on Rough Mill2 and select Insert
Operation.
The Insert Operation dialog
displays.
3. Change the Type of operation to
Finish Mill.
4. Change the Select features from
option to Operations List.
5. Choose Rough Mill2 from the list,
then click the Add -> button.
The feature (Face Feature2) that is
associated to this operation is listed
in the Feature list.
6. Click OK.

The Finish Mill operation is added to the Operation

tree.
7. Repeat the steps for Rough Mill3 in the list. When
complete, the tree should look similar to the example
on the right.

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2 Axis Mill 6

Defining Avoid Areas for Clamps

Rough and Finish operations for 2 and 2.5 Axis features can be modified by specifying
Avoid Areas. Avoid areas can be used as a definition for clamps and large holes in the
feature where machining is to be avoided. Avoid areas can be defined from planar or non-
planar model edges and faces, as well as from sketches. Avoid Areas are considered to be
islands within the perimeter and will be machined around leaving material equal to the sum
of the Side allowance and Avoid allowance parameters.
In this exercise, you define avoid areas for the three face features to avoid machining the
clamps.
1. Right click RoughMill1 in the Operation tree and select Insert Avoid Area on the shortcut
menu.
The 2 Axis Wizard dialog box displays.
2. Select sf000146 in the Available sketches list and click Finish.
When cross section entities were created for the clamps, ProCAM automatically assigned
this identification number.
3. Click the plus sign next to RoughMill1 in the Operation
tree.
The Avoid Area is listed under the operation.
4. Right click RoughMill1 and select Insert Avoid Area on the shortcut menu.
5. In the 2 Axis Wizard dialog box, pick sf000147 and click Finish.
6. Repeat these steps to define avoid areas for RoughMill2 and RoughMill3.

Changing Machining Parameters and Generating Toolpaths

Before generating toolpaths, we will modify some of the operation parameters. Typically,
choosing parameters for machining is based on personal preference. The following is an
example for the purposes of making you more comfortable in making these changes.
EXERCISE 1. Right click Rough Mill1 in the tree and select Parameters.
2. On the Roughing tab, make sure the Cleanup pass option is not checked, then click OK.
3. Repeat steps 1 and 2 for every Rough Mill operation in the list.
If the general rule is to not generate a cleanup pass, the default could be set to off in the
Technology Database.
4. Right click Finish Mill4 and select Parameters.
5. Click the Finish tab in the Machining Parameters dialog box.
By default, the depths of cut will produce multiple finish cuts.
6. Change the value for First cut amt. to 50mm.
7. For Depth processing, select the To depth by region option, then click OK.
8. Repeat steps 4 - 6 for Finish Mill5.

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The default values for milling the counterbore are small and will produce more cuts than are
needed. You can edit the operation and change these values.
9. Right click Finish Mill1 and select Parameters.
10. Click the Finish tab and change the following parameters:
Side Parameters: Cut amt. = 10mm.
Depth Parameters: First cut amt. = 10mm and Max cut amt. = 10mm
11. Click the Tool tab, then
click the Tool Crib tab.
12. Scroll through the tools
until you see the 20mm flat
end mill.
If Flat End tools are not
listed, clear the check mark
to the left of the Filter
button.
13. Click in a cell on the 20mm
tool line to select the tool,
then click the <-- Select
button.
14. Click Yes to replace the
corresponding holder.
15. Click OK to close the Machining Parameters dialog box.

16. Click the Generate Toolpath button on the Solids toolbar or right click the Part Setup
and select Generate Toolpath.
ProCAM generates the toolpaths for all operations.
17. Hold down the Shift key, then pick
the first and last operation in the
tree.
18. Rotate the part and notice how the
toolpath has avoided the clamp
areas.
19. Rotate the part to a side view and
notice that the toolpath has not
gone to the bottom of the material.
20. Right click on the Part Setup and
select Simulate Toolpath.

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2 Axis Mill 6

21. Run the tool path simulation.

The result should be similar to the
example.
22. Close the Simulation to return to
the model.

Inserting a Part Setup and Adding a Facing Cut

This series of steps shows you how to add a facing cut for the bottom side of the part. For
setup purposes, you are going to flip the part over, hold it by the machined rectangular
section, and machine the remainder of the material off with a facing cut. You begin by
creating a Part Setup that is opposite from the existing Part Setup. From this Part Setup, you
will then create a face feature.
EXERCISE 1. Rotate the part so that you can see the bottom face.
2. Click the Solids Machining Feature Tree tab at the bottom of the tree.
3. Right click Part Setup1 and select Insert
Part Setup.
4. Select the bottom face of the part.
The face is shown as the Selected entity.
When you insert a Part Setup, you can
select either a face or one of the planes
listed in the Insert Part Setup dialog box.
5. Make sure the Face option is checked.
When this option is checked, ProCAM
automatically creates a Face feature when
the Part Setup is created if the topmost face
is parallel to the Part Setup and the Part
Setup is parallel to one of the sides of the
workpiece.
6. Click OK.
A new Part Setup is inserted on the bottom of the part
and Part Setup2 is listed in the tree.

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7. Right click Part Setup2 and select

Generate Operation Plan.
8. Click the Solids Machining Operation
Tree tab at the bottom of the tree.
9. Right click Part Setup2 and select
Generate Toolpath.
The resulting tool path should look
similar to the figure on the right.
10. Rotate the part back to view the top.

11. Right click on the NC Manager in the

Operation tree and select Simulate
Toolpath.

12. Click the Run button.

The resulting simulation should appear
as shown. The remainder of the material
has been removed, and the part has been
machined completely.
13. Click the exit button.

Customizing Toolpaths
In the final part of this exercise, you change some of the Part Setup and operation parameters
to customize the toolpaths.
EXERCISE 1. Click in the graphics area, then press W on the keyboard to change to wire frame display.
2. On the System toolbar, change the
View to 4 Bottom.
3. Zoom up on the toolpath shown in the figure below.
4. Right click on Finish Mill3 in the tree and select Parameters.
5. On the Mill Tool tab, set the Cut diameter to 10mm.
6. Click the Leadin tab.
7. Change the Leadin type to Perpendicular.
8. Set the Leadin amount to 5mm.
9. Pick the lower edge of the feature to
change the toolpath start location.

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2 Axis Mill 6

The pierce point displays as a square marker in the middle of the edge because the Mid-
point option is selected.
10. Click OK.
11. Right click on the same Finish Mill operation
and select Generate Toolpath.
12. Rotate the part and notice the leadin line at
the start of the Finish Mill tool path. The
angle is perpendicular to the start angle at the
beginning of the arc.
You can click in the graphics area, then press S on the keyboard to change the display
back to shaded.
13. Right click Part Setup1 in the tree and select Post Process.
14. In the Post Output File dialog box, use the default or type a file name and save the file.
15. Click the Run button in the Post Process Output dialog box to output the G-Code file.
16. After reviewing the code, click OK to close the dialog box.

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 2 Axis Mill 7

2 Axis Mill 7
What You'll Learn
• Extracting Machinable Features and Generating Operations
• Creating an Entry Drill Operation and Generating Toolpaths
• Specifying a Tool Overlap on Open Air Segments
• Using an Avoid Area
• Defining Rapid and Clearance Planes

EXERCISE 1. Open the part file Mill2ax_8.pcii in the \procad\pcii\learn\solid folder.

2. Click the Solids button on the CAD/CAM toolbar.

3. Click the Solids Machining Feature Tree tab at the bottom of the Part Manager.
4. Right click Mill machine – Inch in the Solids Feature tree and select Parameters.
5. Click the Tool crib tab and make sure Crib 1 is the Active tool set.
6. Click the Controller tab and make sure FANTUTM is selected, then click OK.
Extracting Machinable Features and Generating Operations
EXERCISE 1. Click the Extract Machinable Features button on the Solids toolbar or right click NC
Manager and select Extract Machinable Features.
Automatic Feature Recognition creates the Part Setups necessary to machine all of the
machinable features that are recognized. In order to machine the open profile on the right
side of the part with a keyway cutter, you interactively insert the features in a different
lesson.
2. Right click Part Setup1 in the tree and select Generate Operation Plan.
Note that if you click the Generate Operation Plan button on the Solids toolbar,
operations will be generated for all Part Setups. For this exercise, you only need the
operations in Part Setup1.
3. Click the Solids Machining Operation Tree tab at the bottom of the tree.
The operations are listed in the Operation tree.
Creating an Entry Drill Operation and Generating Toolpaths
EXERCISE 1. Right click Rough Mill3 in the Solids Operation tree and select Parameters.
This is the rough operation for the large pocket on top of the part.
2. Click the Roughing tab in the Machining Parameters dialog box and make sure the
Pattern is set to Pocket Out.
3. Click the Feature Options tab.

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2 Axis Mill 7

This page contains parameters that allow you to set the entry type, start location, retract
point and the machining depth for the machinable features associated to the Rough Mill
operation.
4. Click the down arrow next to the Entry type Method and select Entry Drill.
The Generate Operation Plan command does not create Entry Drill operations. If this
option is selected, an Entry Drill operation is created automatically each time toolpaths
are generated for the finish operation. The XY location for the entry drill is at the same
position as the specified Entry Point.
5. Click in the salmon colored Entities selected box in the
Entry point section and pick the edge of the upper hole.
6. Click in the Entities selected box in the Retract point
section and pick the edge of the lower hole.
7. Click OK to exit the dialog box.
8. Right click Part Setup1 in the Operation tree and select
Generate Toolpath.
Toolpaths are created for all
operations in this Part Setup.
9. Left click the Entry Drill
operation in the tree.
The drill toolpath displays at
the hole you selected as the
entry point.
10. Left click Rough Mill3 in
the tree.
11. Rotate the part and notice
that the toolpath starts at the
specified hole for the entry
drill and ends at the hole
specified as the retract point.

Specifying a Tool Overlap on Open Air Segments

When machining an Open Pocket, Slot, Corner Slot or Face Feature, the Feature Parameters
tab in the Machining Parameters dialog box allows you to specify how much to overlap the
air segment edges for 2 Axis rough and finish operations. The amount is specified as a
percent of the tool diameter up to 150%.
EXERCISE 1. Left click Rough Mill1 in the tree.
This is the operation for the Rectangular Slot.

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2. Zoom up on the toolpath and rotate the part to view the

open slot toolpaths.
The toolpath was generated with the overlap set at 75% of
the tool diameter.
3. Right click Rough Mill1 and select Parameters.
4. Click the Feature Options tab.
5. In the Air segment offset, change the % Tool diameter to
100 and click OK.
6. Generate the toolpath.
Notice the overlap on the open side of the slot.

Using an Avoid Area

After rough and finish toolpaths have been generated, you can add avoid areas. Avoid areas
can be used as a definition for clamps and large holes in the feature where machining is to be
avoided.
EXERCISE 1. On the System toolbar, change the View to
1 Top.
2. Click the All button at the bottom right of
the ProCAM window to fit the complete
part in the graphics area.
3. Left click Rough Mill3 in the tree and notice
the toolpath.
4. Right click Rough Mill3 in the tree and
select Insert Avoid Area.

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5. In the 2 Axis Wizard dialog box, select

sf000764 in the Available sketches list. This
is a cross section entity that was created to
represent the perimeter of the drafted
pocket.
Optionally, the Offset option allows you to
offset the avoid area.
6. Click Finish.
7. Click the plus sign (+) next to Rough Mill3.
The avoid area is identified as Avoid Area1.
If you wanted to delete an avoid area, you
would highlight it in the tree and press the
Delete key on the keyboard.
8. Right click Rough Mill3 and select
Generate toolpath.
Notice that the toolpath avoids the selected
sketch.

Defining Rapid and Clearance Planes

For 2 Axis mill operations, the definition of Rapid and Clearance planes can be done locally
within each operation or globally from the Part Setup level.
EXERCISE 1. Right click Rough Mill1 in the tree and select Parameters.
2. Click the NC tab and notice that the Use Part Setup definition options are not checked.
The operations generated for this part all use the default settings that were defined for this
operation in the Technology Database. When the Use Workpiece definition option is not
checked, you can select a different method to define the Rapid and Clearance plane Z
depth.
3. In the Rapid plane section, check the Use Part Setup definition option.
The method and depth change to the current setting for the Part Setup and the options are
grayed out.
4. Click OK.
5. Right click Finish Mill1 in the tree and select Parameters.
6. On the NC tab, check the Use Part Setup definition in the Rapid plane section, then click
OK.

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7. Right click Part Setup1 in the tree and select Parameters.

8. Click the NC Planes tab.
The options on this tab provide methods for identifying the Rapid and Clearance plane
locations for all operations generated for 2 and 2.5 Axis features in a Part Setup.
9. Click the arrow in the Rapid plane is above section and select Top of Workpiece in the list.
10. Set the Distance to 1.00" and click OK.
This value is the distance above the specified location that defines the Z value of the
Rapid plane.
The message displays: The Rapid or Clearance Plane value for an operation is higher than
the value for the Part Setup. Change the Part Setup definition to the highest operation
value?
11. Click Yes.
A Warning message displays indicating that the toolpaths need to be regenerated because
the origin or machining direction has changed.
12. Click Yes.
The toolpaths are regenerated based on the changed setting for the Rapid plane.

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For More Practice

For More Practice

The following exercises provide a chance for you to practice. Instead of the detailed steps in
the previous exercises, only a brief description of the procedure is included.
Part1
Since this part is rectangular, you do not have to machine the outside of the part. AFR will
find the holes and the pocket.
• Open the part file MILLP1.PCII in the \procad\pcii\learn\solid folder.
• Click the Solids Machining button on the
CAD/CAM toolbar.
• Change to the Solids Machining Feature
tree.
• Right click on Mill machine – mm in the
tree and select Parameters. Make sure an
active tool crib and controller are
selected.
• You can use the default bounding box for
the Workpiece.
• Click the Extract Machinable Features
button on the Solids toolbar.
• Right click on the Rectangular Pocket1
feature and select Parameters. Make sure the Attribute is set to Rough Finish.
• Right click on the Hole Pattern1 feature and select Parameters. Change the Attribute to
Ream.
• Click the Generate Operation Plan button on the Solids toolbar.
• Switch to the Operation tree.
• Click the Generate Toolpath button on the
Solids toolbar.
• Right click on the Part Setup and select
Simulate Toolpath. Run the simulation.
• Click the Post Process button on the
Solids toolbar.

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Part2
Since this part is rectangular, you do not have to machine the outside of the part. AFR will
find the holes, bosses, slots, pocket and corner slots.
• Open the part file MILLP2.PCII in \procad\pcii\learn\solid folder.
• Click the Solids Machining button on the
CAD/CAM toolbar.
• Change to Solids Machining Feature tree.
• Right click on the Mill machine – mm in
the tree and select Parameters. Make sure
an active tool set and controller are
selected.
• Right click on the Workpiece and select
Edit Definition. Change the bounding box
Offset to 1mm.
• Extract Machinable Features.
• Right click on the Rectangular Pocket1
feature and select Parameters. Make sure
the Attribute is set to Rough Finish.
• Right click on the Hole Pattern2 feature and select Parameters. Change the Attribute to
Ream.
• Right click on the Part Setup in the Feature tree and select Generate Operation Plan.
• Switch to the Operation tree.
• Reorder the operations using the Sort Operations command so that the Rough Mill
operations are first, followed by the Finish Mill operations and finally the hole
operations.
• Right click on the Part Setup and select
Combine Operations to merge operations
that use the same tool.
In the Combine Operations dialog box,
select the Rough Mill, Finish Mill and
Center Drill options.
• Right click on the Part Setup and select
Generate Toolpath.
• Right click on the Part Setup and select
Simulate Toolpath. Run the simulation.
• Right click on the Part Setup and select
Post Process.

Learning More 2 Axis Mill 2-23

For More Practice

2-24 Learning More 2 Axis Mill

Chapter 3 Learning 3 Axis Mill

This chapter provides an opportunity to learn 3 Axis Mill through a step by step hands-on
tour of the features and functions.
We recommend that you go through the exercises in Chapter 1 and Chapter 2 first. In
addition to learning how to generate 2 axis mill toolpaths, these exercises explain basic
functions and procedures that are used to generate both 2 and 3 axis mill toolpaths and NC
code.
The exercises in this chapter are intended to show you how to use Solids Machining and may
not correspond to actual machining practices.
The part files used in these exercises were originally Parasolid (x_t) files that were opened in
ProCAM and saved in ProCAM (.pcii) format.

IMPORTANT! Solids Machining uses a set of knowledge-based rules to assign machining

operations to features. The Technology Database contains the data for the machining
process plans and can be customized for your facility's machining methodology. When you
do these exercises, your results may not be the same as described in the steps and illustrated
in the figures. This is because the machining sequences and operations data in your
Technology Database may be different from the database used to produce the
documentation.

Learning 3 Axis Mill 3-1

3 Axis Mill 1

3 Axis Mill 1
This exercise provides a hands-on introduction to generating toolpaths and NC code for 3
axis machining.

What You'll Learn

Defining the Machine, Workpiece and Machining Direction
EXERCISE 1. Open the part file Mill3ax_1.pcii in the \procad\pcii\learn\solid folder.
This part was originally a Parasolid (x_t) file that was opened in ProCAM and saved in
ProCAM (pcii) format.
2. Click the Solids Machining button on the CAD/CAM toolbar.
3. Click the Solids Machining Feature Tree tab at the bottom of the
Part Manager.
Define the machine:
4. Right click Mill machine –
Inch in the Solids Feature tree
and select Parameters.
On the Machine tab, Mill
machine – Inch is the active
machine. This machine definition
has been created for these
exercises. When you use
ProCAM to machine your own
parts, select the machine tool you
want to use to machine the part.
5. Click the Tool Crib tab and make
sure Tool Crib 1 is the Active tool set.
6. Click the Controller tab and make sure FANTUTM is selected, then click OK to close the
dialog box.
In the exercises in this manual, when you choose a controller type, select FANTUTM.
This is a sample post processor and is not intended for production use. When you create
your own parts, pick the post processor that will be used to cut the part.
7. Click OK to close the Machine dialog box.
Define the workpiece size and shape:
8. Right click the Workpiece and select Edit Definition on the shortcut menu.

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 3 Axis Mill 1

9. Select Sketch.
The term "sketch" is used to
identify a cross section entity
that can be created to
represent a workpiece, define
features, define a location for
the Part Setup origin, and to
identify contain and avoid
areas for machining. The
procedure to create cross
section entities is explained
in Chapter 1.
10. In the Sketch dropdown list,
select sf000128.
When the cross section entity was created, ProCAM automatically assigned this
identification number.
11. Set the Height to 1.500in and press Enter.
12. Click OK.
Define the machining direction, which will be normal to the face indicated below:
13. Right click Workpiece
in the Solids Feature
tree and select Insert
Part Setup on the
shortcut menu.
14. Pick the top face, then
click OK.
Part Setup1 is added to
the tree.

Creating a 3 Axis Feature

In this exercise, AFR is not used since there are no 2 axis features on the part for AFR to
find. You add the 3 axis feature interactively.
Define a 3 axis feature that includes the faces on the part to cut.
EXERCISE 1. Right click Part Setup1 and select Insert 3 Axis Feature on the shortcut menu.
The Insert 3 Axis Feature dialog box allows you to create and modify a multi-surface
feature. In this example, you cut all the faces.

Learning 3 Axis Mill 3-3

3 Axis Mill 1

2. Click the Select All button

under the Faces to Cut area.
Faces to cut shows 30 Faces.
3. Set the Attribute to Core. This
attribute is defined in the
Technology Database to
generate rough and finish
operations.
4. Click OK.
The 3 Axis feature is listed in
the Solids Feature tree.

Generating an Operation Plan

EXERCISE Generate machining operations for the 3 Axis feature:

1. Click the Generate Operation Plan button on the Solids toolbar or right click Part
Setup1 in the Solids Feature tree and select Generate Operation Plan.
2. Click the Solids Machining Operation Tree tab at the bottom of
the tree.
The Operation tree lists 3 Axis Rough and Finish Mill operations.
Modify machining parameters:
3. Click the Options button on the CAMWorks
toolbar or right click NC Manager in the tree and
select Options.
4. On the Features tab, set the 3 Axis part deviation to
.005", then click OK.
For 3 Axis machining, it is necessary to provide a
part model deviation. For more information, see the
Solids Machining online Help.
5. Right click 3 Axis Rough Mill1 in the tree and select Parameters.
6. Click the Tool Crib tab.
7. Click the check box to the left of the Filter button, then click the Filter button.
The Tool Select Filter dialog box displays. This dialog box allows you to
set filters for displaying and selecting tools.
8. Click the check box for the Filter by option to the right of the Type
type list box.
9. Select Ball Nose for the Tool type and click OK.

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 3 Axis Mill 1

The tool list on the Tool

Crib tab changes to display
only Ball Nose tools.
When you set a tool filter
for an operation, the
setting is stored and
becomes the default for
that type of operation. You
can change the filter
settings as required or turn
off the filter by clearing
the check box.
10. Select a .25"" diameter
ball nose, then click the
< - Select button.
11. Click Yes to replace the
corresponding holder.
12. Click the Rough tab.
13. Set the Mach. deviation
to .01in.
This parameter defines a
tolerance that is used to
condense or shorten the
3 axis toolpath. The
smaller the value, the
greater the number of
linear cuts and the
smoother the surface
finish.
14. For the Processing
Engine, select
Generation 2.
This engine provides
numerous benefits over
the Generation 1 engine:
− For more complex models with smaller machining deviations, the toolpath calculation
time can be significantly less.
− More depth control options are available providing various methods for defining
machining depths and how the depths are processed.
− Additional options are provided to selectively define areas to machine.
− Entry methods have been improved and include a spiral entry method.
Generation 2 is the recommended method. However, if the Generation 2 engine does not
produce the desired toolpath, you can try Generation 1.

Learning 3 Axis Mill 3-5

3 Axis Mill 1

15. In the Depth parameters section, set the First cut

amount and Sub. cut amount parameters to .125in.
16. Click the Feature Options tab and make sure the XY
extents option is set to Workpiece, then click OK.
When Workpiece containment is selected, the
toolpath center extends to the XY perimeter of the
workpiece/contain volume.
17. Right click 3 Axis Finish Mill1 in the tree and select
Parameters.
18. On the Finish tab, select Slice for the Pattern. This
pattern, which generates series of linear parallel cuts
across the part, is appropriate for semi-finishing
almost any part shape and finishing non-vertical areas.
19. Make sure the Allowance is 0.0".
This value represents the amount of material left on the part after generating the toolpath.
20. Set the Mach. deviation to .01".
21. Use Stepover for the Step control and set the Stepover value to .025", then click OK.
Generating Toolpaths and Post Processing
EXERCISE Generate toolpaths, simulate material removal and post process:

1. Click the Generate Toolpath button on the Solids toolbar or right click Part Setup1 in
the Operation tree and select Generate Toolpath.
2. Right click Part Setup1 and select Simulate Toolpath.

3. Click the Turbo mode button on the Simulate Toolpath toolbar.

Turbo mode provides ultra-fast simulation of toolpaths on a single Part Setup.

4. Click Run.
5. Click the X button to exit the simulation.
6. If you were generating the NC program for this part, the last step would be click the
Post Process button on the Solids toolbar and post process the part.

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 3 Axis Mill 2

3 Axis Mill 2
What You'll Learn
• Inserting a Part Setup
• Creating a 3 Axis Feature
• Generating Z-level Rough and Finish toolpaths
• Adding levels and machining depths for 3 Axis Rough toolpaths
• Changing 3 Axis Finish and Rough operation parameters to generate Core toolpaths
EXERCISE 1. Open the part file Mill3ax_2.pcii in the \procad\pcii\learn\solid folder.

2. Click the Solids Machining button on the CAD/CAM toolbar.

3. Click the Solids Machining Feature Tree tab at the bottom of the Part Manager.
Define the machine:
4. Right click Mill machine – Inch in the Solids Feature tree and select Parameters.
− On the Machine tab, Mill machine – Inch is the Active machine.
− Click the Tool Crib tab and make sure Crib 1 is the Active tool set.
− Click the Controller tab and make sure FANTUTM is selected, then click OK.
Define the workpiece:
5. Right click the Workpiece in the tree and select Edit Definition on the shortcut menu.
6. In the Define Workpiece dialog box, select Sketch for the Define workpiece from option
and select sf000401.
When the cross section entity was created to represent the workpiece, ProCAM
automatically assigned this identification number. The procedure to create cross section
entities is explained in Chapter 1.
7. Set the Height to 1.3" and press Enter.
8. Click OK.
Inserting a Part Setup and Creating a 3 Axis Feature
EXERCISE Insert the Part Setup and create a 3 Axis Feature:
1. Right click the Workpiece and select Insert Part Setup.
2. Pick the top of the round cone shown in the figure.
3. Make sure the Face option is not checked, then click
OK.
4. Right click the Part Setup in the tree and select Insert 3
Axis Feature.
5. In the Faces to cut section, click the Select All button.
6. For the Attribute, select Zlevel-SemiCav, then click OK.

Learning 3 Axis Mill 3-7

3 Axis Mill 2

Generating Z-level Rough and Finish toolpaths

EXERCISE Generate operations and toolpaths:

1. Click the Options button on the Solids toolbar and click the Features tab in the
Options dialog box.
2. Change the 3 axis part deviation to .005" and click OK.
When a feature is machined with a 3 Axis Mill machining cycle, the faces of the feature
are approximated by triangles called facets. The 3 Axis part deviation defines the
maximum deviation between any facet and the actual part face. In this exercise, you
generate toolpaths several times and changing this value will increase the speed the
toolpaths are generated.
3. Click the Generate Operation Plan button on the Solids toolbar.

4. Click the Solids Machining Operation Tree tab at the bottom of the tree.
Notice that three operations have been generated from the data in the TechDB. For this
example, you need only one finish operation.
5. Left click 3 Axis Finish Mill1 and press the Delete key on the keyboard.
6. Click Yes to confirm the deletion.
7. Right click the 3 Axis Rough Mill1 in the tree and select Parameters.
8. On the Mill Tool tab, make sure the tool is a .375" Flat End mill.
9. On the Rough tab, make sure these parameters are set to the following values:
− XYZ allowance = .025"
− Mach. deviation = .005"
− Processing Engine = Generation 2. This is the recommended setting (see page 3-5).
− First cut and Sub cut = .185"
10. On the Feature Options tab, set the Containment XY extents option to Feature silhouette.
11. Click OK.
12. Right click 3 Axis Rough Mill1 in the tree and select Generate Toolpath.
13. Change the View to 2 Front.
14. Left click 3 Axis Rough Mill1 in the tree to display the toolpath.
Notice the toolpath levels as they relate to the flats on the part. By default, Engine
Generation 2 creates a Z cut level at an Allowance above the top of the feature (if the
workpiece is above the highest
face in the feature) and a cut at
an Allowance above the lowest
flat face in the feature. The
.185in depth of cut has left a
large amount of material.

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 3 Axis Mill 2

Changing Machining Depths for 3 Axis Rough Toolpaths

ProCAM provides a Hit flats option to automatically add extra roughing levels for each flat
area on a part, so that you are leaving the proper stock allowance at those levels.
1. Right click 3 Axis Rough Mill1 in the tree and select Parameters.
2. On the Rough tab, select the Hit Flats option and click OK.
When the Hit flats option is selected, additional cuts are inserted in the toolpath at a Z
location equal to the Allowance above any flat face between the top and bottom of the
feature. These flat faces may define ledges or island tops.
3. Right click 3 Axis Rough Mill1
in the tree and select Generate
Toolpath.
Notice the toolpath levels as
they relate to the flats on the
part.
When you use the Generation 2 Engine, additional options are provided for controlling the
start and end depths of the toolpath. For example, if you use another operation to face the top
of the cavities, you can start the toolpath at the top of the cavities.
4. Right click 3 Axis Rough Mill1 in the tree and select Parameters.
5. Click the Feature Options tab.
6. In the Containment section, change the XY extents option to Cavity and the First cut
from option to Top of cavity.
7. Click OK.
8. Right click 3 Axis Rough Mill1 in the tree and select Generate Toolpath.
Notice the first toolpath level.
ProCAM calculates the toolpath
and deletes the cuts above the top
of the cavities.
9. Right click 3 Axis Rough Mill1
in the tree and select Parameters.
10. On the Feature Options tab, change the XY extents to Feature silhouette, the First cut
from option to Top of feature and set the Offset to -.15in, then click OK.
11. Right click 3 Axis Rough Mill1 in the tree and select Generate Toolpath.
Notice the first toolpath level.
If you use the Generation 1 processing engine, after the toolpaths have been generated
for a 3 Axis Rough operation, machining depths can be interactively added or subtracted
using the Z Level Edit tab in the Machining Parameters dialog box. The Z Level table shows
the levels and depths that were generated based on the settings for the First cut and
Subsequent cut parameters on the Rough tab. You can use this table to add and delete Z
levels and/or change the depth of each pass. When the toolpath is regenerated, it is updated
based on the Z depths specified in this table.

Learning 3 Axis Mill 3-9

3 Axis Mill 2

Generating Core Toolpaths for Finish and Rough Operations

EXERCISE Change the 3 Axis Z-level Finish operation to generate a core toolpath:
1. Right click 3 Axis Finish Mill2 in the tree and select Parameters.
2. On the Finish tab, set the Mach. deviation to .005" and click OK.
3. Right click 3 Axis Finish Mill2 in the tree and select Generate Toolpath.
4. Left click 3 Axis Finish Mill2 in the tree to display the toolpath.
5. Rotate the part and notice that the toolpath does not cut the outer portion of the part. The
toolpath is contained such that the full diameter of the tool is within the silhouette of the
feature as seen from the Part Setup direction.
6. Right click 3 Axis Finish Mill2 and select Parameters.
7. Click the Finish tab and change the Z level to Core.
The Z level finishing pattern provides options to specify whether the toolpath is
contained inside the perimeter of the feature (cavity) or is allowed to machine around the
inside and outside of the feature outline (core).
8. Set the Filter to Cut Outer Most Only.
9. Click the Leadin tab and change the Leadin and Leadout type to Perpendicular.
10. Set the Leadin and Leadout amounts to .25".
11. Click OK.
12. Right click 3 Axis Finish Mill2 in
the tree and select Generate
Toolpath.
Changing the Z level to Core
allowed the outside to be cut.
Setting the Filter to Cut Outer
Most Only trimmed out all the
toolpaths on the inside of the part
as shown in the figure. Notice the
leadin and leadout move at the
beginning and end of each pass.

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 3 Axis Mill 2

13. Right click 3 Axis Finish Mill2

again and select Parameters.
14. On the Finish tab, change the
Filter to Delete Outer Most, then
click OK.
15. Right click 3 Axis Finish Mill2
and select Generate Toolpath.
The toolpath cuts all of the inner
features of the part while the outer
toolpath has been trimmed out.

EXERCISE Change the Rough operation to rough the outside of the part.
1. Right click 3 Axis Rough Mill1 and select Parameters.
2. On the Rough tab, change the Containment XY extents to Workpiece, then click OK.
3. Right click 3 Axis Rough Mill1 and select Generate Toolpath.
ProCAM roughs the outside of the part.

Rough Toolpath with Cavity Containment Rough Toolpath with Workpiece Containment

Learning 3 Axis Mill 3-11

3 Axis Mill 3

3 Axis Mill 3
ProCAM allows parts to be machined using any combination of 2 and 3 Axis machining
operations. This lesson demonstrates how to create 2 and 3 Axis features for the same part
and explains the options you can use when creating a 3 Axis feature.
What You'll Learn
• Creating 2 and 3 axis features and operations for the same part.
• Defining a 3 Axis feature.
• Changing 3 Axis Roughing and Finishing strategies to see the effects on the toolpaths.
Using AFR to Identify 2 Axis Features
EXERCISE 1. Open the part Mill3ax_3.pcii in the \procad\pcii\learn\solid folder.

2. Click the Solids Machining button

on the CAD/CAM toolbar.

3. Click the Solids Machining

Feature Tree tab at the bottom of the
Part Manager.
This part needs to be machined with a
combination of both 2 axis and 3 axis
machining operations. The 2 axis
features include the counterbore holes
and the two pockets on either end of
the main cavity. The cavity itself has
tapered walls as well as a tapered
bottom, which necessitates a 3 axis machining operation.
4. Right click Mill machine – Inch in the Solids Feature tree and select Parameters.
− On the Machine tab, Mill machine – Inch is the Active machine.
− Click the Tool Crib tab and make sure Crib 1 is the Active tool set.
− Click the Controller tab and make sure FANTUTM is selected, then click OK to close
the Machine dialog box.
5. Right click Workpiece in the tree and select Edit Definition.
The default bounding box displays on the part.
6. Click OK to use the default workpiece for this exercise.
When a part contains 2.5 axis features, normally the next step is to allow ProCAM to identify
features automatically using Automatic Feature Recognition. Then, if AFR does not
recognize features that you are certain could be machined with 2 axis cutting cycles, you can
define the features interactively with the Insert 2.5 Axis Features command.

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 3 Axis Mill 3

7. Click the Extract Machinable Features button on the Solids toolbar or right click NC
Manager and select Extract Machinable Features.
ProCAM finds two features: a Rectangular
Pocket Pattern that includes the two rectangles at
the ends of the cavity and a Counterbore Hole
Pattern that includes the four counterbore holes.
Creating 3 Axis Features
You need to create the cavity feature for this part using the Insert 3 Axis Feature command.
EXERCISE In this exercise, you create a 3 Axis Feature and try the different methods for selecting faces
to cut and faces to avoid.
1. Select Surface Display on the Options menu.
2. In the Surface Display dialog box, make sure the Use Surface Color option is selected,
then click OK.
When this option is selected instead of Use Shade Color, the highlighting makes it easier
to pick faces.
3. Right click Part Setup1 and select Insert 3 Axis Feature on the shortcut menu.
The Insert 3 Axis Feature
dialog box displays. A 3 Axis
feature consists of a list of
faces to cut and optionally for
3 Axis Finish operations, a list
of faces to avoid.
4. Click the Select All button
under the Faces to cut.
The Faces to cut shows 78
Faces. When you click the
Select All button, all faces on
the part are added to the Faces
to cut or Faces to avoid list depending on which button is clicked. The Select All button
selects all faces that can be machined from any machining direction.
5. Rotate the part and examine the bottom of the part.
The face is selected because ProCAM determined that the face could be machined,
However, you cannot machine this face from this Part Setup and you can remove it from
the Faces to cut list.
6. Pick the face in the graphics area.
The Faces to cut list changes to 77 Faces.
7. Rotate the part to display the top side.
The Select All command picked almost all faces of the part including those faces that belong
to the 2 axis features. When defining the 3 axis feature, you do not want to include these
additional faces. Next, you learn how to remove these faces from the Faces to cut list.

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3 Axis Mill 3

There are three Select mode options for selecting faces:

• Default: As you pick each face, it is added to the Faces to cut or Faces to avoid list
depending on the current focus. If the face is already in the list and it is selected again,
the face is removed from the list.
• Window selection: ProCAM allows you to define a box around the desired faces by
positioning the cursor at one corner of the box and holding and dragging the cursor to the
opposite corner of the box. Any face within the box will be added to the Faces to cut or
Faces to avoid list depending on the current focus. If the faces are already in the list and
they are picked again, the faces will be removed from the list.
• Adjacent faces: picking one face automatically selects any adjacent faces that share a
common edge with the selected face. For example, if you picked the bottom face of a
pocket, the side faces connected to the bottom would also be selected.
Hot keys are provided to further aid in selecting the faces. If you hold down the CTRL key
when using the Window selection mode or the Adjacent faces mode, the faces are always
added to the current list, even if the faces are already in the list. If you hold down the SHIFT
key when using either of these two modes, the selected faces are always removed from the
current list, even if the faces are already in the list.
8. With the Select mode set to Default,
pick the top flat face.
You can rotate the part or change to
the Top view to pick faces easily.
This face is removed from the Faces
to cut list. You could continue to pick
the other unwanted faces; however,
that might take numerous picks.

9. Change the Select mode to Adjacent

faces.
10. Pick the bottom face in the
rectangular pocket on the left.
The bottom face as well as the side
faces are removed from the Faces to
Cut list. This is because the side faces
are connected to the bottom face.
Using this mode helps you select a
larger number of faces in less time;
however, you still may not want to do
all of the part this way.
11. Change the Select mode to Window
selection.
12. Put the selection box around one of the counterbore holes.
The faces belonging to the counterbore are removed from the list.

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 3 Axis Mill 3

Using the Select All button and a combination of these modes, you could remove all faces
except those that define the cavity. However, selecting the cavity faces would be easier if
you used the Window selection mode instead.
13. Click the Clear All button to remove
all the faces from the Faces to cut
list.
14. Put the selection box around the
cavity.

The Faces to cut list should list

42 Faces.
15. Select Cavity for the Attribute,
then click OK.
A 3 Axis feature is created and
added to the Solids Feature
tree.

Did You Know ...

A copy of an existing 3 Axis feature can be created by right clicking the feature in the
Solids Feature tree and selecting the Copy Feature command. This feature can then be
modified to include more faces, remove some faces, or to define faces to avoid by right
clicking the feature and selecting the Edit Definition command.
In this example, you rough the 3 Axis feature that was just created. In addition, you define a
second 3 Axis feature that will machine the bottom cavity and the top of the boss. When
machining these two faces, it is critical that the fillets at the bottom of the cavity and the near
vertical walls are not gouged. To do this, you define a 3 Axis feature that includes Faces to
cut and Faces to avoid.
EXERCISE Since the 3 Axis feature contains numerous faces to avoid and only two faces to cut, the
faces to avoid are identified first, then the faces to cut.
1. Right click 3 Axis Feature1 in the Feature tree and select Insert 3 Axis Feature.
The Insert 3 Axis Feature dialog box displays.
2. Click the Faces to avoid box to set the focus to the Faces to avoid list.

Learning 3 Axis Mill 3-15

3 Axis Mill 3

3. With Select mode set to Window

selection, window pick around the
faces defining the entire cavity as
done when you defined 3 Axis
Feature1.
4. Click the Faces to cut box to set the
focus to the Faces to cut list.
5. With the selection mode set to
Default, pick the bottom face and the
top of the boss in the middle of the
cavity.
These two faces are
highlighted in the Faces to cut
color. The Faces to cut list
shows 2 Faces and the Faces to
avoid shows 40 Faces.
6. Change the Attribute setting to
Fine.
Based on the rules specified in
the Technology Database, 3
Axis features assigned a Fine
attribute generate only a finish
operation.
7. Click OK.
A 3 Axis feature is created and 3 Axis Feature2 is added to the Feature tree.
Changing 3 Axis Roughing and Finishing Strategies
EXERCISE Now that all features have been defined, you can generate the operation plan:

1. Click the Generate Operation Plan button on the Solids toolbar or right click Part
Setup1 and select Generate Operation Plan.

2. Click the Solids Machining Operation Tree tab

at the bottom of the tree.
A default operations sequence is generated for the
features. A 3 Axis Rough and 3 Axis Finish
operation are assigned to 3-Axis Feature1. A 3 Axis
Finish operation is assigned to 3-Axis Feature2.
3. To see the feature that each operation will machine,
pick the + sign to the left of each operation in the
Operation tree.

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 3 Axis Mill 3

Before generating toolpaths for the 3 Axis features, you can verify and change machining
parameters:
4. Click the Options button on the Solids toolbar or right click NC Manager in the tree
and select Options.
5. On the Features tab, set the 3 Axis part deviation to .01" and click OK.
This parameter allows you to define the deviation for approximating the faces during 3
axis machining.
6. Right click 3 Axis Rough Mill1 in the tree and select Parameters.
7. On the Rough tab, set the Max deviation to .005" and set the Processing engine to
Generation 2.
8. On the Feature Options tab, make sure the Containment XY extents option is set to
Cavity, then click OK.
9. Right click 3 Axis Finish Mill1 in the tree and select Parameters.
10. Click the Tool Crib tab and select a .25" Ball Nose tool.
If Ball Nose tools are not listed, clear the check mark to the left of the Filter button.
11. Click the <-- Select button, then click Yes to replace the corresponding holder
12. On the Finish tab, set the following parameters:
− Finish Pattern = Z Level (so that the cavity and boss sides are finished)
− Z level = Cavity
− Use the defaults for the other parameters
13. Click OK to close the Machining Parameters dialog box.
14. Change the tool for 3 Axis Finish Mill2 to the same .25in ball nose you selected for 3
Axis Finish Mill1.
15. Right click Rough Mill1 in the tree and select Parameters.
16. On the Tool Crib tab, select a .1875" Flat End Mill, then click the <- Select button.
If Flat End tools are not listed, clear the check mark to the left of the Filter button.
17. Click Yes to replace the corresponding holder.
18. Click OK to close the Machining Parameters dialog box.
19. Click the Generate Toolpath button on the Solids toolbar or right click Part Setup1
and select Generate Toolpath.
If you want to change the machining parameters for one operation, you can make the
desired changes, then select the Generate Toolpath command on that operation's shortcut
menu. ProCAM recalculates only the toolpaths for that operation and you avoid what
could be a time-consuming wait for ProCAM to recalculate the toolpaths for the
operations that have not changed.
Did You Know ...
If you change the 3 Axis part deviation, all 3 axis toolpaths should be regenerated.

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3 Axis Mill 3

20. Right click Part Setup1 and select Simulate Toolpath.

21. Click the Turbo button, then click Run.

22. Exit the simulation.
23. If you were generating the NC program for this part, the last step would be to Post
Process the part.

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 3 Axis Mill 4

3 Axis Mill 4
What You'll Learn
• Inserting a Part Setup
• Creating a 3 Axis Feature
• Defining program zero
• Adjusting machining parameters and generating toolpaths
• Simulating material removal
• Generating Finish toolpaths using Slice, Lace, and Pocket patterns
• Inserting a Pencil Mill operation to cut around the parting line of the mouse mold
Defining the Machine and Machining Direction
EXERCISE 1. Open the part file Mill3ax_4.pcii in the \procad\pcii\learn\solid folder.
The rectangular shape of the part
creates a bounding box material block
that works well for machining the
part.
2. Rotate the part to an orientation
similar to the figure.
3. Click the Solids Machining
button on the CAD/CAM toolbar.

4. Click the Solids Machining

Feature Tree tab at the bottom of the
Part Manager.
5. Right click Mill machine – Inch
in the tree and select Parameters.
− On the Machine tab, Mill machine
– Inch is the Active machine.
− Click the Tool Crib tab and make sure Crib 1 is the Active tool set.
− Click the Controller tab and make sure FANTUTM is selected, then click OK.
6. Right click Workpiece in the tree and select Edit Definition.
The default bounding box displays on the part.
7. Click OK to use the default workpiece.

Learning 3 Axis Mill 3-19

3 Axis Mill 4

8. Right click the Workpiece and select Insert

Part Setup.
The Insert Part Setup dialog displays.
9. Select Front from the list of Reference
planes, then click OK.
The new Part Setup is listed in the tree.
Creating a 3 Axis Feature
EXERCISE In this exercise, AFR will not be used since
there are no 2 axis features on the part for AFR
to find. You add the 3 axis feature interactively.
1. Right click Part Setup1 in the tree and select
Insert 3 Axis Feature.
The Insert 3 Axis Feature dialog displays.
2. Click the Select All button under Faces to cut.
The Faces to cut shows 28 Faces. Since you are machining only on the top of this part,
you can remove the sides and bottom faces.
3. Rotate the part and pick the
five side faces and the bottom
faces.
The dialog box indicates 23
Face to cut.
4. Leave the Attribute set to
Slice-SemiCor.
This attribute has been defined
in the TechDB to generate
Rough, Semi-Finish and Finish
operations.
5. Click OK to close the dialog box and create the 3 Axis Feature.
The new 3 Axis Feature is listed under the Part Setup in the Solids Feature tree.
6. Rotate the part to get an isometric view.

Defining Program Zero

EXERCISE 1. Click the Generate Operation Plan button on the Solids toolbar or right click the 3
Axis Feature and select Generate Operation Plan.

2. Click the Solids Machining Operation Tree tab at the bottom of the tree to display
the three operations that have been created.
3. Right click on the Part Setup in the Operation tree and select Parameters.
The Part Setup Parameters dialog box displays. This dialog box allows you to change the
parameters of the Part Setup you inserted earlier.

3-20 Learning 3 Axis Mill

 3 Axis Mill 4

4. Select the Workpiece vertex option

and use the corner position that is
selected by default.
5. Click OK.
The XYZ zero location is now set at
the theoretical top corner of the
material. This is good practice and
will assure that your default rapid
moves will not contact the part.
Note that the corner positions in the
dialog box may not correspond to the
location of the Part Setup indicator
due to the part viewing orientation.

Adjusting Machining Parameters and Generating Toolpaths

EXERCISE 1. Right click on 3 Axis Rough Mill1 in the tree and select Parameters.
The Machining Parameters dialog box displays. The Mill Tool tab identifies the tool
chosen from the TechDB. For this operation, the tool is a .750" flat bottom end mill. You
can change the cut diameter, change the parameters for the tool or select a different tool.
For this exercise, you can use the current tool.
2. Click the Rough tab.
The Rough parameters control the toolpath cuts. The values that display have been set up
as defaults in the TechDB. These values can be changed to apply to the part that is
currently being machined.
3. In the Processing section, select Generation 2 for the Engine.
This engine provides numerous benefits over Generation 1 and is the recommended
setting.
4. Click the Feature Options tab.
5. Make sure the Entry Method is set to Plunge and the Secondary method is set to Outside
workpiece.
When these options are selected, ProCAM sets the entry point for all roughing levels to
start off the end of the currently defined workpiece.
6. Click OK.
7. Click the Generate Toolpath button on the Solids toolbar or right click Part Setup1 in
the tree and select Generate Toolpath.
The Solids Machining Message Window displays the progress of the 3 Axis toolpath
calculation.

Learning 3 Axis Mill 3-21

3 Axis Mill 4

Simulating Toolpaths
The Simulate Toolpath command provides a graphical representation of the material removal
for the verification of machining operations. Running this simulation helps confirm the
toolpaths created and can reduce the need for dry runs on the machine tool.
EXERCISE 1. Right click Part Setup1 in the tree and select Simulate Toolpath.

2. Click the Turbo mode button and change the end condition to Next Operation.

3. Click the Run button to simulate each of the toolpaths.

4. When the simulation is finished, click the Show Difference button.

5. This function shows the difference between the machined model and the SolidWorks
design model. Note the blue area at the parting line showing material left over by the
radius of the ball tool.
6. Click the X button in the upper right corner of the simulation toolbar or press the
Escape key on the keyboard to exit the simulation.
Generating Finish Toolpaths Using the Lace Strategy
ProCAM provides numerous patterns that can be used to semi-finish or finish a 3 axis
feature. Each pattern has unique characteristics that make it suitable for machining
appropriate part model configurations. For some parts, there may be several patterns that can
be used. In the previous exercise, you generated finish toolpaths using the Slice pattern to
generate a parallel plane type toolpath. In this exercise, you use the Lace pattern to see the
difference in the toolpaths.
EXERCISE 1. Click the Options button on the Solids toolbar.
2. Click the Features tab and change the 3 Axis part deviation to .02, then click OK.
When a feature is machined with a 3 Axis Mill machining cycle, the faces of the feature
are approximated by triangles called facets. The 3 Axis part deviation defines the
maximum deviation between any facet and the actual part face.
When a feature is machined with a 3 Axis machining cycle, the faces of the feature are
approximated by triangles called facets. The 3 Axis part deviation defines the maximum
deviation between any triangle and the actual part face. The smaller the deviation, the
more triangles will be used to approximate the face and consequently the smoother the
surface finish. As the deviation gets smaller, the time required to generate 3 Axis
toolpaths can increase significantly. For this exercise, you can set the value higher to
generate the toolpaths more quickly.
3. Right click on 3 Axis Finish Mill1 in the tree and select Parameters.
The Machining Parameters dialog displays.
4. Click the Finish tab.

3-22 Learning 3 Axis Mill

 3 Axis Mill 4

5. Change the Pattern to

Lace.
The dialog box displays
different parameters.
With the Lace pattern, the
toolpath is similar to a
zigzag rough pattern that
removes material by
making a series of parallel
cuts across the feature.
6. Click the Curve 1 button.
The Lace toolpath is
calculated based on a
user-defined curve. The
resulting toolpath pattern
is similar to generating a
zigzag or zig roughing
toolpath on the curve and
projecting it onto the
feature faces. This curve
must be closed and is
required for the Lace
pattern.
The 3 Axis Wizard:
Select Geometry dialog
box displays.
7. Set the Offset to .25
and press Enter.
This value is the radius
of the tool and allows
the tool to machine the
bottom of the part.
8. Move the dialog box so
you can see the part.

Learning 3 Axis Mill 3-23

3 Axis Mill 4

9. Select the outer edges of the mouse.

10. Rotate the part if necessary.
Note the curve that is generated from
the selected edges. The toolpath will
be created inside of this bounding
curve.
11. Click the Finish button to close the
dialog box.
12. Click OK to close the Machining
Parameters dialog box.

13. Right click 3 Axis Finish Mill1 in the

tree and select Generate Toolpath.
14. Right click Part Setup1 in the tree and
select Simulate Toolpath.
15. Run the simulation to view the results.

Inserting a Pencil Mill Operation

EXERCISE For the Slice, Pocket and Lace toolpaths, the final finish mill leaves a .125 radius at the
parting line. You can add anther operation to clean out that area.
1. Click the Options button on the Solids toolbar.
2. Click the Features tab and change the 3 Axis part deviation to .001, then click OK.
3. Right click 3Axis Finish Mill2 in the tree and select Insert Operation.
4. In the Insert Operation dialog box, change the Type of operation to Pencil Mill.
5. Select 3 Axis Feature1 and click the Add button.
6. Click OK.
The Pencil Mill1 operation is listed in the tree.

3-24 Learning 3 Axis Mill

 3 Axis Mill 4

7. Right click Pencil Mill1 and select Parameters.

8. On the Mill Tool tab, change the cut diameter to .125.
9. Click the Pencil Mill tab.
10. For the Pencil Mill Type,
leave Parallel Lace
selected.
With Parallel Lace
selected, the cutting
motion of the tool is
perpendicular to that for
corner lacing. The tool
strokes are parallel to each
other where the distance
between strokes is equal to
the Stepover amount. The
size of the region being
machined is based on a
user-defined previous tool
diameter and the diameter
of the current tool.
Toolpaths will be created
in corner areas whose radii
are less than the radius of
the Previous Operations Tool
diameter.
11. Change the Stepover to .02".
12. Change the Mach. deviation to .001.
The Mach. deviation controls the
accuracy of the tool offset for each
tool.
13. In the Previous Operations section,
change the Tool diameter to .25,
which was the diameter of the
previous finish tool.
14. Click the Leadin tab and set the
Leadin and Leadout amount to .125",
then click OK.
15. Right click Pencil Mill1 and select
Generate Toolpath.
ProCAM generates the toolpath.
16. Right click Pencil Mill1 and select Simulate Toolpath.
17. Run the Simulation to view the results.

Learning 3 Axis Mill 3-25

3 Axis Mill 5

3 Axis Mill 5
For a 3 Axis Finish operation, the Flowline pattern has unique characteristics that make it
appropriate for machining areas that are defined using loft or sweep features.
The Flowline pattern produces toolpaths based on two user-specified curves. The toolpath
can be generated parallel to (Along) or between (Across) the two curves. The curves can be
either open or closed.

What You'll Learn

• Generating Flowline machining toolpaths using curves to direct the flow of the toolpath
• Using contain and avoid areas to modify toolpaths
EXERCISE Define the Part Setup and insert the 3 Axis Feature:
1. Open the Open the part file Mill3ax_5.pcii in the \procad\pcii\learn\solid folder.
2. If necessary, rotate the part to a view similar to the figure below.
3. Click the Solids Machining button on the CAD toolbar.

4. Click the Solids Machining Feature Tree tab at the bottom of the Part Manager.
5. Right click Mill machine - Inch in the tree and select Parameters.
− On the Machine tab, Mill machine – Inch is the Active machine.
− Click the Tool Crib tab and make sure Crib 1 is the Active tool set.
− Click the Controller tab and make sure FANTUTM is selected, then click OK.
6. Right click the Workpiece and select Edit Definition.
7. Click OK to use the default Workpiece for this exercise.
8. Right click the Workpiece and select Insert Part Setup.
The Insert Part Setup dialog displays.
9. Select Front from the list of Reference planes.
10. Make sure the Face option is not checked, then click OK.
The new Part Setup is listed in the Feature tree.
11. Right click Part Setup1 in the tree and select Insert 3 Axis Feature.

3-26 Learning 3 Axis Mill

 3 Axis Mill 5

12. In the Insert 3 Axis Feature dialog box, click

the Adjacent faces option, then pick top face
on the part.
The Faces to cut lists 5 Faces.
13. Set the Attribute to Fine, then click OK.
This attribute has been set up in the TechDB
to generate one 3 Axis Finish operation.

Generating Finish Toolpaths Using the Flowline Pattern

EXERCISE Generate an Operation Plan, modify machining parameters and generate toolpaths:

1. Click the Generate Operation Plan button on the Solids toolbar.

2. Click the Solids Machining Operation Tree tab at the bottom of the tree.
3. Right click 3 Axis Finish Mill1 in the tree and select Parameters.
4. On the Finish tab, set the
Pattern to Flowline.
5. Set the Mach. Deviation
to .001.
6. In the Curve section, set
the Cut option to Along.
7. Click the Curve 1 button.
The Curve 1 and Curve 2
buttons are used to choose
the curves to direct the
toolpath. Each of the
curves must be a unique
cross section entity.
8. In the 3 Axis Wizard:
Select Geometry dialog
box, select sf000055 in the
Available sketches list.
This is the unique
identification number that
ProCAM assigned when
the cross section entity
was created.

Learning 3 Axis Mill 3-27

3 Axis Mill 5

Cross section entities are listed as sketches in the dialog boxes.

The curve is highlighted on the part and
sf00055 displays in the Entities selected list
and.
Optionally, you can add an offset to the
curve if needed. For this exercise, an offset
is not needed.
9. Click Finish.
10. Click the Curve 2 button.
11. In the 3 Axis Wizard: Select Geometry
dialog box, select sf00054 in the Available
sketches list, then click Finish.
12. Click OK.
13. Click the Generate Toolpath button on
the Solids toolbar.
The toolpath starts in the direction of the
first curve, then translates to the shape of the
second curve as it progresses.

Defining Contain and Avoid Areas to Modify Toolpaths

Finish toolpaths for 3 Axis features can be modified to stay contained within an area or to
avoid a specified area. Contain and avoid areas can be used to selectively machine within
specified areas for re-machining or other purposes.
EXERCISE 1. Right click 3 Axis Finish Mill1 in the tree and select Insert Contain Area.
2. In the 3 Axis Wizard: Select Geometry dialog box, select sf00052 in the Available
sketches list, then click Finish.
The rectangular cross section entity is highlighted on the part.
3. Left click the plus sign (+) to the left of 3 Axis Finish Mill1 in the tree.
The Contain Area item displays. If you needed to delete the contain area later, you would
highlight and delete this item.
4. Click the Generate Toolpath button on the Solids toolbar.

3-28 Learning 3 Axis Mill

 3 Axis Mill 5

The toolpath is contained within the

rectangular cross section entity that was
chosen for the Contain Area. The toolpath is
trimmed to the contain geometry. The
radius of the tool would pass beyond this
boundary. Use the Offset value when
choosing the curve if this is not desirable.
5. Right click 3 Axis Finish Mill1 in the tree
and select Insert Avoid Area.
Notice that the Insert Contain Area
command is not listed on the menu. There
can be only one contain area per operation.
6. In the 3 Axis Wizard: Select Geometry
dialog box, select sf00053 in the Available
sketches list, then click Finish.
7. Click the plus sign (+) to the left of 3 Axis Finish Mill1 in the
tree.
The Contain Area and Avoid Area items display.

8. Click the Generate Toolpath button on

the Solids toolbar.
The toolpath is generated based on the
contain and avoid areas. You can insert
multiple avoid areas in the same operation.

Learning 3 Axis Mill 3-29

3 Axis Mill 6

3 Axis Mill 6
ProCAM provides numerous patterns that can be used to finish or semi-finish a 3 Axis
feature. Each pattern has unique characteristics that make it appropriate for machining
appropriate part model configurations. The following exercises explain how to generate
toolpaths using UV, Spiral, Radial and Offset patterns. While you may not use these for
general machining, occasionally you will machine a part that is appropriate for one of these
styles.

What You'll Learn

• Inserting operations
• Generating Finish toolpaths using the UV, Spiral, Radial and Offset machining styles

EXERCISE Define the Part Setup and insert the 3 Axis Feature:
1. Open the Open the part file Mill3ax_6.pcii in the \procad\pcii\learn\solid folder.
2. If necessary, rotate the part to an orientation similar to the figure below.
3. Click the Solids Machining button on the CAD/CAM toolbar.

4. Click the Solids Machining Feature Tree tab at the bottom of the Part Manager.
5. Right click Mill machine – Inch in the tree and select Parameters.
− On the Machine tab, Mill machine – Inch is the Active machine.
− Click the Tool Crib tab and make sure Crib 1 is the Active tool set.
− Click the Controller tab and make sure FANTUTM is selected, then click OK.
6. Right click the Workpiece and select Edit
Definition.
7. Click OK to use the default workpiece for
this exercise.
8. Right click the Workpiece and select Insert
Part Setup.
9. In the Part Setup dialog box, select Top
from the list of Reference planes, then
click OK.
10. Right click Part Setup1 in the tree and
select Insert 3 Axis Feature.
11. Pick the revolved surface on the top of the
part.
12. In the Insert 3 Axis Feature dialog box, set
the Attribute to Fine to generate only a
finish cut, then click OK.

3-30 Learning 3 Axis Mill

 3 Axis Mill 6

Generating Finish Toolpaths Using the UV Pattern

EXERCISE Change the Part Setup origin, generate the operation, modify the machining parameters and
generate the toolpath:
1. Click the Generate Operation Plan button on the Solids toolbar.

2. Click the Solids Machining Operation Tree tab at the bottom of the tree.
3. Right click Part Setup1 in the Solids Operation tree and select Parameters.
4. On the Origin tab, select the Workpiece
vertex option and pick a corner position that
moves the Part Setup indicator to the top of
the material.
Note that the corner positions in the dialog
box may not correspond to the location of
the Part Setup indicator due to the part
viewing orientation.
5. Click OK.
6. Right click 3 Axis Finish Mill1 in the tree
and select Parameters.
7. On the Mill Tool tab, change the Cut Diameter to .25.
8. On the Finish tab, select UV for the Pattern.
9. Set the Max Scallop to .01.
10. Change the Mach. deviation to .001.
11. In the UV Options section, click the Direction button.
12. In the Feature Direction dialog box, select
the Reverse direction option to reverse the
direction of the toolpath, then click OK.
13. Make sure the Fillet machine option is not
checked, then click OK to close the
Machining Parameters dialog box.
14. Click the Generate Toolpath button
on the Solids toolbar.
15. Left click 3 Axis Finish Mill1 in the tree
to display the toolpath.
The toolpath follows the shape of the part.
The UV pattern removes material by
making a series of cuts along the U or V
flow directions of the surface.

Learning 3 Axis Mill 3-31

3 Axis Mill 6

The UV pattern produces perhaps the best-machined finish because it follows the UV
flows of each individual surface. Whether the slope of the face is shallow or steep, the
resulting finish will be consistent. To achieve this consistent finish, each face in the
feature is machined completely, one at a time.
Generating Finish Toolpaths Using the Radial Pattern
EXERCISE Insert an operation, change the Finish pattern to Radial and generate the toolpath:
1. Right click 3 Axis Mill Finish1 in the tree and select Insert Operation.
This command allows you to insert additional operations. In some situations, the
operations defined for a feature in the TechDB may not be sufficient and additional
operations may be required. Inserting operations in this exercise allows you to easily
compare the toolpaths generated by the different patterns.
2. In the Insert Operation dialog box, select 3 Axis Finish Mill for the Type of operation.
3. Select 3-Axis Feature1 in the list box on the left and click the Add button.
4. Click OK.
The new operation is listed in the tree.
5. Right click the new 3 Axis Finish Mill2 item in the tree and select Parameters.
6. On the Mill tab, change the Cut Diameter to .25.
7. On the Finish tab, change the Pattern to Radial.
8. Leave the Angular increment set to 1 degree.
Each pass of the radial toolpath is defined by an angular increment.
9. Change the Mach. deviation to .001.
10. Click the Center Point button at the bottom of the dialog box.
The Define Point dialog box displays. This dialog box allows you to define the center of
the radial toolpath. You can define the applicable point relative and associative to a
vertex, planar arc edge or arc segment defined in a cross section entity on the part.
11. Make sure the cross section entity is highlighted in the Available sketches list, then click
OK.
12. Leave the Start on option set to Inside.
This option allows you to specify whether the tool will enter the material at the center or
on the diameter of the radial pattern.
13. Click OK to close the Machining Parameters dialog box.
14. Right click 3 Axis Finish Mill2 in the tree and select Generate Toolpath.
15. Left click 3 Axis Finish Mill2 in the tree to view the toolpath.
The toolpath radiates from the center out at 1 degree increments.

3-32 Learning 3 Axis Mill

 3 Axis Mill 6

Generating Finish Toolpaths Using the Spiral Pattern

EXERCISE Insert an operation, change the Finish pattern to Spiral and generate the toolpath:
1. Right click 3 Axis Mill Finish2 in the tree and select Insert Operation.
2. In the Insert Operation dialog box, select 3 Axis Finish Mill for the Type of operation.
3. Select 3-Axis Feature1 in the list box on the left and click the Add button.
4. Click OK.
The new operation is listed in the tree.
5. Right click the new 3 Axis Finish Mill3 item in the tree and select Parameters.
6. On the Mill tab, make sure the tool is a Ball Nose with a Cut Diameter of .25".
7. On the Finish tab, change the Pattern to Spiral.
8. Change the Pitch to .05".
This option specifies the stepover distance between each pass.
9. Change the Mach. deviation to .001".
10. Click the Center Point button at the bottom of the dialog box.
11. Make sure the cross section entity is highlighted in the Available sketches list, then click
OK.
12. Click OK to close the Machining
Parameters dialog box.
13. Right click 3 Axis Finish Mill3 in the tree
and select Generate Toolpath.
ProCAM generates a spiraling circular
toolpath starting from the center of the
part. You can set the start and end radius
in the Machining Parameters dialog box
to limit the extents of the toolpath.
14. Right click 3 Axis Finish Mill3 item in
the tree and select Parameters.
15. Change the End radius to 1.5" and click
OK.
16. Right click 3 Axis Finish Mill3 in the tree
and select Generate Toolpath.
ProCAM generates the toolpath from the center outward to the 1.5 end radius.
Generating Finish Toolpaths Using the Offset Pattern
EXERCISE Insert an operation, change the Finish pattern to Offset and generate the toolpath:
1. Right click 3 Axis Mill Finish3 in the tree and select Insert Operation.
2. In the Insert Operation dialog box, select 3 Axis Finish Mill for the Type of operation.
3. Select 3Axis Feature1 in the list box on the left and click the Add button.

Learning 3 Axis Mill 3-33

3 Axis Mill 6

4. Click OK.
The new operation is listed in the tree.
5. Right click the new 3 Axis Finish Mill4 item in the tree and select Parameters.
6. On the Mill tab, change the Cut Diameter to .25".
7. On the Finish tab, change the Pattern to Offset.
8. Change the Mach. deviation to .001".
9. In the Limit control section, change the Type to Number of passes and set the Number of
passes to 25.
The Limit control option allows you to specify whether the toolpath will continue until
the entire part is machined in the direction of the offset or will be generated a specific
number of passes. The first pass is always on the defined curve.
10. Click the Curve 1 button.
The Offset toolpath is calculated based on a user-defined curve, which can be open or
closed.
11. In the 3 Axis Wizard: Select Geometry dialog box, make sure the cross section entity is
highlighted in the Available sketches list.
12. Set the Offset to .126" (slightly larger than the radius of the tool).
13. Select the Flip direction to cut option so the arrow points to the
outside.
14. Click the Reverse option until the curve offsets to the outside of the
part.
15. Click the Finish button, then click OK.
16. Right click 3 Axis Finish Mill4 and select
Generate Toolpath.
ProCAM generates the toolpath in a
pattern of offsets from the user specified
closed curve. The offset is parallel with
the Part Setup. Because the Limit control
is set to 25 passes, the revolved surface is
not machined completely.

3-34 Learning 3 Axis Mill

Chapter 4 Learning 2 Axis Turn

This chapter provides an opportunity to learn 2 Axis Turn through a step by step hands-on
tour of the features and functions.
The exercises in this chapter are intended to show you how to use Solids Machining and may
not correspond to actual machining practices.

IMPORTANT! Solids Machining uses a set of knowledge-based rules to assign machining

operations to features. The Technology Database contains the data for the machining
process plans and can be customized for your facility's machining methodology. When you
do these exercises, your results may not be the same as described in the steps and illustrated
in the figures. This is because the machining sequences and operations data in your
Technology Database may be different from the database used to produce the
documentation.

Learning 2 Axis Turn 4-1

Turn 1

Turn 1
What You'll Learn
Steps to Generate Turn Toolpaths and NC Code
The following steps are used to generate Turn toolpaths and NC code:
1. Create the solid model in a solid model design program and
save the file in one of these formats: Parasolid ASCII (x_t) or
Binary (x_b), ACIS ASCII (sat) or Binary (sab), AutoCAD DWG
(dwg) or DXF (dxf).
2. In ProCAM, set the Units Type in the Units dialog box.
3. Open the solid model file in ProCAM: make sure you select the
applicable file type (x_t, x_b, sat, sab, dwg or dxf) in the Files of
type list and check the Solids option in the Open dialog box.
4. Start Solids Machining and change to the Solids Machining
Feature tree.
5. Define the Machine and modify the controller parameters.
6. Edit the Workpiece definition.
7. Define machinable features and adjust feature parameters.
8. Generate the operation plan and adjust machining parameters.
9. Generate toolpaths.
10. Post process the toolpaths.

START

Adjust machining
parameters as Generate toolpaths
Open solid model needed
file in ProCAM

Post process
Generate operation
Start Solids & plan
change to Solids
Feature tree Transmit file into
Define machinable
CNC
features

Define machine
& change controller
Edit Workpiece
parameters END
definition

4-2 Learning 2 Axis Turn

 Turn 1

The next series of exercises show you how to generate finish toolpaths on a solid model.
When you define the operations and toolpaths, you will follow steps that are not explained in
depth. This is done to show you the basics of generating toolpaths from start to finish
without getting into the details at this time.
Sample parts are provided for the exercises in this manual. When you install Solids
Machining, these files are installed automatically.
Step 1: Open the Solid Model Part
In order for Solids Machining to generate turn toolpaths and NC code, the part must be a
solid model created in a solid model design system that supports exporting to Parasolid,
ACIS, DXF or DWG format.
EXERCISE 1. Select Setup on the menu bar, then select the Units command or use the shortcut key
CTRL + U.
Before opening the solid model file in ProCAM, you must make sure the units are set
correctly in ProCAM. You cannot change the units after a solid model file is opened. The
file used in this exercise was saved in Parasolid format. Since Parasolid uses the metric
system of measurement, when you save a solid model in Parasolid format, the file is
always saved in meters.
2. In the Units dialog box, make sure the Units Type is set to English Decimal, then click
OK.
English Decimal units are used in this exercise. If the Units Type were set to Metric
Decimal, the part units would be meters when it is opened.
3. Click the Open button on the File toolbar.
4. In the Open dialog box, change the Files of type to Parasolid ASCII (*.x_t).
5. Make sure the Solids option is checked.
This option allows you to choose the type of machining you want to use to cut the part:
− If the Solids option is checked, the part is opened as a solid that must be cut using
Solids Machining.
− If the Solids option is not checked, the part is opened as surfaces that must be cut
using Surface Machining.
6. Open the \Procad\pcii\Learn\Solid folder and double-click part file Turn2Ax_1.x_t.
Step 2: Change to Solids Machining Feature Tree
EXERCISE 1. Click the Solids Machining button on the CAD/CAM toolbar.
The Solids Features and Operations tabs display at the bottom of the Part Manager.
If the Solids tabs are not visible, you can expand the size of the Part Manager. Position
the cursor on the line that divides the Part Manager from the graphics area. When the
cursor changes to a bar, drag the bar to the right until the tabs display.
2. Click the Solids Machining Feature Tree tab at the bottom of the
tree. The Feature tree displays. Initially, the tree lists Workpiece,
Machine and Recycle Bin items.

Learning 2 Axis Turn 4-3

Turn 1

The icons that display for the Workpiece and Machine may indicate that a mill
machine is currently selected. Step 3 on page 4-5 explains how to change the machine to
a turn machine.
If you work mainly with turn parts, you can set the default to Turn in the TechDB so that
ProCAM will select a Turn machine and workpiece when you open part files. To change
the default, click the TechDB button on the Solids toolbar. Under the navigation tree in
the Technology Database – Main Menu window, change the Appln default to Turn and
click Quit. When you open a part file, ProCAM will select a Turn machine.

Solids toolbar Solids menu

Graphics area

Feature tree

Part model
Feature
Tree tab
Operation Tree tab

Machining Trees
The Solids Machining trees provide an outline view of the machining information for the
model. Initially, the Feature tree shows the NC Manager, Workpiece, Machine and Recycle
Bin. As you follow the steps to generate an NC program, this tree expands to include Turn
Setups and machinable features. The tabs at the bottom are for moving between the trees.
• Turn Workpiece Mill Workpiece
The turn Workpiece is the stock from which the part will be machined. You can define
the Workpiece as a cylinder (for bar stock) or as a closed sketch (for a forging or casting)
and specify the type of material.
• Turn Machine Mill Machine
The Machine item defines the machine tool that will be used to machine the part. The
machine definition includes tool definitions and the post processor. The machines are set
up in the Technology Database.

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 Turn 1

• Recycle Bin - The Recycle Bin in the Feature tree is used to store machinable
features that you do not intend to machine.
Solids Menu
1. Click Solids on the ProCAM menu bar. The Solids menu lists the Solids Machining
commands. The commands are explained in the online Help.
2. Right click on the NC Manager in the tree. A menu of commands displays. This is a
shortcut menu. The right-click shortcut menus provide access to a variety of commands.
Solids Toolbar
The Solids toolbar provides access to the main commands found on the Solids menu.
Clicking a toolbar button is the same as selecting a command from the NC Manager level,
regardless of the active item in the tree.
1. Locate the Solids toolbar and click the Options button.
2. In the Options dialog box, click each tab to view the options
and settings that you can change.
3. Click the Help button at the bottom of the dialog box. Each tab is explained in the online
Help.
4. Click the Close button in the upper right corner of the Help window to close the window.
5. Click Cancel to close the Options dialog box.

Step 3: Define the Machine

The machine definition specifies the type of machining that will be done for the current
model (i.e., mill or turn) and the associated machine tool control (post processor) for proper
generation of the NC program. Based on the selected machine, the Extract Machinable
Features command will recognize either mill or turn features. The machine can be changed
later to produce NC code for an alternate machine tool of the same type. The icons that
display in the tree identify the machine as either mill or turn.
Turn Machine Mill Machine
1. Right click the Machine item in the Feature tree.
The shortcut menu displays. Right-mouse shortcut menus
display commands that are appropriate for the item that is
highlighted in the tree.
2. Select Parameters on the shortcut menu.
The Machine dialog box displays.

Learning 2 Axis Turn 4-5

Turn 1

3. Select Turn Machine – inch in the list of Available

machines and click the Select button.
This is the machine used for some of the exercises in
this manual. When you use ProCAM to machine your
own parts, select the machine tool you want to use to
machine the part.
Machine tools are set up in the Technology Database.
Before using ProCAM to machine your parts, make
sure you define the machine tools available in your
facility. For more information, see the online Help.

4. Click the Tool Crib tab and

make sure Inch Turret 1 is
selected.
The Tool Crib page allows you
to choose the Turret (set of
tools) that is used with the
machine you have chosen.
These are not all the tools that
are available, but a subset that
you can modify to represent the
actual set of tools that the
machine has loaded.
Inch Turret 1 is a default tool
turret that has been set up for
the sample turn machine. When
you define your machine tools
in the Technology Database,
you can set up your own turrets.
5. Click the Controller tab.

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The Controller tab allows you to select

the post processor. The list that displays
depends on the post processors that are
installed on your system. By default,
ProCAM supplies several default post
processors that may or may not be
suitable for your needs. Contact your
TekSoft reseller for information on
making changes to these post processors
or for other post processors.
If the controllers do not display, use the
Browse button to locate the folder
containing the controller files (*.ctl).
If FANTUTL (the tutorial post
processor) is not highlighted, highlight
it in the list and click the Select button.
FANTUTL is the controller used for the
exercises in this manual. When you use
ProCAM to machine your own parts,
select your machine tool controller or
post processor.
The Current Information area displays
information about the FANTUTL
controller. A short description displays
in the window below the Current
information. This window contains information only if an optional file has been created
for the post processor.
6. Click the More button.
A longer description displays. The More button is activated only if a second optional file
has been created. This information is intended for use in training or as a detailed
description of post processor attributes that can be created.
Information files are provided for the sample FANTUTM post processor. Your TekSoft
dealer or your company manager may be able to supply these files if they are available
for your post processor. If files are not available, you can create post information files as
explained in the online Help.
7. Click the Parameters tab.
These parameters provide information required to
generate the NC program. The parameters are machine-
dependent and different parameters may display for your
controller. The value for a parameter is output in the NC
code if the machine requires it.

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Turn 1

If you have installed the Feed and Speed Library, you can specify a material on this tab or
when you define the Workpiece. If the Feed and Speed Library is not installed, you can
specify the material only on this tab.
The Maximum RPM defines the maximum RPM that your machine allows when running
Constant Surface Feed per Minute (CSFM). This prevents an overspeed spindle alarm as
the tool moves to centerline. If necessary, you can set a lower maximum RPM for
individual operations.
The Z and X Preset values are used by the system for a return position. These values are
absolute numbers from X0,Z0. If your machine requires an absolute preset to be output in
the program, these values are used. If you always change tools at the same position,
setting these values saves you time later.
8. Type 1001 for the Program Number, then click OK to close the Machine dialog box.
Step 4: Edit the Workpiece Definition
The Workpiece is the stock from which the part will be machined. The default Workpiece is
the smallest cylinder (bar stock) that the part will fit into. Typically, this is not the size of the
stock you will be using. You can change the Workpiece definition either by offsetting the
length and/or diameter of the bar stock from the part or by defining the Workpiece from a
closed sketch (for a casting or forging). Currently, the sketch has to be in the same plane as
the Workpiece in terms of the X and Z plane and must be a closed profile. No revolve line is
needed for the geometry.
In this exercise, you define the Workpiece as a cylinder (bar stock) offset from the part in
length.
1. Right click Workpiece in the Feature tree and select Edit
Definition on the shortcut menu.
The Define Turn Workpiece dialog box displays.
2. Leave the Type set to Bar stock.
3. Change the Length dimension to
6.850in and press Enter.
You can leave the Diameter set to
4.00in.
4. Click the Material button.
5. In the Workpiece Material dialog box,
click the down arrow button and select
304L for the Common name, then click
OK.
6. Click OK to close the Define Turn
Workpiece dialog box.

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 Turn 1

3. Change the View to Top.

The Workpiece is updated in the
graphics area.
Notice the Workpiece line moved
out from the face by .100 (in the
+Z-axis direction )

Step 5: Define Machinable Features

In Solids Machining, machining can be done only on machinable features. You use the
following two methods to define machinable features:
• Automatic Feature Recognition (AFR)
Automatic Feature Recognition analyzes the part shape and attempts to define most
common machinable features such as grooves, outside and inside profile features, and
face features. Depending on the complexity of the part, AFR can save considerable time
in defining turn machinable features.
• Interactively created features
If AFR does not recognize a feature you want to machine, you can define the feature
interactively using the Insert Turn Feature command.
Using Automatic Feature Recognition (AFR)
Automatic Feature Recognition is one of Solids Machining's most powerful features. The
idea of AFR is to scan the part for features that can be machined. This process is much the
same as what you would do if you were to pick up a part that you had to machine. You
would look it over, take measurements, and begin deciding what machining processes you
would need.
ProCAM is not machining the design features directly. It creates a separate list of
Machinable Features instead. This is because a single design feature may have several areas
that need to be machined in different ways with different tools.
The part in this exercise contains the following machinable features, which are defined
automatically by AFR:
• One Face Feature
• One OD Profile Feature
• Two Rectangular Groove Features
• One Cutoff Feature

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Turn 1

Define machinable features automatically:

1. Click the Extract Machinable Features button on the Solids toolbar or right click NC
Manager in the tree and select Extract Machinable Features on the shortcut menu.
The Message Window displays. This window
displays automatically to report the progress
of the current process. Generating Setups is
always the last item in AFR. When you see it,
you know the process is almost complete.
You can control whether this window
displays temporarily or permanently by
selecting the Options command on the NC Manager shortcut
menu or the Solids menu and checking the Message Window
option on the General tab in the Options dialog box.
ProCAM generates the Turn Setup and the machinable
features. The items display in the Feature tree.
The Turn Setup is the 2 axis (X and Z) plane that the tool
movement will be based on. It has an origin location, and X,
Y, and Z direction vectors. The Turn Setup is created
automatically; however, you can move the origin and change
the direction and angles of the axis. Most turning applications work in the X and Z plane,
which is relative to the ProCAM Y and X axis plane respectively.
When you define the Workpiece as bar stock, only one Turn Setup (X and Z) is created
and all features will be machined using tool orientations that are relevant for a rear turret
machine configuration.
The Feature tree allows you to:
− Copy, rename, suppress, delete and combine machinable features
− Change machinable feature parameters
− Change the order in which the features are machined
− Insert Turn features
− Search for a feature based on item name
− Hide or show feature display in graphics area
− Generate an Operation Plan and find the first operation for a feature
Most feature parameters are fixed; however, some parameters can be changed using the
Parameters command on the feature shortcut menu.
2. Right click OD Feature1 in the tree and select Parameters on the shortcut menu.

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The OD Profile parameters

include the length,
maximum and minimum
diameter and maximum
back angle. Since there is no
physical information about
the type of profile, ProCAM
allows you to define an
attribute for the profile.
3. Click the down arrow next
to Coarse to see the choices.
Coarse, Taper, Reverse
Taper and Thread are
system attributes. User-
defined attributes are also
listed. For example, RF80-
80 is a shortcut name for
roughing and finishing the
profile using 2 tools (80
degree diamond tools).
4. Leave the Attribute set to
Coarse and click OK or Cancel to exit the dialog box.
Save the part with the machinable feature data:
5. Click the Options button the Solids toolbar.
Note that you can also click Solids on the menu bar or right click NC Manager in the tree
and select the Options command.
6. Make sure the Save/Restore part option on the General tab is checked, then click OK.
If this option is checked, when you save and close a part document, the machining data is
saved. When the part document is opened again, the machining data is restored along
with the part design information.
If this option is not checked, when you save and close a part document that contains at
least one Setup, a message indicates that Save/Restore is disabled. If you click Yes,
ProCAM saves all machining data before closing the file. If you click No, ProCAM
closes the part and discards any new machining data since the last save.
7. Click Save As on the File menu.
The Save As dialog box displays.
8. In the Save As dialog box, type turn1 and click the Save button.
Make sure you save frequently. When you open a file, you are actually working on a
copy of the file. The original is still stored on disk. Periodically saving your file ensures
that your latest work is retained.

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Defining Features Interactively

Automatic Feature Recognition can save a significant amount of time; however, AFR does
have limitations. AFR cannot recognize every feature on complex parts and does not
recognize some features such as certain types of grooves. To machine these areas, you need
to define machinable features interactively using the Insert Turn Feature command.
ProCAM also provides the flexibility to edit machinable features to accommodate machining
requirements. For example, if you want the OD machined in segments to take into account
possible machining rigidity, you can define features for the segments in the OD Feature as
shown in the following exercise.
In this exercise, you insert an OD Feature so that you can rough turn the first OD step of the
part. This OD segment will be finished in the Turn Finish operation for OD Feature1.
1. Right click OD Feature1 in the
Feature tree and select Insert Turn
Feature on the shortcut menu.
The Insert Turn Feature dialog
box displays. The profile of the
part is shown. If necessary, move
the dialog box to view the part.
2. Click in the Selected entities list
box to set the focus.

3. Pick the first OD profile segment

to the right of the groove closest to the
face to select it.
The single segment is highlighted.
4. Click the down arrow next to the
Feature info list box.
The turn machinable features that
can be inserted are listed.
5. Select OD Feature.
6. Click on Extend 2 in the Selected
entities list, then select Along X in
the Extend group.

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This terminates the feature at the end of the segment and up to the
Workpiece major OD.
7. Click OK to exit the Insert Turn Feature dialog box.
OD Feature2 displays in the Feature tree. You have now defined all the
machinable features in this part.
8. Drag OD Feature2 above OD Feature1 in the tree.
You need to reorder these features because you want to rough OD Feature2 before cutting
the entire OD. If you generated operations and toolpaths without reordering, ProCAM
would generate toolpaths for OD Feature1 first, which includes the segment in OD
Feature2. Toolpaths would not be generated for OD Feature2 since there would be no
material left to remove.
Step 6: Generate Operation Plan and Adjust Machining Parameters
An Operation Plan contains information on how each machinable feature is to be machined
and how the NC code will be output. When Generate Operation Plan is run, operations for
each machinable feature are created automatically based on information in the TechDB.
Did You Know ...
In some situations, the operations defined for a feature in the TechDB may not be
sufficient and additional operations may be required. You can insert operations
manually using the Insert Operation command. This command is explained in the
online Help.

1. Click the Generate Operation Plan button on the Solids toolbar or right click Turn
Setup1 in the Feature tree and click Generate Operation Plan on the shortcut menu.
ProCAM generates the operation plan for all the machinable features in Turn Setup1. The
operations are listed in the Operation tree.
2. Click the Solids Machining Operation Tree tab at the bottom of
the tree.
The Operation tree lists the operations that were generated.
The Operation tree provides an outline view of the operations for the machinable
features. Operations are listed under the Turn Setup in the same order as the machinable
features. At the top of the tree is the NC Manager. The Workpiece and Machine items
function the same as in the Feature tree. You can change the definition of your material
block and the controller definition used by ProCAM to produce G-Code.

Learning 2 Axis Turn 4-13

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The Operation tree allows you to:

− Insert, rename, suppress and delete
operations
− Change operation parameters
− Edit the feature list
− Change the machining order
− Generate toolpaths
− Simulate toolpaths
− Hide or show toolpath display
− Post process the toolpaths
− Search based on an item name
3. Click the plus sign (+) next to Turn Finish1.
Clicking a plus sign displays the name of the machinable feature that this operation is
going to machine.
4. Right click Turn Finish1, select Delete on the shortcut menu and click Yes to confirm the
deletion.
− Based on the information in the TechDB, rough and finish operations were generated
for OD Feature2. In this exercise, you want to finish turn this OD segment in the
finish operation for the entire OD (Turn Finish2) so you can delete the finish
operation.
− If you typically machine the OD in segments, you can customize the TechDB and set
up an Attribute to generate only a rough turn operation for this type of OD feature.
The operations that are generated by ProCAM are based on information stored in the
Technology Database. Each operation contains machining parameters that affect how the
toolpath is created and specific parameters that will be output to the NC program. These
parameters can be edited before generating the toolpaths and post processing the part.
5. Right click on Turn Rough1 (OD Feature2) and select Parameters on the shortcut menu.
The Machining Parameters dialog box displays.
This dialog box gives you access to all the parameters used to define the toolpath. This
dialog box also provides access to the parameters for the tool you are using and allows
you to select a different tool.

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6. Click the Rough Turn

tab and remove the
check mark from the
Canned cycle output
option.
7. Change the following:
First cut amount = .15"
Max cut amount = .10"
Final cut amount = .10"
Step in angle = 45^
Step in amount = .01"
Step out angle = 45^
Step out amount = .01"
8. Click OK to exit.
Step 7: Generate Toolpaths
ProCAM calculates toolpaths using the operation parameters to define how to machine each
machinable feature.
1. Click the Generate Toolpath button on the Solids toolbar or right click Turn Setup1
in the Operation tree and select Generate Toolpath on the shortcut menu.
ProCAM calculates the toolpaths for each operation in the Setup.
2. Hold down the Shift key and select the first and last operation in the tree.
The toolpaths for all the operations display on the part showing the centerline of the
toolpath.
3. Left click an operation in the Operation tree.
− The toolpath for that operation displays. As you click each operation, the toolpaths for
that operation display.
− Turning operation parameters can be edited and the operation can be renamed, moved,
suppressed, deleted, etc. after toolpaths have been generated. If you make any
changes, the toolpaths must be updated by selecting Generate Toolpath again at the
Setup level.
Simulate Toolpaths
ProCAM provides the ability to simulate the toolpaths showing the tool movement and the
resulting shape of the part.
1. Click the Simulate button on the Solids toolbar or right click on Turn Setup1 and
select Simulate Toolpath.
The Turning Simulation toolbar displays.

Learning 2 Axis Turn 4-15

Turn 1

Some of the options you can select to customize the simulation include:
− Update the Workpiece after each cut or show the completed part at the end of the
simulation.
− Change the display of the stock, tool, tool holder, and target part (wireframe,
translucent, shaded, or no display).
− Run the simulation to the end or advance by single step or by feature.
− Compare the design part and the simulated part during simulation.
− Show a cross section of the material removal.
− Show holder and fixture collisions.
− Control the simulation speed by dragging the Simulation Speed Control slider up or
down.
If you want to simulate only the toolpath for a given operation, you can right click that
operation, then select Simulate Toolpath.

2. Click the Run button.

The simulation runs in Tool mode with the tool displayed during simulation.
3. Click the X button in the upper right corner to exit the simulation.
Did You Know ...
ProCAM provides an option to display the XZ position of the tool in the Message
Window during simulation. To activate this option, select the Options command on the
Solids menu or the NC Manager shortcut menu. On the General tab, select the Message
Window option. On the Simulation tab, select the Display Coordinates option.

Change the Machining Order

Operations are generated in the same order that the
machinable features are listed in the tree. This may
not cut the part in the order you think is most
efficient or practical for your machining
requirements. You can drag and drop operations in
the tree to reorder them.
1. Drag and drop the Groove operations in the
order shown in the tree on the right.
2. Right click Turn Setup1 in the Operation tree
and select Generate Toolpath on the shortcut
menu.
If you change the order after you generate toolpaths, you must re-generate the toolpaths
so that the work in process can be updated.
3. Right click Turn Setup1 and select Simulate Toolpath.

4. Run the simulation and notice that the groove closest to the face is cut first and both
grooves are rough cut, then finished.

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Step 8: Post Process Toolpaths

Post processing is the final step in generating the NC program file. This step translates
generalized toolpath and operation information into NC code for a specific machine tool
controller. ProCAM creates NC code for each toolpath in the order the toolpath operation
appears in the Operation tree. When you post process a part, ProCAM creates two files: the
NC program and the Setup Sheet. These are text files that you can read, edit and print using a
word processor or text editor.
In this exercise, you post process all the operations and generate the NC program:
1. Click the Post Process button on the Solids toolbar or right click NC Manager in the
Operation tree and select Post Process on the shortcut menu.
The Post Output File dialog box displays so you can name the NC program file.
If you are running ProCAM in
Demo mode, the Post Output File
dialog box does not display because
you cannot save NC code in Demo
mode.
Typically, the NC program and
Setup Sheet files are stored in the
folder that contained the last part
that was opened. If you want these
files in another location, you can
change the folder.
If Post Process is grayed out on a
menu or the Solids toolbar, make
sure that you have selected a post processor and generated the toolpaths.
2. Click the down arrow to the right of the Save as type box.
ProCAM provides a list of commonly used extensions that you can select. For this
exercise, use fantutl (*.txt).
Did You Know ...
If you want change the default extension from txt to one of the ones in the list or if
you want a different file name extension for NC program files, you can edit or create
a .pinf file and specify the new extension. For more information on making these
changes, see the online Help.

3. If turn1.txt is not in the File name text box, type TURN1, then click Save.
You do not have to type the extension if you are using the default .txt. Naming the post
output file the same as the part file is the most common way of saving parts and NC
programs. Both files can have the same name because they have different extensions.

Learning 2 Axis Turn 4-17

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The Post Process Output dialog box

displays.
4. Click the Step button at the top of the
Post Process Output dialog box.
ProCAM starts to generate the NC Run
program and the first line of NC code Step
displays in the NC code output view box.
When you click the Step button,
ProCAM generates one line of code.
5. Click the Step button again.
The next line of NC code displays.
6. Click the Run button.
Post processing continues until it is
completed.
When the post processing is finished,
you can view the code using the vertical
scroll bar.
7. Click OK to close the Post Process Output dialog box.

More About Setup Sheets

The Setup Sheet is a printable file that contains information the machine tool operator can
use to set up the part and the tools required to produce a part. The information includes
the machine, the controller, estimated machine time, the part material, and the tooling
used to machine the part.
ProCAM provides two methods for creating Setup Sheets:
− During post processing, ProCAM automatically creates a simple text file with a .set
extension.
− The Setup Sheet command on the NC Manager shortcut menu allows you to generate
a Setup Sheet that is based on an Access database report template and store the
information in the Report Database to view at any time. ProCAM supplies several
report templates that can be used as is. You can also open the Report Database in
Access and create customized reports based on these templates or design your own
original reports.

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Turn 2
What You'll Learn
Extracting and Working With Machinable Features
ProCAM Solids Machining is a feature-based machining system. Feature-based machining
provides numerous benefits because the definition of the feature enables a higher level of
automation when creating machining operations and associated toolpaths. Adding to this
benefit, ProCAM provides both an automatic method of extracting features called Automatic
Feature Recognition (AFR), and an interactive method using the Insert Turn Feature
function. A part file can contain both types of features.
The following feature types are currently supported:
• Face Feature
A Face feature exists on the outermost portion of the part.
• OD Profile Feature
An OD profile feature covers the entire outer surface of the part.
• ID Profile Feature
An ID profile feature covers the entire inner surface of the part.
• Groove Feature with vertical walls
A Groove is a feature that is totally closed and below the surrounding features.
− Grooves are further broken down into one of two categories: rectangular and
outbound.
− Three types of grooves are supported: OD Groove, ID Groove, and Face Groove.
• Cutoff Feature
A Cutoff feature is generated on the opposite side of the Face feature when the
Workpiece is defined as bar stock. A Cutoff feature is similar to a face and can be
converted to a Face feature for two-step turning operations.
This exercise demonstrates the types of features identified automatically by the Extract
Machinable Features command.
1. Open the part file Turn2Ax_3.pcii in the \Procad\pcii\Learn\Solid folder.
This part file was originally a Parasolid file
(.x_t) that was opened in ProCAM and saved
in ProCAM (.pcii) format.
2. Click the Solids Machining button on
the CAD/CAM toolbar.

Learning 2 Axis Turn 4-19

Turn 2

3. Click the Solids Machining Feature Tree tab at the bottom of the
tree.
4. Right click the Machine in the Feature tree and select the
Parameters command on the shortcut menu.
5. Highlight Turn Machine – inch and click the Select button.
This machine definition has been created for these exercises. When you use ProCAM to
machine your own parts, select the machine tool you want to use to machine the part.
6. Click the Tool Crib tab.
7. Make sure Inch Turret 1 is the
Active tool crib.
From this page, you can add,
remove and edit tools in the
Tool Turret.
8. Select a tool from the Active
tool crib list and click Edit.

The Machining Parameters

dialog box displays three tabs
that allow you to change the
parameters for the selected tool.
The changes you make in this
dialog box affect only the tool
turret for the current part. To change the tool
definition for all future jobs, you need to edit
the Tool Turret definition in the Technology
Database.
9. Click the tabs to view the tool parameters,
then click OK to close the Machining
Parameters dialog box.
10. Click the Add button in the Machine dialog
box.

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The Tools Database

form displays.
This form allows you
to add an existing
tool in the TechDB to
your Tool Turret. The
list contains all the
tools that have been
entered into the
TechDB. You cannot
use this form to add
new tools to the TechDB.
11. Click OK or Cancel to exit the Tools Database.
12. Click the Controller tab in the Machine dialog box and make sure FANTUTL (the tutorial
post processor) is selected.
FANTUTL is the controller used for the exercises in this manual. When you use
ProCAM to machine your own parts, select your machine tool controller or post
processor.
13. Click the Parameters tab.
These parameters provide information required to generate the NC program. When you
use ProCAM to machine your own parts, change these parameters as required.
14. Click OK.
15. Right click the Workpiece in the Feature tree and select Edit Definition.
16. Change the Length of the bar stock to 6.85in and press Enter, then click OK.
Extract machinable features:
1. Click the Extract Machinable Features button on the Solids toolbar.
The Message Window displays. This window shows the
progress of the process.
When AFR is finished, the Feature tree displays the
machinable features. Five machinable features were found by
AFR. From the tree, you can reorder features (using drag and
drop), change feature names and suppress features.

Feature recognition also created Turn Setup1. The Setup

defines the tool direction necessary to machine these features. The origin
of the Setup is program zero for the Setup. By default, the origin is set to
the front of the part. In some situations, you will want to change this.
Exercise Turn 4 explains how to change the origin.

Learning 2 Axis Turn 4-21

Turn 2

OD Feature1
Groove Rectangular OD1
Cutoff
Groove Rectangular OD2

Face Feature1

2. Click each machinable feature in the Feature tree.

As you pick each machinable feature, the geometry for that feature highlights on the part.
Machinable features are recognized based on the part's geometry (the shape of a feature) and
topology (how the features are related to one another). However, not all attributes of a
feature can be determined from the geometry and topography. For example, AFR cannot
determine that a ID profile has been threaded, reamed or bored. ProCAM allows you to
specify additional attributes to a feature so that more accurate operations can be created.
3. Right click OD Feature1 and select Parameters.
The Parameters dialog box provides a geometric and dimensional report on the feature
and allows you to assign additional information to the feature. Depending on the
Attribute, a different
machining process can be
assigned. You can change
how each feature is
processed by defining the
sequence in the Technology
Database.
4. Click the down arrow to the
right of the Attribute box.
The attributes in the list are
user-defined attributes that
have been set up in the
TechDB for other operation
sequences. After you have
learned how to use ProCAM,
you can modify or delete
these user-defined attributes
and you can define additional
attributes to customize the
TechDB.

4-22 Learning 2 Axis Turn

 Turn 2

5. Leave the Attribute set to Coarse.

This attribute has been defined to generate Rough Turn and Rough Finish operations
using an 80-degree diamond insert.
6. Click OK to close the dialog box.
7. Review the parameters of other machinable features to understand more about the
features.
Generate the operation plan for OD Feature1:
1. Right click OD Feature1 in the tree and select Generate Operation Plan.

2. Click the Solids Machining Operation Tree tab at the bottom of the tree.
The Operation tree lists Turn Rough and Turn
Finish operations for the OD feature.
3. Right click Turn Setup1 and select Generate
Toolpath.
Notice the amount of material remaining
after the Turn Rough operation. The
back angle of the insert does not allow
the tool to machine the entire feature.

4. Click the Solids Machining

Feature Tree tab.
5. Right click OD Feature1 and select
Parameters on the shortcut menu.
6. Set the Attribute to RF80-GR, then click
OK.
This attribute has been defined in the TechDB to generate rough turn, finish turn rough
groove and finish groove operations for an OD Profile feature.
7. Right click OD Feature1 and select
Generate Operation Plan.
If Generate Operation Plan has been run
once, ProCAM displays a dialog box
with choices:
Update: Select this option to generate
operations for new features or if you
have deleted previously generated
operations for existing features. The operation list will not be updated for features that
have previously generated operations.
Regenerate: If you select this option, all previously generated operations are deleted and a
new operation list is created. If you have modified any operations, these modifications
will be lost.

Learning 2 Axis Turn 4-23

Turn 2

8. Click Regenerate to delete the previous operations and generate a new operation list.

9. Click the Solids Machining Operation

Tree tab at the bottom of the tree.
The Operation tree lists four operations for the
OD feature.
10. Right click Turn Setup1 and select Generate Toolpath.
Notice the toolpaths generated by the
groove operations.

11. Click the Solids Machining

Feature Tree tab.
12. Click the Generate Operation
Plan button on the Solids toolbar or
right click Turn Setup1 and select
Generate Operation Plan.
The Generate Operation Plan message window displays again.
13. Click either Update or Regenerate.
Since you have not changed any machining parameters for the operations that have
already been generated, you could select either Regenerate or Update. If you had
modified these operations, you would want to select Update to generate an operation list
only for the features that do not have operations.

14. Click the Solids Machining Operation Tree tab at the bottom of the tree.
The Operation tree now contains operations for all machinable features in the selected
Turn Setup.
To generate the NC code for this part, you would:
• Adjust the machining parameters as required for the operations
• Reorder the operations in the tree if necessary
• Generate toolpaths
• Post process the part

Did You Know ...

Depending on your machining preferences, you could delete the OD feature and the
two rectangular groove features found by AFR, then interactively insert an OD feature
that includes the grooves. This feature could be machined completely with the
operations generated by the RF80-GR attribute. The next exercise explains how to
insert Turn features.

4-24 Learning 2 Axis Turn

 Turn 3

Turn 3
What You'll Learn
• Inserting an OD Profile for Threading
• Reorganizing Machinable Features
• Suppressing Machinable Features
• Generating an Operation Plan and Toolpaths
• Post Processing Toolpaths

In this exercise, assume that the part starts out as a casting and machining is required only for
the features up to the larger diameter.
In Turn Setup1, you face the part, rough and finish the OD profile, rough and finish the
rectangular grooves and cut the part off.
1. Open part file Turn2Ax_1.pcii in the \Procad\pcii\Learn\Solid folder.

2. Click the Solids Machining button on the CAD/CAM toolbar.

3. Click the Solids Machining Feature Tree tab at

the bottom of the Part Manager.
4. Right click the Machine in the Feature tree and
select the Parameters command on the shortcut
menu.
− Highlight Turn Machine – Inch and click Select.
− Click the Tool Crib tab and make sure Inch
Turret 1 is the Active tool crib.
− Click the Controller tab and make sure FANTUTL is selected, then click OK to exit
the Machine dialog box.
5. Right click Workpiece in the Feature tree and select Edit Definition on the shortcut menu.
The Define Turn Workpiece dialog box displays.
By default, the Workpiece shape is a cylinder whose dimensions enclose the part. For this
example, the part is machined from bar stock that has .10in material to be removed from
the face. Assume that the largest OD of the part is to size and does not get machined in
this Setup. Since ProCAM currently defines the Workpiece as round bar stock, you will
use the default round shape and offset the minimum Workpiece size by .10in in length.
6. Change the Length of the bar stock to 6.850" and press Enter.
7. Click OK.

Learning 2 Axis Turn 4-25

Turn 3

8. Click the Extract Machinable Features button on the

Solids toolbar or right click NC Manager and select Extract
Machinable Features.
Turn Setup1 is created and AFR recognizes five features.

9. Left click Turn Setup1 in the tree and notice the machining direction
indicated by the datum that displays on the part model.
You can change the machining direction using the Parameters
command on the Turn Setup shortcut menu.
For this exercise, you can use the current machining direction.
Inserting an OD Profile for Threading
Now that a Turn Setup has been defined, you can create an OD profile feature to thread the
part. The OD Feature is created using the Insert Turn Feature command.
1. Right click OD Feature1 in the Feature tree and select Insert Turn Feature.
The Insert Turn Feature dialog box displays.
2. Click in the Selected entities list box
to set the focus.
3. Pick the OD profile on the right at the
part face.
Notice that as you move your cursor
over the profile, the entities change
color and are highlighted.
Turn features are defined by an outside
shape and optionally inside shapes to
represent profiles. These shapes can be
sketches or part profiles found by AFR
that are normal to the current Setup.
If the dialog box obstructs your view
of the part, move the dialog box by
dragging the title bar of the window to
a new location.
4. Make sure OD Feature is selected in
the Feature info list.
5. Click the down arrow next to the
Attribute list box and select Thread.
The Thread attribute has been defined in the TechDB to generate a thread operation.

4-26 Learning 2 Axis Turn

 Turn 3

6. For Extend 1 and Extend 2, make sure None is selected in the Extend group.
If ProCAM is calculating the Work In Process (WIP), ID and OD Thread features should
not be extended in either Z or X. If you extend Thread features, ProCAM determines the
feature length relative to the WIP and may extend the feature to start threading closer to
the face than you want. Typically, this would occur when the thread feature is not located
at the face of the part.
7. Click OK.
A feature labeled OD Feature 2 is listed under OD Feature1 in the Feature tree.
Reorganizing Machinable Features
To change the machining order, you can reorder either the machinable features or the
operations that are generated for the features. You can drag a feature in the Feature tree from
the current location to a position above or below another feature in the same Setup.
1. Click Groove Rectangular OD1, then click Groove Rectangular OD2 and notice the order
the grooves are highlighted on the model.
This may not be the order you want to machine these features.
2. Hold down the left mouse button and drag Groove
Rectangular OD1 over Groove Rectangular OD2, then release
the button.
Notice that as you drag the item, an arrow displays to indicate
where the item will be positioned. Rectangular OD2 is now
listed before Rectangular OD1 and will be machined first.
Suppressing Machinable Features
You can suppress a machinable feature and machine the feature later. Suppressing a feature
prevents operations (and associated toolpaths) from being created for that feature. For
example, if there is not enough tool capacity to do threading on the machine you are using,
you can suppress OD Feature2 and output the thread operation separately.
1. Right click OD Feature 2 in the Feature tree and select Suppress on the shortcut menu.
The OD Feature2 icon is grayed out in the tree.
2. Click Save As on the File menu.
3. Type turn3 and click the Save button.

Generating an Operation Plan and Toolpaths

1. Click the Generate Operation Plan button on the Solids toolbar or right click NC
Manager in the Feature tree and select Generate Operation Plan.
Operations are created for the machinable features in the Turn Setup.

Learning 2 Axis Turn 4-27

Turn 3

2. Click the Solids Machining Operation

Tree tab at the bottom of the tree.
The operations are in listed in the Operation
tree.
3. Right click an operation and select Parameters.
4. Change the cutting parameters according to
your machining practices.
5. Repeat steps 3 and 4 for all the operations.
6. Click the Generate Toolpath button on the Solids toolbar or right click Turn Setup1
in the Operation tree and select Generate Toolpath.
7. Check the Message Window.
− The Message Window provides information you may find helpful. For example,
based on the information in this window, you may want to change a tool or insert a
finish operation in order to cut a machinable feature completely.
− If the Message Window is not displayed, select Options on the NC Manager shortcut
menu or the Solids menu and check the Message Window check box on the General
tab.
− You can move and resize the window. To change the size, point to a border or corner
of the window (the pointer changes to a two-headed arrow). Drag the corner or border
until the window is the size you want, then release the mouse button.
8. Experiment by changing parameters for the operations and regenerating the toolpaths for
all operations in the Setup.
Did You Know ...
When you change operation parameters after generating toolpaths, we recommend
that you regenerate toolpaths at the Setup level so the work in process can be
updated correctly.
9. Right click NC Manager and select Simulate Toolpath.

10. Click the Do Section button.

11. Select the following display
options:

Stock Translucent Display

Tool Shaded Display

Target Shaded Display

12. Rotate the part, if necessary so
you can see the simulation.

13. Click the Run button.

4-28 Learning 2 Axis Turn

 Turn 3

14. Click the X button in the upper right corner of the Simulation toolbar to exit
Simulation mode.
Post Processing Toolpaths
1. Click the Post Process button on the Solids toolbar or right click Turn Setup1 in the
Operation tree and select Post Process.
2. In the Post Output File dialog box, click Save to accept the default file name (turn3.txt).
Note that if you are running ProCAM in Demo mode, this dialog box does not display.
3. In the Post Process Output dialog box, check the Display Centerline option so that the
toolpath will be highlighted as each line of code is produced.
4. Click the Run button (the double arrow).
NC code is generated.
5. After viewing the code, click OK.

Did You Know ...

You should save the part frequently. If you want the CAM information saved with the
part, make sure that the Save/Restore part option is checked on the General tab in the
Options dialog box before you save. When you open the part, make sure that
Save/Restore is checked or the CAM information will not be restored.
The General tab in the Options dialog box also has an Auto save option for
automatically saving your machining data.

Learning 2 Axis Turn 4-29

Turn 4

Turn 4
What You'll Learn
• Defining the Workpiece as a Forging or Casting
• Defining Additional Turn Features
• Deleting an Operation
• Adjusting Machining Parameters
• Defining Program Zero
This lesson guides you through the steps for the sequence of machining the part shown
below. The bottom depressions of the part will not be machined in this exercise. The
machining sequence is:
− Rough and finish the face of the part
− Rough and finish the OD profile
− Rough and finish the groove
EXERCISE 1. Click the Open button on the File toolbar.
2. In the Open dialog box, set the File of type option to Parasolid ASCII (*.x_t).
3. Make sure the Solids option is checked.
4. Select the part Turn2Ax_4.x_t in the \Procad\pcii\Learn\Solid folder and click OK.
5. Change the View to 1 Top.
6. Click the Solids Machining button on the CAD/CAM toolbar.

7. Click the Solids Machining Feature Tree tab.

8. Right click the Machine and select Parameters.
− On the Machine tab, make sure that Turn Machine - inch is the active machine.
− Click the Tool Crib tab and make sure Inch Turret1 is the Active tool crib.
− Click the Controller tab and make sure FANTUTL is selected, then click OK to exit
the Machine dialog box.
Defining the Workpiece as a Forging or Casting
In this example, the Workpiece is a forging. To represent the forging, you need to insert
geometry, then create cross section entities as explained below.
Did You Know ...
The term "sketch" is used to identify a cross section entity that can be selected to define
turn features and to represent a revolved workpiece.

EXERCISE 1. Click the CAD button on the CAD/CAM toolbar.

2. Click the Line button on the CAD toolbar.

4-30 Learning 2 Axis Turn

 Turn 4

3. Click the Keyboard button on the Snap toolbar.

The prompt line reads: ENTER X coordinate for line start.
4. Type –3.8 and press ENTER.
5. Press ENTER twice to accept the default 0.000 for the Y Start and Z Start.
The prompt line reads: ENTER X coordinate for line end.
6. Type –3.8 and press ENTER.
7. For the Y End, type 1.9750 and press ENTER.
8. For the Z End, press ENTER to accept the default 0.0000.
The line is inserted and the prompt line continues to read: : ENTER X coordinate for line
end.
9. Continue inserting lines by entering the XYZ coordinates for each line end as shown in
the following table.
Line X End Y End Z End
2 -1.6063 +1.9750 +0.0000
3 -1.6063 1.0836 +0.0000
4 -1.2175 +1.0187 +0.0000
5 +0.3937 +1.0187 +0.0000
6 +0.3937 +0.0000 +0.0000
7 -3.8000 +0.0000 +0.0000

10. Click BUTTON 2 (middle button) when you are finished.

The sketch is inserted.
11. Click the Fillet button on the CAD toolbar.
12. Double-click the Radius text box on the InfoBar tab.
13. Type 0.200 and press ENTER.
14. Insert fillets on the drawing as shown above.

Learning 2 Axis Turn 4-31

Turn 4

The next step is to insert a cross section entity on the geometry.

1. Click the Solids Machining button on the CAD/CAM toolbar.
2. Click the Cross Section Entity button on the Cross Section Entity
Solids toolbar.
3. Make sure the Check Breaks/Sharp Corners
modifier is not highlighted.
The prompt line reads: PICK entity for cross
section start.
4. Pick the horizontal line at the upper left corner of
the sketch.
The prompt line reads: PICK next entity for cross
section.
5. Pick the vertical line on the left near the top of
the line.
6. Click BUTTON 2 to insert the cross section entity.
A closed cross section entity is inserted.
7. Right click the Workpiece and select Edit Definition.
ProCAM automatically calculates the
Workpiece size based on the smallest
cylinder possible. You can change this
definition by specifying a sketch
(cross section entity) to use.
8. Select Revolved for the Type.
In the Available sketches list, the cross section entity is listed and the cross section entity
representing the shape of the stock is highlighted on the part model.
9. Click OK. An outline of the stock displays in the graphics area.
10. Click the Extract Machinable Features button on the Solids toolbar or right click NC
Manager and select Extract Machinable Features.
The recognized features in Turn Setup1 are the Face Feature, an OD Feature and a
Rectangular OD groove. ProCAM also created a separate setup for the second side of the
part, which includes a Face feature. When the Workpiece is defined from a sketch,
ProCAM creates a second setup with a Face feature.
When AFR is run on some parts, ProCAM may not recognize all the features you want to
machine or AFR may recognize a feature that might not be suitable for the intended
machining process. When this occurs, you can delete unwanted features and define
features interactively. For learning purposes, in this exercise you delete the rectangular
OD groove and insert the feature interactively.

4-32 Learning 2 Axis Turn

 Turn 4

11. Right click Groove Rectangular OD1 in the tree and select
Delete on the shortcut menu.
12. Click Yes to confirm the deletion.
The feature is moved to the Recycle Bin. When a feature is
deleted, it is automatically placed in the Recycle Bin, which is
used to store machinable features that you do not intend to
machine.
13. Click the minus sign to the left of the Recycle Bin to collapse
it.
Defining Additional Turn Features
You can now define a rectangular OD groove feature to machine the undercut.
1. Right click OD Feature1 and select Insert
Turn Feature.
2. Select <Part Profile> in the Define from
list.
All profiles in the current section plane
are highlighted on the model.
3. Change the Feature info to Groove
Rectangular.
4. Make sure the Attribute is Coarse.
5. Click in the Selected entities list box
to set the focus.
6. With the Window selection check box
checked, select the geometry for the
groove by drawing a window around
the groove entities as shown in the
figure.
The Selected entities list should
contain 5 selected entities and 2
extend entities.
7. Pick Extend 1 and set the Extend to Along X.
8. Pick Extend 2 and set the Extend to Along X.
The extends display on the model.
9. Click OK.

Learning 2 Axis Turn 4-33

Turn 4

Groove Rectangular OD2 is added to the tree.

10. Click the Generate Operation Plan button
on the Solids toolbar or right click NC
Manager and select Generate Operation Plan.

11. Click the Solids Machining Operation

Tree tab at the bottom of the tree.
The operations for Turn Setup1 and Turn
Setup2 are listed in the Operation tree.
Deleting an Operation
In some cases, it may be desirable to delete operations that are created automatically. In this
example, all of the operations that were generated for Turn Setup1 are needed to machine the
part. If the stock is a casting or forging and you use a sketch to define the Workpiece,
ProCAM generates a second setup for the other side of the part. Depending on whether or
not a second setup is needed for this machining session, you can delete or suppress the
operations that were generated for Turn Setup2. In this example, you delete the second setup
and all the operations under it.
1. In the Operation tree, right click Turn Setup2 and select Delete on the shortcut menu.
2. Click Yes to confirm you want to delete the Setup and all dependant operations under it.
The Setup and associated operations are removed from the tree.
Adjusting Machining Parameters
Each operation contains machining parameters that affect how the toolpath is created and
specific parameters that will be output to the NC program. These parameters can be edited
before generating the toolpaths and post processing the part.
1. Click the + next to Face Rough1 in the Operation tree.
The tree expands to identify the machinable feature the operation was generated to
machine (Face Feature1).
2. Click the - next to Face Rough1.
3. Right click Face Rough1 and select
Parameters.
The Machining Parameters dialog box
displays.
4. Click the NC tab and change the Clearance
Plane to .150in.
This parameter specifies the distance away from the part to start the cycle in the X and Z
axis. This is where the tool rapids to at the beginning of the cycle and the distance the
tool retracts from the part after each cutting pass.
5. Click OK.
Right click Face Finish1 and select Parameters.

4-34 Learning 2 Axis Turn

 Turn 4

6. Click the Tool Crib tab

on the Tool page.
7. Select the Diamond
55deg tool, then click
the <-- Select button.
The current tool is
replaced with the tool
you selected.
8. Click OK to close the
Machining Parameters
dialog box.
Defining Program Zero
The Turn Setup defines the
tool direction and program
zero. Program zero can be changed in the Setup by picking one of the following that is
closest to the desired work Z0 face: an OD, angle or ID face that is concentric to the part.
Each Setup has a different origin.
1. Right click Turn Setup1 and select
Parameters.
The Operation Setup Parameters dialog box
displays.
2. On the Origin tab, select Automatic in the
Defined from list box and check the Other
end option to move the origin to the left side
of the part.
The Chuck Location and Chuck Parameters
tabs are explained in the next lesson.
3. Click OK.
A dialog box displays the following
message: The origin or machining
direction has changed, toolpaths need to
be recalculated. Regenerate toolpaths
now?
4. Click No.
In this case, you could click either Yes
or No. If there were multiple Setups,
however, and you clicked Yes, toolpaths would be regenerated only for the operations in
the Setup you changed. Because ProCAM keeps track of the work in process, you should
always regenerate toolpaths from the NC Manager level.

Learning 2 Axis Turn 4-35

Turn 4

5. Click the Generate Toolpath button on the Solids toolbar.

Toolpaths are generated for all operations. A
message may display indicating ProCAM
could not generate WIP. This is because the
sketch at the largest diameter matches the
actual OD profile maximum diameter and
therefore there is no material to update. If this
message displays, click OK to continue.
6. Click each operation in the tree to view the toolpaths.
7. Change the View to 7 ISO 1.
8. Right click Turn Setup1 and select Simulate Toolpath.

9. Click the Do Section button.

10. Select the following display options:

Stock Shaded Display

Tool Shaded Display

Target Shaded Display

11. Click the Run button.

Since you deleted Turn Setup2 and the Face Feature,
material is left on the locating face. This could be
machined in another setup.
12. Click the X to exit the simulation.
13. Using drag and drop, reorder the operations to cut the
part in the order you think is most efficient.
14. Save the part as TURN4.
15. Click the Post Process button on the Solids toolbar
or right click Turn Setup1 and select Post Process.
16. In the Post Output File dialog box, click Save to use turn4.txt for the NC program file
name.
If you are running ProCAM in Demo mode, this dialog box does not display.
17. Click the Run button in the Post Process Output dialog box.
ProCAM generates the NC code.
18. After viewing the code, click Cancel to close the dialog box.

4-36 Learning 2 Axis Turn

 Turn 5

Turn 5
What You'll Learn
• Adding an ID Groove Feature
• Adding OD Thread and ID Thread Features
• Generating Operations and Toolpaths
• Displaying Locating Symbols
• Defining the Chuck and Viewing in Toolpath Simulation
EXERCISE 1. Open the part file Turn2Ax_5.pcii in the \Procad\pcii\Learn\Solid folder.
2. Click the Solids Machining button on the CAD/CAM toolbar.

3. Click the Solids Machining Feature Tree tab at

the bottom of the tree.
4. Right click the Machine and select Parameters.
− On the Machine tab, make sure that Turn
Machine-inch is the active machine.
− Click the Tool Crib tab and make sure Inch
Turret 1 is the Active tool crib.
− Click the Controller tab and make sure close the
dialog box.
5. Right click on the Workpiece and select Edit
Definition on the shortcut menu.
6. In the Define Turn Workpiece dialog box, leave the Type set to Bar stock, change the
Length to 2.050" and press Enter.
7. Click the Material button in the top right corner of the dialog box.
8. In the Workpiece Material dialog box, select a material in the pulldown list, then click
OK.
9. Click OK to close the Define Workpiece dialog box.
10. Click the Extract Machinable features button on the Solids toolbar.

Learning 2 Axis Turn 4-37

Turn 5

AFR analyzes the model for features to machine. When AFR is completed, the tree
displays Turn Setup1, which establishes the workplane for
turning, and the machinable features that were recognized:
− one Face feature that is at the length of the part
− one OD profile feature that encompasses the entire length
of the part
− one Groove Rectangular OD feature
− one ID Feature profile
− one Groove Rectangular ID feature
− one CutOff feature

When AFR is run on some parts, ProCAM may not recognize all the features you want to
machine or AFR may recognize a feature that might not be suitable for the intended
machining process. When this occurs, you can delete unwanted features and define
features interactively.
For learning purposes, in this exercise you delete the Groove Rectangular ID2 feature and
insert it interactively.
11. Left click the Groove Rectangular ID2 feature to highlight it and press the Delete key on
the keyboard.
Adding an ID Groove Feature
You are going to add three features interactively. The first feature is the groove that you
deleted. ProCAM understands the shape of a groove and knows how it is to be machined.
The typical groove configuration is defined as a rectangular shape consisting of two equal
length walls, which may or may not have fillet radii and may or may not have corner breaks.
When you insert a Groove feature for this undercut area, ProCAM knows how to machine
the area using the standard Rectangular Groove machining techniques.
1. Right click on Turn Setup1 and select Insert Turn feature.
The Insert Turn feature dialog box displays.
2. In the Feature info selection box, select Groove Rectangular and set the Location to ID.
3. Leave the Attribute set to Coarse.
4. Make sure the Window selection check box is checked.
5. Hold down the left mouse button, draw a
window around the groove area on the ID
profile, then release the button.
The Selected entities list is updated to
contain 2 Extend entities and a total of 5
Selected entities (Selected 1-5).

4-38 Learning 2 Axis Turn

 Turn 5

6. Select the Extend 1 in the list

and set the Extend option to
Tangential
7. Click Extend 2 in the list and
set the Extend option to
Tangential, then click OK.

The tree lists Groove Rectangular ID3.

8. Drag the new feature below ID Feature1.
You can insert a turn feature anywhere in the tree, then move
it to a different position. You can also change the machining
order after generating operations.
Adding OD Thread and ID Thread Features
Thread information comes in many different formats and has many parameters. For a
CAD/CAM system, it is not practical to model threads on a solid. Even though this can be
done, it is very difficult for software to interpret a helical cut in the OD of a part and
decipher what type of thread it is. In ProCAM, you use attributes to define a thread on a
feature.
In this exercise, you define OD and ID features to be threaded.
1. Right click OD Feature1 and select Insert Turn feature.
2. Leave the Feature info selection box set to OD Feature.
3. Set the Attribute to Thread.
4. Pick the OD segment where the
thread will be machined (indicated
by the arrow in the figure).
5. For Extend 1 and Extend 2, make
sure None is selected in the Extend group.

Learning 2 Axis Turn 4-39

Turn 5

If ProCAM is calculating the

WIP (work in process), ID and
OD Thread features should not
be extended in either Z or X. If
you extend Thread features,
ProCAM determines the feature
length relative to the WIP and
may extend the feature to start
threading closer to the face than
you want. Typically, this would
occur on thread features such as
this one where the feature is not
located at the face of the part.
To adjust the machining length
for a Thread feature, you can
− Specify a Start length in the
Thread operation machining
parameters.
− Set up the TechDB to define an amount that you want the tool to go beyond the thread
length into a thread relief area.
6. Click OK.
OD Feature2 is listed in the tree.
7. Right click OD Feature2
and select Parameters.
The OD Profile Parameters
dialog box displays.
The Maximum diameter for
this feature is 1.5in. In
order to generate a Thread
operation, the
corresponding thread
condition must be selected
from the TechDB. The
major diameter in the
TechDB must match the
feature maximum diameter.
Initially, the Thread
Parameters display the
values in the first record in
the TechDB; however, this
record has not been
selected.
8. Click the Library button.

4-40 Learning 2 Axis Turn

 Turn 5

The Tools Database - Thread Condition form displays.

Several thread conditions have been set up in the TechDB. When you machine your own
parts, you will add data for additional threads.
9. Select ID 3, which has
a 1.5 Major Dia, then
click OK.
10. Click OK to close the
OD Profile Parameters
dialog box.
11. Right click ID Feature1 in the tree and select Insert Turn feature.
The Insert Turn Feature dialog box displays.
12. For the Feature info, select ID
feature.
13. Set the Attribute to Thread.
14. Select the ID segment at the
front of the part (indicated by
the arrow on the figure).
15. For Extend 1 and Extend 2,
make sure None is selected in
the Extend group.
16. Click OK.
ID Feature2 is listed in the
tree.
17. Right click ID Feature2 and
select Parameters.
The ID Profile Parameters
dialog box displays. You need ID segment
to select the thread condition
for ID Feature2.
18. Click the Library button.

19. On the Tools Database - Thread Condition form, select ID 5, which has a .95 Major Dia,
then click OK.
20. Click OK to close the ID Profile Parameters dialog box.
Generating Operations and Modifying Machining Parameters
Before generating operations, you can change feature parameters and rename features so that
they are more descriptive.
1. Right click ID Feature1 in the tree and select Parameters.
2. Change the Attribute to Coarse and click OK.

Learning 2 Axis Turn 4-41

Turn 5

3. Right click OD Feature2 in the tree and select Rename.

A text box displays around the item.
4. Type OD Thread and press Enter.
5. Right click ID Feature2 and select Rename.
6. Type ID Thread and press Enter.
7. Click the Generate Operation Plan button
on the Solids toolbar or right click Turn
Setup1 in the tree and select Generate
Operation Plan.

8. After the operations have been

generated, click the Solids Machining
Operation Tree tab.
You can modify machining parameters before
or after generating toolpaths.
9. Right click Thread2 in the tree and select
Parameters.
10. On the Orientation tab, make sure the Tool orientation is set to Left up, then click OK.
11. Right click Thread1 in the tree and select Parameters.
12. Change the following values on the Thread tab, then click OK.
− Depth per cut = .03in
− Final cut amount = .009in
− Start length = .15in
The start length is measured from the start of the
OD Thread feature that you created and is a
distance in front or to the right of the feature.
Since this is an OD feature and the tool is on a
rear turret, the tool orientation is down and left.
− Pitch = .065in
13. Right click Rough Groove1 and select Parameters.
14. On the Rough Groove tab, change the Radial (X) and
Axial (Z) allowances to 0.0, then click OK.
15. Right click Finish Groove1 in the tree, select Delete and click Yes to confirm the
deletion.
By setting the Rough Groove allowances to 0.0, you can rough and finish the groove in
one operation.
16. Right click Rough Groove2 and select Parameters.
17. On the Boring Bar tab, make sure the Holder edge is set to End.
This setting is necessary because of the insert orientation of the holder.

4-42 Learning 2 Axis Turn

 Turn 5

18. On the Rough Groove tab, change the Radial (X) and Axial (Z) allowances to 0.0.
19. On the NC tab, change the Clearance plane to .10in, then click OK.
20. Right click Finish Groove2, select Delete and click Yes to confirm the deletion.
Defining the Machining Sequence and Generating Toolpaths
The order that the operations are listed is relative to the feature order. Both the Feature tree
and the Operation tree can be reordered to achieve the specific machining sequences that are
needed in terms of tool order and material removal.
1. In the tree, drag Rough Groove2 above Bore Finish1.

2. Click the Generate Toolpath button on the Solids toolbar or right click on Turn
Setup1 and select Generate Toolpath.
The following message may display when a Center Drill toolpath is generated:
Machining length is greater than overall tool length. Tool may gouge the part. Do you
want to continue? This message warns you that if you expect the center drill to go to the
full feature depth, the tool may gouge the part. Otherwise, you can disregard the message.
3. If this message displays, click Yes to continue.
The following message may display when the Drill2 toolpath is generated: Tool dia is
greater than minimum feature dia. Tool may gouge part. Do you want to continue? This
message is similar to the warning for the Center Drill.
4. If this message displays, click Yes to continue.
5. Click on each operation to view the toolpath.
Displaying Locating Symbols and Defining the Chuck
You can position two triangles to provide a graphical representation of where the part will be
clamped in the chuck or collet.
1. Left click on Turn Setup1.
A triangle displays at the part zero location on the
part. This locating symbol can be used to show where
the chuck or collet is located.
2. Right click Turn Setup1 and select Parameters.
The Origin tab displays in the Operation Setup
Parameters dialog box.
3. Select Automatic in the Defined from list.
This is where the origin or piece part zero is
located.

Learning 2 Axis Turn 4-43

Turn 5

4. Click the Chuck Location tab.

The Workpiece boundary displays. The two triangles display at part zero. This is the
default position for the locating symbols.
You can position the two triangles to reflect where the chuck or Collet will be located.
You can also change the size of the triangles.
5. Pick the OD line and the workpiece boundary
to position the triangles as shown in the figure.

A graphic of the part can be added to the

setup sheet to give the shop floor a better
understanding of the setup.

6. Click the Chuck Parameters tab.

7. Change the following values:
− Step Length = .36in
− Step Width = .35in
− Base radius = 2.0in
− Base width = .50in
The Equal step width and length
options apply only when there are
multiple steps.
8. Click OK to exit the dialog box.

9. Change the View to 7 ISO 1.

10. Right click Thread2 in the tree and select Suppress.
You do not need to simulate this operation.
11. Right click Turn Setup1 and select Simulate Toolpath.

4-44 Learning 2 Axis Turn

 Turn 5

The Fixture Shaded Display button is

enabled and the chuck that you just defined
displays.

12. Click the Do Section button.

13. Click the Target button and select Shaded

Display.

14. Run the simulation.

15. Exit the simulation.
16. Right click on Turn Setup1 in the Operation tree
and select Parameters.
17. Click the Chuck Parameters tab.
18. Try different settings: change the number of
steps and the size of the steps and the base, then click OK.
19. Run the Toolpath Simulation again and view the changes.

Learning 2 Axis Turn 4-45

Turn 6

Turn 6
Double chucking is a method that allows the programmer to machine a workpiece on both
sides of the part. Double chucking operations are supported in ProCAM turning. The method
for doing a double chucking operation is explained below.

What You'll Learn

• Defining the Workpiece from a sketch for double chucking
• Establishing Part Zero
• Defining Machinable Features
• Generating an Operation Plan
• Changing the origin machining direction and generating toolpaths
• Defining the chuck location and simulating toolpaths

In this exercise, assume that Side 1 and Side 2 are established as shown below. Side 1 will be
machined first and you will be chucking on side 2. Since the material is a solid billet, you
will be locating on the billet OD on side 2.
1. Open part file Turn2Ax_6.pcii in the \Procad\pcii\Learn\Solid folder.

2. Click the Solids Machining button on the CAD/CAM Side 1 Side 2

toolbar.

3. Click the Solids Machining Feature Tree tab at the

bottom of the Part Manager.
4. Right click the Machine in the Feature tree and select
the Parameters command on the shortcut menu.
− Highlight Turn Machine–inch and click Select.
− Click the Tool Crib tab and make sure Inch Turret 1 is
the Active tool crib.
− Click the Controller tab and make sure FANTUTL is selected, then click OK to exit
the Machine dialog box.
Defining the Workpiece from a Sketch for Double Chucking
The part is being made from a solid Workpiece. In order for ProCAM to define 2 Setups in
the tree, a sketch (cross section entity) must be used for the Workpiece. The cross section
entity in this part is longer than the part on both sides. For more information on creating a
cross section entity, see exercise Turn 4.
Did You Know ...
The term "sketch" is used to identify a cross section entity that can be selected to define
turn features and to represent a revolved workpiece.

4-46 Learning 2 Axis Turn

 Turn 6

1. Right click Workpiece in the Solids Feature tree and select Edit Definition.
The Define Turn Workpiece dialog box displays.
2. Select Revolved for the Type.
3. In the Available sketches list, select the sketch.
Selecting a sketch (cross section entity) establishes 2 distinct faces (or ends of the part).
Because bar stock has an infinite side length and one face, you cannot select Bar stock for
double chucking.
The cross section entity representing the shape of the stock is highlighted on the part
model.
4. Click OK.
Establishing Part Zero
Since this part is a cylinder, ProCAM already knows where the centerline is. ProCAM
automatically sets the origin to a default setting and establishes a default centerline. For a
single chucking operation, the default origin may be acceptable. Since you are doing a
double-chucking operation, however, you need change the default to set the system origin for
side 1.
1. Select Define Turn Section Plane on the NC Manager shortcut menu.
The Turn Section Plane dialog box displays. The origin X and Z symbol displays on the
part in the default location (at the face of the part) for Side 2.
2. On the Origin tab, select the Other end option.
The origin marker moves to Side 1. Notice that the Z axis is still
pointing into the part. You want it pointing away.
3. Click the Centerline tab and select the Reverse direction option.
The Z axis is arrow is flipped 180 degrees as shown in the figure.
4. Click OK.

Defining Machinable Features

1. Click the Extract Machinable Features button on the Solids
toolbar or right click NC Manager and select Extract Machinable Features.
Two Turn Setups are created and AFR recognizes the features that can be machined in
each Setup.
AFR found an OD Feature and an ID Feature in Setup 1 that each extend from the front
face to the back face. However, to machine this part in a double-chucking environment
with 2 Setups, you need an ID Feature and an OD Feature in each Setup. In order to
accomplish this, you edit the feature definitions in Setup 1 and create new features in
Setup 2.
2. Right click OD Feature1 in the tree and select Edit Definition.
3. In the Edit Turn Feature dialog box, make sure the Window selection option is checked.

Learning 2 Axis Turn 4-47

Turn 6

4. Window pick the segments of the part

as shown in the figure.
The segments are removed from the
Selected entities list.
5. Click OK.
6. Right click Face Feature2 in Setup2 and select Insert Turn Feature.
7. In the Insert Turn Feature dialog box, make sure the Window selection option is checked.
8. Window pick the same segments that you removed from OD Feature1 as shown in the
figure above.
9. Click OK. OD Feature2 is added to Setup2.
10. Right click ID Feature1 in the tree and select Edit Definition.
11. In the Edit Turn Feature dialog box, make sure the Window selection option is checked.
12. Window pick the segments of the
part as shown in the figure.
The segments are removed from the
Selected entities list.
13. Click OK.
14. Right click OD Feature2 in Setup2
and select Insert Turn Feature.
15. In the Insert Turn Feature dialog box, make sure the Window selection option is checked.
16. For the Feature info, select ID Feature.
17. Window pick the same segments that you removed from ID Feature1 as shown in the
figure above.
18. Click OK.
The OD and ID features in Setup2
should look like the features in the
figure on the right.

Changing the Origin Machining Direction and Generating Toolpaths

1. Click the Generate Operation Plan button on the Solids toolbar or right click NC
Manager in the Feature tree and select Generate Operation Plan.
Operations are created for the machinable features in the Turn Setups.

2. Click the Solids Machining Operation Tree tab at the bottom of the tree.
The operations are in listed in the Operation tree.
3. Left click each Turn Setup in the tree and notice the machining direction indicated by the
datum that displays on the part model.
The origin is at the back of the part for both Setups. Turn Setup1 is correct; however, the
origin needs to be changed for Setup2.

4-48 Learning 2 Axis Turn

 Turn 6

5. Right click Turn Setup2 in the tree and select Parameters.

6. On the Origin tab, select Automatic for the Defined from option,
then click OK.
The origin moves to the front face.
7. Click No when asked if you want to regenerate toolpaths now.
8. Right click Rough Groove1 in the tree and select Parameters.
9. Click the Groove Insert tab and change the Width to .125in.
10. Click the Boring Bar tab and change the Holder edge to End.
11. Click OK.
This message displays: Tool parameters changed. Add as a new tool? No will change tool
for all operations sharing this tool.
12. Click No.
The Width and Holder edge are changed automatically for the Finish Groove1 operation,
which uses the same tool.
13. Right click Drill1 in the tree and select Parameters.
14. On the Tool tab, change the Depth to option to Drill diameter.
With the option selected, ProCAM takes into account the drill point angle when
generating the toolpath.
15. On the Feature Options tab, change the Machining length to 5.1in and click OK.
Increasing this length will drill the part all the way through.
16. If the message displays indicating tool parameters changed, click Yes to add as a new
tool.
17. Right click Drill2 in the tree and select Parameters.
18. On the Tool tab, change from Depth to option to Drill diameter.
19. On the Feature Options tab, change the Machining length to 6.1in and click OK.
20. If the message displays indicating tool parameters changed, click Yes to add as a new
tool.
21. In Turn Setup2, hold down the Shift key and right click the Center Drill2, Drill3 and
Drill4 operations in the tree.
22. Select Delete on the shortcut menu.
As a result of the changes to the drill operations in Setup1, you can delete these
operations because there will no longer be stock on the face.
23. Click the Generate Toolpath button on the Solids toolbar.
24. If any warning messages display, click Yes to continue.
25. Click each operation in the tree to view the toolpaths.

Learning 2 Axis Turn 4-49

Turn 6

Defining the Chuck Location and Simulating Toolpaths

You are now ready to define the chuck location for each Setup and run the Toolpath
Simulation.
1. Click the Workpiece in the tree to display the workpiece in the graphics area.
2. Rotate the part 60 degrees about the Z axis as shown in the figure on the right.
This changes the view to be parallel to the Setup plane.
3. Right click Setup1 in the tree and select Parameters.
4. Click the Chuck Location tab.
5. Pick the horizontal line representing the OD of the
Workpiece, then pick the vertical line representing
the face of the part.
The triangles move as shown in the figure.
6. Click the Chuck Parameters tab and change the
parameters as follows:
− Length = .50in
− Width = .50in
− Base radius = 3.00in
− Base width = 1.00in
7. Click OK.
8. Right click Turn Setup2 in the tree and select
Parameters.
9. Click the Chuck Location tab.
10. Locate the triangles by picking the small OD on the
left side and the vertical edge for the chuck face.
Note that you may need to zoom in to this area in
order to pick these segments easily.
11. Click the Reverse direction option.
12. Click the Chuck Parameters tab and use the same
values for the parameters that you used for Setup1.
13. Click OK.

14. Click the Simulate Toolpath button on the Solids toolbar.

The Fixture Shaded Display button is enabled and the chuck defined for Turn
Setup1 displays.
15. Click the down arrow next to End and select Next Setup.

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 Turn 6

16. Select the following display options:

Stock Translucent Display

Target Shaded Display

17. Rotate the part so you can see the part being machined in Setup1.

18. Click Run.

The simulation runs through the operations in Turn Setup1, then the chuck display
changes to Turn Setup2.
19. Rotate the part so you can see the part being machined in Setup2.

20. Click Run

The toolpaths for the operations in Turn Setup2 are simulated.

Learning 2 Axis Turn 4-51

Turn 7

Turn 7
Turn features that are recognized automatically and created interactively are based on the
spindle centerline location and spindle direction. In addition, if you select Generation 1 as
the Method on the Features tab in the Options dialog box, turn features are also based on a
section plane. When Generation 1 is used, ProCAM sections the part through the centerline
and along the X axis. If this section plane does not cross through all areas of the part, the
resulting features will not be correct. The Define Turn Section Plane command allows you to
define the section plane so the features will be correct.
What You'll Learn
Generation 1 would normally be used when the model contains protrusions or ears on the
OD of the part as shown in the following exercise.
1. Open part file TURN2AX_7.PCII in the \Procad\pcii\Learn\Solid folder.
Notice the protrusion on the OD of the large
diameter of the part.
2. Click Options on the menu bar and select Surface
Display.
3. Make sure the Shade Color is set to Use Surface
Color and click OK.
4. Click the Solids Machining button on the
CAD/CAM toolbar.

5. Click the Solids Machining Feature Tree tab.

6. Right click the Machine in the Feature tree and
select Parameters.
7. Highlight Turn Machine–inch, click Select, then click OK.
8. Click the Options button on the Solids toolbar.
9. On the Features tab, make sure the Method is set to Generation 2 and click OK.
With this option, ProCAM recognizes features based on the spindle centerline location
and spindle direction. Any user defined section plane is ignored. Generation 2 is the
preferred method.
10. Click the Extract Machinable Features button on the Solids toolbar.
11. Change the View to Section2, which has been
created for this exercise.
12. Click OD Feature1 in the tree and notice that
the OD feature does not include the shape of
the protrusion. In this case, Generation 2 does
not recognize the protrusion. You need to change the Method to Generation 1 and define
a section plane that cuts through the protrusion.

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 Turn 7

Using the Generation 1 Method to Extract Machinable Features

1. Click the Options button on the Solids toolbar.
2. On the Features tab, change the Method to Generation 1 and click OK.
When you select this option, ProCAM will find the features based on the Turn Section
Plane that you define next.
3. Right click NC Manager in the tree and select Define Turn Section Plane.
The spindle centerline and origin are automatically determined properly for most turning
parts requiring a single Setup. By default, ProCAM will position the machining origin at
one end of the part and set the positive Z machining direction to be in the same direction
as the positive ProCAM X,Y, or Z axis. For this part, the origin is on the front right side
of the part. The Turn Section Plane command is used, when necessary, to modify the
automatically determined origin, spindle centerline, machining direction and AFR section
plane (for Generation 1).
4. In the Turn Section Plane dialog box, the Origin tab defines the machining origin and the
location of the spindle centerline for the part. The origin specifies program zero and the Z
axis identifies the location and direction of the spindle axis, which determines the
features that will be automatically recognized and interactively created.
5. Click the Centerline tab.
This tab defines the spindle centerline direction, which also affects the recognition of
features. If the part contains more than one centerline direction, you can define the
desired centerline by selecting a ProCAM axis entity, a cylindrical or conical face, or a
circular edge. In this example, there is only one logical centerline direction and the
Automatic setting finds it properly.
6. Click the Section Plane tab.
When recognizing features using Generation 1, ProCAM
sections the part through the centerline and along the X axis.
If this section plane does not cross through all areas of the
part, the resulting recognized features will not be correct.
7. Change the View Section1, which has been created for this
example.
8. Click the Zoom All button.
The X axis, which defines the section plane, is vertical and
will not cut through the protrusion, so the protrusion would not be included in the OD
feature.

Learning 2 Axis Turn 4-53

Turn 7

The center of the protrusion is 20 degrees counterclockwise off

the vertical, so you need to rotate the section plane to cut through
the protrusion.
9. Change the Angle to 20 and press Enter.
The X axis and section plane now point through the center
of the protrusion.
10. Click OK.

11. Click the Extract Machinable Features button on the

Solids toolbar.
12. Change the View to Section2.
13. Click the Zoom All button.
ProCAM displays turn features from a single
view that is normal to the Turn Section Plane.
14. Click on the OD feature in the tree to verify
that the protrusion is included in the feature.

4-54 Learning 2 Axis Turn

Chapter 5 Learning 4 Axis Turn

Solids Machining uses the Rear turret for 2 Axis Turn machining and as the default for 4
Axis Turn machining. All tool motion and output is displayed and output from a Rear turret
perspective. When the machine has 4 Axis capability, you can define the machine in the
Technology Database to use both Back and Front turrets. Then, you can choose to have the
display and output for any of the operations in the Solids Operation tree generated from the
Rear or Front turret (providing there is a tool available on the Front turret).
This chapter provides an opportunity to learn 4 Axis Turn. The exercises in this chapter are
intended to show you how to use ProCAM and may not correspond to actual machining
practices.

Learning 4 Axis Turn 5-1

4 Axis Turn 1

4 Axis Turn 1
Solids Machining provides support for machines with front and rear turret configurations
allowing 2+2 axis machining. For machines that are defined as 4 axis in the Technology
Database, an option is provided to select either Front or Rear turret for each operation. Sync
codes are manually provided by the user.
What You'll Learn
• Defining a 4 Axis machine
• Defining machinable features
• Editing features
• Generating operations and adjusting parameters for front turret
• Generating toolpaths

There are 5 grooves on the part in this exercise: 2 face grooves, 2 OD grooves and 1 ID
groove. There is also an OD thread that will be machined.
EXERCISE 1. Open part file Turn4ax_1.pcii in the \procad\pcii\learn\solid folder.

2. Click the Solids Machining button on the

CAD/CAM toolbar.

3. Click the Solids Machining Feature Tree tab at

the bottom of the Part Manager.
4. Right click the Machine in the tree and select the
Parameters command on the shortcut menu.
5. Highlight Turn Machine 4-Axis (2+2) and click Select.
This machine has been defined as a 4 axis machine in
the Technology Database. Before using Solids
Machining to machine your parts, make sure you
define the machine tools available in your facility.
6. Click the Tool Crib tab.
7. Click the down arrow next to the Turret type.
When you select a 4 axis machine, you can choose a tool set to use with each turret. For
this part, you can use Inch Turret 1 as the Active tool set for both Rear and Front turrets.
8. Click the Controller tab and make sure FANTUTL is selected, then click OK to exit the
Machine dialog box.
9. Right click the Workpiece in the tree and select Edit Definition.
10. Leave the Type set to Bar stock.
11. Set the Length to 4.05" and press Enter.
12. Click OK.

5-2 Learning 4 Axis Turn

 4 Axis Turn 1

Defining Machinable Features Automatically and Interactively

In order to define the machinable features on this part, you run the Extract Machinable
Features command and insert the OD Thread feature.
EXERCISE 1. Click the Extract Machinable Features button on the
Solids toolbar or right click NC Manager and select Extract
Machinable Features.
Two Turn Setups are created and AFR recognizes the
features that can be machined in each Setup.
2. Since you are chucking, delete Cutoff Feature1.
3. Right click on Groove Rectangular OD3 in the tree and
select Insert Turn Feature.
The Insert Turn Feature dialog box displays.
4. For the Feature info, select OD Feature.
5. For the Attribute, select Thread from the list.
6. Pick the horizontal segment shown in the figure.
The selected entity and two extend entities display in the
Selected Entities list. You do not need to extend either end of
the segment.
7. Click OK.
OD Feature2 is listed in the tree.
8. Right click on OD Feature2 and select Parameters.
9. In the OD Profile Parameters dialog box, click the Library
button.
10. In the Tools Database - Thread Condition (inches) form, select ID 3 and click OK.
11. Click OK to exit the OD Profile Parameters dialog box.
Editing Machinable Features
When you machine a part, the length of the workpiece may change. Because ProCAM uses
WIP (work in process), you can edit the definition of the OD and ID profiles to make sure
these features are cut completely if the workpiece changes.
EXERCISE 1. Right click OD Feature1 in the tree and select Edit Definition.
2. Pick Extend 1 in the Selected entities
list and select Along Z for the
Extend option.
The line at the end of the profile is
extended.
3. Pick Extend 2 in the Selected entities
list and select Along X for the Extend option.
The line should point upward as shown in the figure.

Learning 4 Axis Turn 5-3

4 Axis Turn 1

4. Click OK.
5. Right click ID Feature1 and select
Edit Definition.
6. Pick Extend 1 in the Selected entities
list and select Along X.
7. Click the Reverse option to point the
line down.
8. Pick Extend 2 in the Selected entities list and select Along Z, then click OK.
The line should point away from the part.
Generating Operations and Adjusting Parameters for Front Turret
EXERCISE 1. Click the Generate Operation Plan button on the Solids toolbar.
Operations are created for the machinable features in the Turn Setups.

2. Click the Solids Operations tab at the bottom of the tree.

The operations are listed in the Solids Operation tree.
3. Right click on Rough Groove2 (Groove Rectangular OD2) in the tree and select
Parameters.
4. On the Rough Groove tab, change the Groove peck type to Constant.
With this option selected, the tool feeds in the First peck amount, then continues feeding
in the Sub peck amount until the depth is reached.
5. Set the First peck amt. and the Sub peck amt to .05".
6. Make sure the Groove style is set to Normal.
This option generates a toolpath where the tool plunges perpendicular to the bottom of
the groove. Multiple parallel plunge cuts will be produced when the width of the groove
is wider than the tool. The sequence of the cuts is based on the specified order. Using the
optional Deep groove cycle, the tool can be retracted between each depth of cut to allow
chip removal.
7. Check the Deep groove cycle option.
With this option, the tool pecks at a specific depth (much like in the Cutoff cycle). This
cycle is used for machining grooves that are unusually deep and require using a thin
insert that would break if you could not peck the groove.
8. Select Front for the Turret option.
9. Click the Tool tab.
10. On the Orientation page, change the Tool orientation to Left Up and click OK.
In the TechDB, operations are defined with the tool orientation set for the rear turret.
When you want to perform an operation on the front turret, you can either change the
orientation on this tab for each operation or ProCAM can make the changes when
generating toolpaths. If the orientation is incorrect, ProCAM displays a message and you
can click Yes to allow ProCAM to select the correct orientation.

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 4 Axis Turn 1

11. Right click Finish Groove2 in the tree and select Parameters.
12. On the Finish Groove tab, select Front for the Turret option.
13. Click the Tool tab.
14. On the Orientation page, change the Tool orientation to Left Up and click OK.
15. Right click Rough Groove4 (Groove Rectangular ID4) and select Parameters.
16. On the Groove Insert tab, change the Width to .125".
17. On the Boring Bar tab, make sure the Holder edge is set to End and the Lead angle is 0
degrees.
18. Click OK.
This message displays: Tool parameters changed. Add as a new tool? No will change tool
for all operations sharing this tool.
19. Click Yes.
20. Right click Finish Groove4 in the tree and select Parameters.
21. On the Boring Bar tab, make sure the Holder edge is set to End and the Lead angle is 0
degrees, then click OK.
22. Right click Drill1 and select Parameters.
23. On the Feature Options tab, change the Machining length to 4.5" and click OK.
Increasing this length ensures that the full diameter of the drill will pass through the back
of the part.
24. Click the Generate Toolpath button on the Solids toolbar.
25. If any warning messages display, click Yes continue.
The message that the machining length is greater than the overall tool length displays
when a Center Drill toolpath is generated to warn you that if you expect the center drill to
go to the full feature depth, the tool may gouge the part.
Defining the Chuck Location for Setup1
EXERCISE Define chuck to use for toolpath simulation.
1. Right click Setup1 in the tree and select Parameters.
2. Click the Chuck Location tab.
3. Pick the horizontal line representing the OD of
the workpiece, then pick the vertical line
representing the back (locating) face of the
part.
The triangles move as shown in the figure.
4. Click the Chuck Parameters tab and change
the parameters as follows, then click OK.
− Length and Width = .35"
− Base radius = 4.00"
− Base width = 1.00"

Learning 4 Axis Turn 5-5

4 Axis Turn 1

5. Click OK.
A dialog box displays the following message: The origin or machining direction has
changed, toolpaths need to be recalculated. Regenerate toolpaths now?
6. Click No.
If you clicked Yes, toolpaths would be regenerated only for the operations in Setup1.
However, because ProCAM keeps track of the work in process, you should always
regenerate toolpaths from the NC Manager level.
Defining the Chuck Location for Setup2
EXERCISE 1. Right click Turn Setup2 in the tree and select Parameters.
2. On the Origin tab, change the Origin Defined from option to Automatic.
3. Click the Other end option.
The origin marker displays as shown in the figure on the next page.
4. Click the Chuck Location tab.
5. Locate the triangles by picking the small OD on
the right side and the back vertical edge of the
small diameter for the chuck face.
Note that you may need to zoom in to this area in
order to pick these segments easily.
6. Click the Reverse direction option.
7. Click the Chuck Parameters tab and use the
following values for the parameters:
− Length and Width= .35"
− Base radius = 4.00"
− Base width = 1.00"
8. Click OK.
The following message displays: The origin or machining direction has changed,
toolpaths need to be recalculated. Regenerate toolpaths now?
9. Click No.
If you clicked Yes, toolpaths would be regenerated only for the operations in Setup2.
However, because ProCAM keeps track of the work in process, you should always
regenerate toolpaths from the NC Manager level.
10. Click the Generate Toolpath button on the Solids toolbar to regenerate toolpaths for
both Setups.
Simulating the Toolpaths for Turn Setup1 and Setup2
EXERCISE 1. Right click Thread1 in the tree and select Suppress.
This toolpath does not need to be simulated for this exercise and suppressing it speeds up
the simulation.

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 4 Axis Turn 1

2. Click the Simulate Toolpath button on the Solids toolbar.

The Fixture Display button is enabled and the chuck defined for Turn Setup1
displays.
3. Click the down arrow next to End and select Next Setup.
4. Select the following display options:

Stock Translucent Display

Tool Shaded Display

Holder Shaded Display

Target Shaded Display

5. Click Run.
The simulation runs through the operations in Turn Setup1, then the chuck display
changes to Turn Setup2.
6. Rotate the part so you can see the face with the groove.

7. Click Run.
The operations in Turn Setup2 are simulated.

Learning 4 Axis Turn 5-7

4 Axis Turn 1

5-8 Learning 4 Axis Turn

Chapter 6 Learning the TechDB

The intelligence behind ProCAM Solids Machining automation is TekSoft’s proprietary

Technology Database (TechDB). The Technology Database is shipped with data that is
considered generally applicable to most machining environments. In order to gain full
advantage of ProCAM Solids Machining, you will want to modify this data and input
additional knowledge that represents your expertise and your facility's capabilities and
machining methods. This knowledge can then be recalled and applied in Solids Machining to
help automate and promote consistency in NC programming and machining.
Even without this individual tailoring, Solids Machining can be used as a productive tool.
With the exception of tooling and machine information, any method or machining procedure
that is defined in the Technology Database can be applied interactively and modified in
Solids Machining.
The TechDB is responsible for the following:
• definition and selection of machine tools
• definition and selection of tool sets
• definition and selection of cutting tools and holders
• determination of machining methods
• definition of speeds and feeds conditions

Learning the TechDB 6-1

TechDB 1

TechDB 1
What You'll Learn
Adding and Editing Mill Machines
One of the first steps when using Solids Machining is to define the machine that the part will
be programmed for. The machine tool used for the manufacturing of a part will influence the
methods used to complete the task. Solids Machining has automated this by allowing your
facility to create a database of the existing milling centers.
When you set up a mill machine in the TechDB, you can:
• Define the CNC machine tools in your facility.
• Assign a name or machine number to each machine tool.
• Assign a Post Processor to each individual machine.
• Assign Tool Cribs to each individual machine.
• Define the machine as a light duty or heavy duty machine, which if used, will directly
influence the speeds and feeds output by the MES Speed and Feed library.
• Set X & Y travel limits of the machine tool.
• Define the number of axes that the machine tool is capable of machining to.
The following exercise explains how to use the Machine Parameters form to add additional
machines.
1. Open a mill part file, click the Solids Machining button on
the CAD/CAM toolbar, then click the TechDB button on the
Solids toolbar.
Microsoft Access starts and the TechDB Main Menu
displays.
The TechDB, which is based on the Microsoft Access
database engine, contains a navigation tree, menus and
forms that are used to modify and enter data.
2. For this exercise, you can use either Inches or Metric for
the Units option below the navigation tree.
The information in the database is stored in two sections:
metric and inch. If your part is metric, ProCAM will
access the metric information in the database. If the part
is inch, ProCAM will access the inch information. When
you enter information in the TechDB, you need to
specify which section of the database you are editing:
metric or inch.
3. If necessary, expand the Mill item in the navigation tree,
then click the Machine item to select it.

6-2 Learning the TechDB

 TechDB 1

The Machine Parameters form displays the machine information in the first record. All
data in the TechDB is considered a record. The Machine Parameters form is divided into
three sections: General, Specifications and Tooling.

Machine name, Machine ID, Machine description

These are user description fields. The Machine name is the name that appears in the list
of machines in ProCAM. Machine ID is used to reflect a number or name the user can
assign to the machine. Machine description allows for a description that is shown in
ProCAM along with the name. These fields do not affect code output.
Default machine
Only one machine can be the default. This machine is the one chosen automatically when
you enter Solids Machining. Normally, you would make the default machine the one you
program most. If you program on different machines, you can change the machine easily
in Solids Machining.
Controller
This parameter defines the Solids Machining post processor file to use for the selected
machine.
Machine duty
This option allows you to specify the kind of work this machine does. Changing the
setting changes the speeds and feeds coming out of the database. A different speed and
feed can be set for each material depending on this setting. This allows you to set speeds
and feeds according to the particular machine’s capabilities. For instance, a machine with
a 20 hp spindle motor may be set as Heavy Duty, while another machine with a 10 hp
spindle motor may be set as Medium or Light Duty.

The Specifications section allows you to set some operating parameters for the machine.
Most are self-explanatory such as Horsepower, Max spindle speed and Max feed rate.
These values are available during posting.

Learning the TechDB 6-3

TechDB 1

The No. of axis can be set to 3, 4, or 5. This parameter determines the number of axes
available in Solids Machining. A machine set to 3 axis would not be able to perform
rotary work.
The Mode for 4 or 5 axis parameter is not used since Solids Machining supports only
prepositioning rotary at this time.
Table travel sets the maximum table travel in X,Y, and Z.

The Tooling section allows you to set the standard tools for this machine.
The Tool crib pulldown lets you select the standard set of tools this machine uses by
default.
The Tool crib priority option tells Solids to override some settings for choosing a tool if
the tool exists in the tool crib. For example, a 20mm cobalt end mill chosen because of
the material being machined would be overridden if another 20mm end mill exists in the
tool crib. When this option is selected, Solids changes the icon of an operation in the
Operation tree to indicate a tool has been chosen that did not come from the Tool crib.
For more information on the Tool Crib and how to use it, see the TechDB 2 and TechDB
3 exercises.
4. Locate the Record buttons at the lower left of the form
and click the Next button.
The Record buttons allow you to navigate through the list of machines. All forms in the
TechDB have these buttons. You can move to the beginning and end of the list, as well as
move through each record one at a time. The total number of records is displayed here. In
this case, there are 4 mill machines in the database. ProCAM supplies sample machines.
You can modify or delete these machine definitions as required.
5. Click the Go To Last button.
The form displays an empty record that you would use
to add an additional machine.
6. Click the Close button.
When you finish entering information for machines, there are no additional commands
needed to save the data. The information is saved when you click Close.

6-4 Learning the TechDB

 TechDB 2

TechDB 2
What You'll Learn
Adding Tools to the Tools Library
The Tools Library command on the Technology Database Main Menu provides access to
various commands for adding, deleting, and editing mill tools, holders, tool assemblies, and
tool cribs. Tool types supported by Solids Machining include drills, taps, end mills, user
defined tools and many others. While the Technology Database is supplied with many
different tool types and sizes, it will not likely include all various tools used within your
facility. Ideally, to take the most advantage of Solids Machining, it is recommended that you
add or modify the tool libraries to include the tools used in your machining practices.
Each tool is defined with both geometric and non-geometric characteristics. Some of these
parameters are used directly by ProCAM in the calculation of toolpaths and speeds and feeds
and for display during toolpath simulation. Other parameters are provided for the purpose of
user identification and tool management.
Optionally, holders can be defined and mated to tools for increased tool reference
information and management as well as enhancing toolpath simulation and validation.

The following exercise shows you how to add a tool.

1. Open a mill part file, click the Solids Machining button on the
CAD/CAM toolbar, then click the TechDB button on the
Solids toolbar.
Microsoft Access starts and the TechDB Main Menu
displays.
2. For this exercise, you can use either Inches or Metric for
the Units option.
The information in the database is stored in two sections:
metric and inch. If your part is metric, ProCAM will
access the metric information in the database. If the part
is inch, ProCAM will access the inch information. When
you enter information in the TechDB, you need to
specify which section of the database you are editing:
metric or inch.
3. Expand the Tools Library item under Mill in the
navigation tree and click Drill under Point-to-Point Tools
to select it.
The Tools Database – Drill form displays. The tool
library contains all of the standard drill sizes. The tool
expressions for hole features are based on the standard drill sizes so that ProCAM will
automatically find the proper size tool for a hole feature. All of the drills entered in the
database are cobalt.

Learning the TechDB 6-5

TechDB 2

The field name is listed across the top of the form above each column. Most of these fields
are self-explanatory as they pertain to the size and configuration of the tool. There are 3
fields for user customization.
The ON field allows you to control whether ProCAM can select the tool. When this option is
checked, ProCAM can select the tool when an operation plan is generated. When it is not
checked, ProCAM will not select the tool. For example, if a tool that is normally used is
temporarily not available, the check mark can be removed so that the tool will not be
selected when Generate Operation Plan is selected.
Tool ID can be used to identify tools. For example, if you have a tool crib identification
system in use, this field could reflect it or you could use the stock # or order # for the
specified tool.
The Comment field at the far right can be used to customize the comment shown for each
tool when displayed in ProCAM.
Sorting

Below the list of tools is an area with search and show options. These options allow you to:
• Type a tool diameter and click the Find button to display only tools with a specified
diameter.
• Click the Show All button to reset the list to show all tools.

• Select the Active or Inactive radio button to display only active tools (those tools with
the ON option checked) or only inactive tools (those tools with the ON option not
selected).
1. Type .5 in the Enter diameter text box and click the Find button.
The list displays only tools with a .5in diameter and the total number of tools that were
found displays at the bottom of the form.
2. Click the Show All button to display the entire list again.
You can also use the Sort command to sort records by field:
3. Click in a cell in the Eff. Cut length column.
4. Select Records on the menu bar at the top of the
Access window and select Sort, then select Sort
Ascending.
The tools are sorted based on the cut length value.
5. Click the Show All button to return the list to the original order.

6-6 Learning the TechDB

 TechDB 2

Navigating Through the Tool List and Adding Tools

At the bottom of the form are buttons and options that can be used to navigate through the
list of tools. The total number of records is also displayed. In the figure below, there are 367
drills in the database.
Use the Record buttons to navigate to the beginning and end of the list or move through the
list one record at a time. All forms in the TechDB have these buttons.

1. Click the Go To End button.

The end of the list displays with an empty record at the end to allow you to add new
records. Every list in the TechDB has an empty record at the end.
Note that you can also use the scroll bar on the right side of the form to move through the
list.

2. If you were entering a tool, you would start typing values into the fields.
IMPORTANT! As soon as you start typing in an empty record, a new record will
display below the one you are editing. It can be confusing to determine which record you
are working on since the record you are editing is no longer the last record.
3. Click the Close button.
When you finish adding new tools, there are no additional commands needed to save the
data. The information is saved when you click Close.

Learning the TechDB 6-7

TechDB 3

TechDB 3
What You'll Learn
Using Tool Cribs
After you have entered all the tools into the Tool Library to meet your manufacturing needs,
you need to build a Tool Crib for each milling center or build one Tool Crib for use with all
of your machining centers. A tool crib is a subset of all the tools in the library and usually
represents the tools that are commonly loaded into the machine's turret or are commonly
used. A Tool Crib is then associated to a Machine definition so that when the machine is
selected in Solids Machining, these common tools are made available during the
programming of the part. There is no limit to the number of tools in a Tool Crib or the
number of tool cribs you can create.
Solids Machining is supplied with several example tool cribs that are intended to be used
with the Solids Machining example files. These tool cribs can be modified or deleted as
required.
1. Open a mill part file, click the Solids Machining button on the
CAD/CAM toolbar, then click the TechDB button on the
Solids toolbar.
Microsoft Access starts and the TechDB Main Menu displays.
2. For this exercise, you can use either Inches or Metric for
the Units option.
The information in the database is stored in two sections:
metric and inch. If your part is metric, ProCAM will
access the metric information in the database. If the part
is inch, ProCAM will access the inch information. When
you enter information in the TechDB, you need to
specify which section of the database you are editing.
3. Click the Tool Crib item under Tools Library in the
TechDB navigation tree.
The Tool Crib form displays.
Using standard Access commands, you can perform the
following functions in the Tool Crib form: create new
Tool Cribs with an unlimited number of tools in each
one; modify the tools in an existing tool crib; and delete a
tool crib or selected tools in a tool crib.
When assigning a Tool Crib to the machine that you are programming for, you are
indicating that only these tools should be available for use.

6-8 Learning the TechDB

 TechDB 3

At the top of the Tool Crib form is the name of the crib and the number of stations the
Tool crib has. You cannot have more tools in the list than the number in Total stations.
For example, you may have a machine tool with a 30-tool position magazine and there
are an additional 20 tools that are readily available. You could define a Tool Crib of 50
tools. When programming a part within ProCAM, you can easily select the tools to use
from this Tool Crib. There is no limit to the number of tools in a Tool Crib or the number
of tool cribs you can create.
The Define using Tool Assemblies option determines if the tool crib will be defined
individually from tools and holders (unchecked) or using tool and holder assemblies
(checked). Crib 1 was defined individually from tools and holders.
There are three main fields on the Tool Crib form:
The Stn no. refers to the particular tool turret station that the tool will be loaded in, and
will be the tool number output in the G-Code.
The Tool type reflects the type of tool, such as Flat End Mill, Ball Mill, Drill, etc.
The Key parameters field is filled automatically after the tool is selected.
4. Under Tool type, click the down-arrow button to the right of the tool type of the first tool.
If you were adding a tool, you would choose the tool type from the list of available types.
5. Leave the current tool type selected.
6. To the right of the Tool ID column is an edit button to select the particular
tool for this station. Click the button to display the selection form.
7. The Tool Database form for the type of tool selected under the Tool Type
column appears.
If you were adding a tool to the crib or replacing the existing tool in this station, you
would locate the tool in the list, select it, then click OK.
8. Click Cancel to keep the existing tool and exit the Tools Database form.
9. Click the edit button to the right of the Holder ID column to open the Mill
Holder Library form.
Each tool in the Tool Crib has a tool holder associated with it. You can display the holder
during toolpath simulation and check for collision between holder and workpiece.

Learning the TechDB 6-9

TechDB 3

10. Click Cancel to keep the existing holder, then click Close to exit the Tool Crib form.
11. Click the Machine item in the TechDB navigation tree to display the Machine Parameters
form.

12. In the Tooling section at the bottom of the form is a pulldown list for selecting the Tool
Crib to associate to the machine. When you define a machine, you would select the
desired Tool Crib for the machine.
The Tool Crib Form button is another method for opening the Tool Crib form.
When the Tool Crib Priority option is checked, ProCAM changes the icon of an operation
in the Operation tree to indicate a tool has been chosen that did not come from the Tool
crib.

6-10 Learning the TechDB

 Tech DB 4

Tech DB 4
What You'll Learn
Feature and Operation Basics
The Feature & Operations area of the database is essentially the brain of the TechDB. The
operations generated in Solids Machining and all the parameters they contain come from
Feature & Operations. This example explains how to define:
• Defaults for the Setup Clearance and Retract planes.
• Operation defaults that display when you define new operations in the TechDB.
• Default sort sequences for operations when you use the Sort Operation command in
Solids Machining.
• New attributes.

1. Open a mill part file, click the Solids Machining button on the CAD/CAM toolbar,
then click the TechDB button on the Solids toolbar.
Microsoft Access starts and the TechDB Main Menu displays.
2. For this exercise, you can use either Inches or Metric for the Units option at the bottom of
the navigation tree.
The information in the database is stored in two sections: metric and inch. If your part is
metric, ProCAM will access the metric information in the database. If the part is inch,
ProCAM will access the inch information. When you enter information in the TechDB,
you need to specify which section of the database you are editing: metric or inch.
Default Setup Retract
3. Click the Default Setup Parameters item
under Feature & Operations in the
TechDB navigation tree.
The Default Setup Parameters form
displays. This form allows you to set the
default Rapid and Clearance settings for
the Setup.
The Rapid plane is the safe Z retract
position that the tool enters from and
returns to before and after each
operation is complete.
The Clearance plane is a Z position that
the tool retracts to between Z cutting
depths within the operation.
4. Click the down arrow next to the Rapid
plane is and Clearance Plane is parameters to view the choices, then click Close.

Learning the TechDB 6-11

Tech DB 4

Default Operation Parameters

5. Click the Default Operation
Parameters item under Feature &
Operations in the TechDB navigation
tree.
The Default Operation Parameters
form displays. This form controls the
defaults that display when you create
new operations in the TechDB
database.
For example, if you were to add a
new Rough Mill operation in the
database, the fields on the form
would display default values. This is
where those parameters come from.
Setting your preferences beforehand
can save you a significant amount of
time later.
Additionally, when using the Insert
Operation and Insert Hole Operation command to insert operations manually in ProCAM,
if the option Use default parameters is active, the default parameters for the inserted
operation are also derived from this form.
For increased flexibility, this form allows you to define different sets of defaults, where
each set should contain only one of each operation type. The Default check box on the
form defines which set is active.
6. Click the edit button next to the
Drilling operation.
The Drill Operation Parameters form
displays.
The settings in this form are the
defaults for new drill operations.
Remember, this is for new operations,
not for existing ones.
7. Click Close to return to the Operation
Default Parameters form
8. Click the edit button for the other
operation types and view the default
parameters.
9. When you are finished, click Close to
exit the form.

6-12 Learning the TechDB

 Tech DB 4

Sort Operations Default

10. Click the Sort Operations item under
Feature & Operations in the TechDB
navigation tree.
The Sort Operations form displays. In
ProCAM, the operations that have
been generated can be sorted either
manually by dragging and dropping in
the Operation tree or automatically
using the Sort Operations command.
This form controls the default order
for how the operations would be
sorted using the command.
Note that hole operations are listed
first followed by Rough Milling, and
then Finish Milling.
To change the order of the operations
in the form, highlight the operation to
be moved and use the Decrease or
Increase buttons to change the
position.
11. Click Close to exit the form.

User-defined Attributes
12. Click the User Defined
Attributes item under Feature &
Operations in the TechDB
navigation tree.
The Feature & Attributes form
displays. Every feature in Solids
Machining, (pocket, hole, slot, 3
axis feature, etc.) has attributes
assigned to it. Attributes allow
you to set up multiple methods
for machining the same type of
feature. The hole feature shown
here is a good example. You
may want to drill, ream, bore or
thread a hole. The attribute
allows you to choose the
method for each feature in
Solids Machining before
generating the operation plan.

Learning the TechDB 6-13

Tech DB 4

The Feature & Attributes form allows you to define the names of the attributes. That is all
you do on this form. The parameters for the given attribute are set elsewhere.
The User Defined Attributes section at the top allows you to add and change names. After
adding a new attribute in this form, you set up the machining method for the new
attribute in a different form (Feature & Operations).
Default Defined Attribute names cannot be changed. For example, the Drill, Bore, Ream,
and Thread attribute names for hole features cannot be changed; however, the parameters
that those attributes call can be changed in the Feature & Operations form.
13. Click Close to exit the form.
14. On the navigation tree, click the Features & Operations item under Feature & Operation.
The Feature & Operations form displays the conditions and operations defined for a hole
feature.
15. Locate the
Attribute column in
the Feature
Conditions section.
16. Click the down
arrow to the right
of the Drill
attribute in the first
record and notice
that the names of
the attributes in the
list are the same as the names in the Feature & Attributes form. The next exercise
explains how to set up the machining sequences associated to an attribute.

6-14 Learning the TechDB

 TechDB 5

TechDB 5
What You'll Learn
• Creating an attribute and associating a machining sequence
• Applying the attribute in Solids Machining
Creating new attributes allows you to customize the TechDB so that ProCAM will machine
features using your exact methods. In the following exercise, you create a new attribute and
associate a machining sequence in the TechDB, then apply the attribute to a feature and
generate the operations in ProCAM.
Creating an Attribute and Associating a Machining Sequence
1. Open the part file MILL2AX_11.PCII in the \Procad\pcii\Learn\Solid folder.
2. Click the Solids Machining button on the CAD/CAM toolbar.
3. Click the TechDB button on the Solids toolbar.
4. Make sure the Units selection box is set to Inches.
The information in the database is stored in two sections:
metric and inch. If your part is metric, ProCAM will
access the metric information in the database. If the part is
inch, ProCAM will access the inch information. When
you enter information in the TechDB, you need to specify
which section of the database you are editing: metric or
inch.
5. Click the User Defined Attributes item under Feature &
Operations in the TechDB navigation tree.
The Feature & Attributes form displays.
There are five attributes listed in the User Defined
Attributes section. An empty record is under the Drill
Entry attribute.
6. Click the down arrow below
the Feature and select
Rectangular Pocket.
7. Click in the empty record text
box and type Example.
8. Click Close to exit the form.
The attribute is saved
automatically when you close
the form.

Learning the TechDB 6-15

TechDB 5

Associate a Machining Sequence to the Attribute

1. In the TechDB navigation tree, click the Features &
Operations item under Feature & Operations.
The Feature & Operations form displays. This form is
where all of the machining operations and their
parameters are contained and where most TechDB editing
is done.
This form has three sections:
− Feature Type is the type of feature, such as Hole,
Rectangular Slot, Irregular Pocket, etc.
− Feature Conditions sets a particular condition that the
feature will fit into based on its size and attribute.
− Operations for Matching Conditions is the list of machining operations and associated
tools that ProCAM will generate when a feature is found that matches the feature type
and conditions.
2. Under Feature Type, click the down arrow and select Rectangular Pocket.
3. In the Feature Conditions section, scroll the list to the end using the scroll bar on the
right. The last record does not have an ID number. This is an empty record that you can
use to add your new attribute.

4. In the empty record, click the down arrow next to the Coarse attribute and select the
Example attribute.
This is the attribute you defined in the first part of this exercise.

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 TechDB 5

5. Leave the Base Attribute set to None.

The Base Attribute is a feature condition that is used to distinguish features with a fillet
between the bottom and the sides of the feature.
None indicates that there is no fillet. Bottom Radius indicates that there is a fillet.
Features with bottom radius fillets can be defined interactively using the Insert 2.5 Axis
Feature command.
6. Under the Lower Range column, enter a value of 1.
7. Under the Upper Range column, enter a value of 10.
Reading across the record, you have defined a blind rectangular pocket, using the
Example attribute, no base attribute, with a feature size ranging from greater than 1" to
less than or equal to 10".
The last step is to define the operations you want generated when this pocket is found.
Notice that under Operations for Matching Conditions, the Operation field is grayed out.
Operations cannot be selected until this field is activated.

8. In the list of Feature Conditions, select the record above the new record for the Example
attribute, and then select the Example record again.
The Operation field is now active.
The Operations for Matching Conditions area has three fields:
− Operation selects the type of Operation, such as Rough Mill, Drilling, Reaming, etc.
− Tool Selection Summary allows you to pick the tool to be used.
− Depth Criteria Summary sets the depth of cut.
In this exercise, you define operations for roughing and finishing a pocket. You set up
two roughing operations, the first with a large tool and a second with a smaller tool
cutting only where the large tool could not. There are two
finishing operations, the first for cutting the bottom of the
pocket and the second for cutting the side walls.
9. Click the down-arrow button under Operation and select
Rough Mill.
A new empty operation displays below the first one.
10. Select Rough Mill for the second operation.

Learning the TechDB 6-17

TechDB 5

11. Select Finish Mill for the third and fourth operations.
When complete, four operations are listed as shown here.
To the right of each operation is an edit button to access all the
machining parameters.
12. Click the edit button next to the first Rough Mill operation.
13. In the Roughing Parameters section,
make sure the Generate leftover
option is checked.
14. Scroll down to the Depth Parameters
and set the Allowance to .05.
15. Under the Depth Parameters, set the
First cut amt. and Sub cut amt. to 1.
16. Click Close.
17. Click the edit button for the
second Rough Mill operation.
18. In the Operation Parameters – Rough
Mill form:
Set the Pattern to Pocket In.
Under Depth Parameters, set the
Allowance to .05.
Under Depth Parameters, set the First
cut amt. and Sub cut amt. to .5.
19. Click Close.
20. Click the edit button for the first
Finish operation.
21. In the Operation Parameters – Finish
Mill form, set the Side Parameters
Allowance to .05.
22. Under the Depth Parameters, set the First cut amt. to
2.
23. Scroll to the Flat Areas section at the bottom of the
form and select the Bottom finish option.
24. Set the Stepover % to 50.
25. Click Close.
26. Click the edit button for the second Finish operation.
27. In the Operation Parameters – Finish Mill form, set the
Ramp to Angle and the Ramp angle to 3.
28. Click Close.

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 TechDB 5

Select Tools for Each Operation

The next step is to select the tools for each operation.
1. For the first Rough operation, click the
edit button under Tool Selection
Summary.
The Tool Selection form displays.
2. Leave the Tool type set to Flat End Mill.
3. In the Tool Selection section, click the Use
constant radio button.
With this method, you are specifying only a
constant diameter, not a particular tool.
ProCAM uses other criteria, such as the
material being cut, to choose the tool.
There are two other methods for choosing a
tool:
Use expression allows you to give a tool
diameter range. If you use a range, when an
Operation Plan is generated, ProCAM searches
the Tools database for a tool diameter that is
within the specified upper and lower diameter.
If a tool cannot be found, the ProCAM Message
Window will inform you that a tool of the
required size could not be found.
With the Select tool option, you can click the
Select Tool button and choose a particular tool
from the tools database.
4. Set the Constant value to 1. This sets the basic
tool diameter to 1in. The exact tool chosen will
be determined by other factors, such as the
material being machined.
5. Click Close.

6. Edit the Tool Selection Summary for the second Rough Mill operation.
7. In the Tool Selection form, click the Use constant radio button and set the Constant value
to .25.
8. Click Close.
9. Edit the Tool Selection Summary for the first
Finish Operation.
10. Click the Select Tool radio button.
11. Click the Select Tool button.

Learning the TechDB 6-19

TechDB 5

12. In the Tools Database - Mill form, scroll

down and select ID number 683, which is a
¼", 4 flute carbide end mill.

13. Click OK.

The Tool ID and summary display in the Tool
Selection form.
14. Close the Tool Selection form.
15. Edit the Tool Selection Summary for the second Finish Mill operation.
16. Click the Select Tool radio button.
17. Click the Select Tool button.
18. In the Tools Database Mill form, select ID number 683 again and click OK.
19. Close the Tool Selection form.
20. Click the edit button under Depth Criteria Summary for
the first Rough Mill operation.
21. In the Depth Evaluation form, select Use
Expression.
Note that the default expression is Feature Depth
+ zero (0). This tells ProCAM to machine to the
bottom of the feature.
22. Close the form.
23. Repeat these steps for the remaining three
operations.

When you are finished, the Operations for

Matching Conditions section of the Feature &
Operations form should look like the figure
below.

24. Click Close to close the Feature & Operations form.

25. Click Quit to exit the TechDB and return to ProCAM.

6-20 Learning the TechDB

 TechDB 5

Applying the Attribute in Solids Machining

1. Click the Solids Machining Feature
Tree tab at the bottom of the
FeatureManager design tree.
2. Click the Extract Machinable Features
button on the Solids toolbar.
Automatic Feature Recognition finds a
rectangular pocket pattern feature.

3. Right click Rectangular

Pocket Pattern1 in the tree and
select Parameters on the
shortcut menu.
4. In the Rectangular Pocket
Parameters dialog box, click
the down arrow to the right of
the Attribute selection box and
select Example.
5. Click OK.

6. Click the Generate Operation Plan button on the

Solids toolbar.
7. Click the Solids Machining Operation Tree tab at
the bottom of the tree.
The Operation tree lists the four operations. This is the
machining sequence that you defined in the TechDB for
the Example attribute.
8. For each operation, right click on the operation and select Parameters on the shortcut
menu. In the Machining Parameters dialog box, notice that the parameters are set to the
values you specified in the TechDB, then click OK.

Learning the TechDB 6-21

TechDB 5

9. Click the Generate Toolpath button on the Solids toolbar or right click the Part Setup
in the tree and select Generate Toolpath.
10. Right click on the Part Setup in the tree and select Simulate Toolpath.
The Simulate Toolpath toolbar displays.

11. Click the Run button to start the simulation.

12. Close the Simulate Toolpath toolbar when you are finished.

6-22 Learning the TechDB

 TechDB 6

TechDB 6
What You'll Learn
Understanding Threading Parameters
The thread portion of the TechDB is a departure from the method the database normally
uses. In all other cases, the definition of the tool, the feature, and the operations to machine
the feature are in different places in the TechDB. Threads are different in that all the
parameters are on the same form.
Defining Taps and Associated Operations
1. Click the TechDB button on the Solids toolbar.
Microsoft Access starts and the TechDB Main Menu displays.
2. For this exercise, you can use either Inches or Metric for the Units option.
The information in the database is stored in two sections: metric and inch. If your part is
metric, ProCAM will access the metric information in the database. If the part is inch,
ProCAM will access the inch information. When you enter information in the TechDB,
you need to specify which section of the database you are editing.
3. In the TechDB navigation tree, expand Tools Library, expand Threading, then click the
Tap – Cutting item.
The Tools Database – Tap form displays. The form is divided into two sections.

The top section lists the taps and associated parameters. This section is similar to the
forms for other tool types. There are fields for the physical size aspects of the tap, as well
as fields for material, hand of cut, and comments.
The Operations for Tapped Holes section is a list of the operations that will be generated
for a threaded hole using the selected tap in the top section of the form. Next to each
operation is an edit button to customize the operation parameters.
4. Click the edit button
to the right of the
Center Drill
operation.

Learning the TechDB 6-23

TechDB 6

The Operation Parameters - Center Drill form

displays.
Any changes to the parameters in this form
apply to operations generated for the
particular tapped hole size and do not affect
operations for other hole sizes.
5. Click Close to exit the Operation Parameters
form.

6. For the same Center Drill operation,

click the edit button to the right of the
tool under Summary of Tool
Selection.
The Tool Selection form displays.
The Tool Selection form allows you to choose
the particular tool to be used for this Center
Drill operation.
The tool can be chosen using two methods: Use
constant or Select Tool.
With Use Constant, you are not specifying a
particular tool, only a constant diameter.
ProCAM uses other criteria, such as the material
being cut, to choose the tool.
With the Select Tool option, you can click the
Select Tool button and choose a particular tool
from the database.
7. Click Close to close the Tool Selection form.

6-24 Learning the TechDB

 TechDB 6

8. For the same Center Drill operation, click the edit button to the right of Summary of
Depth Criteria.

Because this is a drilling operation, there are three

depth setting sections in the form. The first is for
blind/flat bottom holes, the second for through holes,
and the third for blind/drill point holes.
In each of the depth sections, there are three methods
for determining the depth the tool reaches.
− Use constant specifies a constant Z depth for the
tool to drill to.
− Use expression allows you to use a mathematical
expression to determine the depth. For instance,
you can specify a depth that is more or less than
the depth of the feature.
− Use countersink diameter allows you to specify the
diameter of the countersunk hole as opposed to a
depth setting. In this case, ProCAM would figure
the depth necessary to obtain the desired diameter.
9. Click Close to exit the Machining Depth form.
10. Once all the operations and their respective
parameters have been set, the tapped hole settings are complete and you can click Close
to exit the Tools Database – Tap form.

Learning the TechDB 6-25

TechDB 7

TechDB 7
Solids Machining supports keyway and dovetail cutting tools. In this exercise, you create a
user-defined T-slot attribute in the TechDB using a keyway cutter and apply it to a
machinable feature.

What You'll Learn

• Defining a keyway cutter in the Technology Database
• Creating a user-defined T-slot attribute in the Technology Database
• Inserting a 2 Axis Feature and applying the TechDB T-slot attribute
• Generating Operations and Toolpaths

1. Open the part file MILL2AX_8.PCII in the \Procad\pcii\Learn\Solid folder.

2. Click the Solids Machining Feature Tree tab at the bottom of the tree.
3. Use Mill machine – Inch in the Feature tree.
4. Click the Extract Machinable Features button on the Solids toolbar or right click NC
Manager and select Extract Machinable Features.
Defining an Attribute in the Technology Database
First, you need to define the keyway cutter in the TechDB.
1. Click the TechDB button on the Solids toolbar or
select Technology Database on the Solids menu.
Microsoft Access starts and the TechDB Main Menu
displays.
2. Make sure the Units selection box is set to Inches.
3. In the Mill section, scroll down in the Tools Library to
Mill tools and select Keyway.

6-26 Learning the TechDB

 TechDB 7

4. On the Tools Database – Keyway (inches) form, scroll down to the last record and use
the following information and define the tool:
− Tool ID = 1010 Diameter = 1.75
− Shank = .75 Bottom Radius = .05
− Top Radius = .05 Cut Length = .5
− Overall Length = 3 Protrusion = 2
− Hand of Cut = Right hand No of flutes = 8
− Tool Class = carbide Comment = 1.75" Keyway
5. After verifying the tool is defined on the form, click Close.
Next, you create a user-defined attribute to apply a machining
process in the TechDB.
6. On the main menu, scroll down the tree to the Features and
Operations section and click User Defined Attributes.
The Feature & Attributes form displays.
7. For the Feature, select Open Profile on the drop down list.
8. In the User Defined Attributes section,
click in the empty cell below Taper
and type T-slot.
9. Click Close.

10. On the main menu, click Features & Operations under Feature & Operations in the tree.
The Feature & Operations form displays.
11. For the Feature Type, select Open Profile on the drop
down list.
12. In the Feature Conditions section, scroll down to the
last record, which is identified with an asterisk (*),
and click the asterisk.
13. In the Attribute column, click the down arrow and
select T-slot from the list.
14. Click in the Upper Range cell and type 1.
Notice that the Dimension for Range field at the top of the form is set to Feat Depth. This
means that the values of the lower and upper ranges apply to the feature depth. The
Dimension for Range changes depending on the feature type (for example, holes use
diameter).

Learning the TechDB 6-27

TechDB 7

Now, you can specify the tool to use and the feature conditions to apply to this attribute.
Notice that under Operations for Matching Conditions, the Operation field is grayed out.
Operations cannot be selected until this field is activated.
15. In the list of Feature Conditions, select the record above the new record for the T-slot
attribute, then select the T-slot record again.
The Operation field is now active.
16. In the Operations for Matching Conditions section, scroll down and click the asterisk.
17. In the Operation column, click the down arrow and select Finish Mill on the list.

18. Click the Pencil button next to the Tool Selection Summary cell.
The Tool Selection form displays.

6-28 Learning the TechDB

 TechDB 7

19. Select Keyway for the Tool Type.

20. Click the Select tool option and click the Select
Tool button.
The Tools Database – Keyway form displays.
21. Select the 1.75 inch keyway tool defined earlier
in this exercise.
22. Click OK.
The tool information displays on the Tool Select
form.
23. Click Close.
24. Click the Pencil button next to the cell in the Depth Criteria Summary column.

Learning the TechDB 6-29

TechDB 7

25. In the Depth Evaluation form, click the Use

Expression option and use the defaults in the
Matching Depth Expression section.
26. Click Close.
The Feature & Operations form should look like the
figure below.
27. Click Close.
28. On the main menu, click Quit to exit the TechDB.

Inserting a 2 Axis Feature and Applying the T-slot Attribute

Define two machinable features and apply the new TechDB information to one of the
features.
1. Make sure the Solids Machining Feature tree is displayed.
2. Right click NC Manager in the tree and select Collapse items.
This makes it easier to work with the items in the tree.
3. Click the plus (+) symbol next to Part Setup3 to expand it.
4. Right click Part Setup3 and select Insert 2.5 Axis Feature.
5. In the 2.5 Axis Feature Wizard: Feature & Cross Section Definition dialog box, select
Open Profile for the Feature Type.

6-30 Learning the TechDB

 TechDB 7

6. Rotate the part and pick the edge shown in the figure.
7. Click Next.
The 2.5 Axis Wizard: End Conditions dialog box
displays.

8. Pick the face shown in the figure.

Upto Face displays as the End Condition Type
and the depth is calculated automatically.
9. Make sure the Edit feature profiles option is checked.
10. Click Next.
Notice that the direction of the arrow that displays on the
part indicates the incorrect side to cut.

11. In the 2.5 Axis Feature Wizard: Edit Feature Profiles dialog
box, select the Flip direction to cut option.
The arrow direction changes as shown in the figure.
12. Click Finish.
The 2.5 Axis Feature Wizard: Feature & Cross Section
Definition dialog box displays again.

Define the open profile for the keyway cutter.

13. Make sure Open Profile is selected for the listed for the Feature
Type.
14. Pick the bottom inside edge of the t-slot.
15. Click Next.
16. For the Attribute, select T-slot.

Learning the TechDB 6-31

TechDB 7

17. For the End Condition, rotate the part and pick the underside of the keyway.
Upto Face displays as the End Condition Type
and the depth is calculated automatically.
18. Remove the check mark from the Edit feature
profiles option and click Finish.
19. Click Close to exit the wizard.
The two Open Profile Features are listed in the
tree.
20. Hold down the left mouse button and drag Open Profile1 over Open Profile2.
This is the order you would want to machine this area. Note that you can also change the
machining order in the Solids Machining Operation tree after operations have been
generated.
Generating Operations and Toolpaths
1. Right click Part Setup3 and select Generate the Operation Plan.

2. Click the Solids Machining Operation Tree tab at the bottom of the tree.
Two Finish Mill operations have been generated for the Open Profile features.
3. Right click the first Finish Mill operation in the tree and select Parameters.
4. On the Leadin tab, select Parallel for the Leadin type.
5. Set the Leadin amount to 1.00in and the Leadin overlap to .10in, then click OK.
6. Right click the second Finish Mill operation and select Parameters.
7. Make the same changes on the Leadin tab, then click OK.
8. On the Finish tab, set the First cut amount and Max cut amount to 1.00in, then click OK.
This value is greater than the depth of the profile and will generate only one pass with the
keyway cutter.
9. Right click Part Setup3 and select Generate Toolpath.
10. Right click Part Setup3 and select Simulate Toolpath.
11. Set the End condition to Next Operation.

12. Click the Run button.

13. When the first operation has completed, click the Single Step button to see the
keyway tool cut the T-slot.

6-32 Learning the TechDB

 Index

Auto save option 1-11, 4-29

Index Automatic Feature Recognition (mill) 1-9, 1-19, 2-3
Automatic Feature Recognition (turn) 4-9, 4-19
.nc, NC program file extension 1-18 avoid areas 2-12, 2-19, 3-28
.pcii, ProCAM II file extension 1-11 B/C
.pinf, post info file extension 4-17 bar stock, defining Workpiece 4-8
.set, Setup file extension 1-18, 4-18 CAD command, using to insert geometry 1-36, 4-30
.txt, NC program file extension 1-18, 4-17 CAD/CAM toolbar
.x_b, Parasolid file extension 1-3, 4-3 CAD button 1-36, 4-30
.x_t, Parasolid file extension 1-3, 4-3 Solids Machining button 1-3
2 Axis Rough Mill operation, machine island tops 2-4 casting, defining workpiece 4-30
2 Axis Wizard dialog box 2-12, 2-20 centerline (turn)
2.5 Axis feature changing direction 4-47, 4-53
autodecting islands 1-33, 1-41 defining 4-53
defining islands interactively 1-41 chuck
inserting 1-12, 2-9 defining 4-43
inserting multiple features 1-31 double-chucking 4-46, 4-50, 5-5
2.5 Axis Feature wizard 1-12, 1-31, 2-9 locating symbols 4-43, 5-5
3 Axis feature, inserting 3-3, 3-13, 3-20 clamps, identifying as areas to avoid 2-12
3 Axis Finish Mill operation Clearance plane 2-20
defining contain and avoid areas 3-28 contain areas 3-28
Flowline strategy 3-27 cross section entity, inserting on geometry 1-36, 4-30
generating core toolpaths 3-10 cross section entity, using
Offset strategy 3-33 defining 3 axis finish flowline curves 3-27
Pocket strategy 3-23 defining a feature 1-41
Radial strategy 3-32 defining curve for 3 axis finish offset toolpath 3-33
Slice strategy 3-6 defining Part Setup origin 1-36, 1-45
Spiral strategy 3-33 defining workpiece (mill) 1-36, 2-8, 3-3
UV strategy 3-31 defining workpiece (turn) 4-30, 4-46
Z level pattern 3-17 identifying avoid areas 2-19, 3-29
Z level strategy 3-10 identifying center point of 3 axis finish spiral
3 Axis part deviation 3-4, 3-17 toolpath 3-33
3 Axis Rough Mill operation identifying clamps 2-12
generating cavity toolpaths 3-17 identifying contain area 3-28
generating core toolpaths 3-11
D
generation 1 & 2 processing engines 3-5, 3-9
hit flats option 3-9 deep groove cycle option 5-4
Z levels 3-9 Default Operation Parameters form (TechDB) 6-12
3 Axis Wizard Default Setup Parameters form (TechDB) 6-11
Select Geometry dialog box 3-23, 3-27, 3-28, 3-34 Define Point dialog box 3-32
4 axis turning 5-2 Define Turn Section Plane command 4-47, 4-52
Define Turn Workpiece dialog box 4-8, 4-32
A Define Workpiece dialog box 1-8, 1-39, 3-3
attribute delete operation (mill) 1-43
applying to machinable feature 1-10, 1-24, 1-25, demonstration mode 1-35
1-42, 2-3, 4-11, 4-22, 4-39, 6-21, 6-30 Depth Evaluation form (TechDB) 6-20, 6-30
associating machining sequences (TechDB) 6-16 double-chucking 4-46, 4-50
defining in TechDB 6-13, 6-15, 6-26

i
Index

E/F Insert Part Setup command 1-29, 2-14, 3-3, 3-7, 3-20,
Edit feature profiles option 1-12, 1-32, 1-40 3-30
Edit Pattern dialog box 1-33 Insert Pattern command 1-33
Edit Tool Parameters dialog box (mill) 1-20 Insert Turn Feature command 4-12, 4-26, 4-33, 4-38
Edit Turn Feature dialog box 4-47 K/L
Entry Drill operation (mill) 1-15 keyway cutter
Extract Machinable Features command (mill) 1-9, applying attribute to machinable feature 6-30
1-19, 1-28 defining attribute in Technology Database 6-26
Extract Machinable Features command (turn) 4-10, Leadin/Leadout, changing 2-15
4-19, 4-26, 4-47, 5-3 locating symbols 4-43
FANTUTL 4-7, 4-21
M
FANTUTM 1-7, 1-21, 3-2
Mach. deviation 3-25
Feature & Attributes form (TechDB) 6-13, 6-15, 6-27
machinable features (mill)
Feature & Operations form (TechDB) 6-16, 6-27
combining 1-33
Feature tree (turn) 4-3, 4-10
creating Face feature 1-12
file
defining 3 axis feature 3-3, 3-13
NC program 1-18, 4-17
defining automatically 1-9, 1-19, 2-3
opening Parasolid 4-3
defining interactively 1-12, 2-9
opening solid model 1-3, 4-3
deleting 1-28
saving machining data 1-11, 4-11
features recognized automatically 1-9, 1-19, 1-22,
Flowline strategy, 3 Axis Finish operation 3-27
2-3
forging, defining workpiece 4-30
modifying 1-25
G/H reorganizing 1-30
Generate Operation Plan command (mill) 1-13, 1-26, suppressing 1-30
1-34, 1-42, 3-4, 3-16 using attributes 1-10, 1-24, 1-25, 1-42, 2-3, 6-21,
Generate Operation Plan command (turn) 4-13, 4-23, 6-30
4-27, 4-42, 4-48 machinable features (turn)
Generate Toolpath command (mill) 1-15, 1-34, 3-6 creating OD feature 4-12, 4-26
Generate Toolpath command (turn) 4-15, 4-28 defining automatically 4-9, 4-19
Generation 1 & 2 processing engines 3-5, 3-9 defining groove feature 4-38
Generation 1 AFR method (turn) 4-52 defining interactively 4-12, 4-26, 4-38
groove feature (turn), defining 4-38 defining OD rectangular groove feature 4-33
Hit flats option, 3 Axis Rough Mill operation 3-9 defining thread feature 4-39
Hole Feature Definition dialog box 1-44 editing 4-47, 5-3
Hole Parameters dialog box 1-10 extracting OD feature with protrusion 4-52
I extracting with Generation 1 4-52
Insert 2.5 Axis Feature command 1-12, 2-9 features recognized automatically 4-9, 4-19, 4-21
Insert 3 Axis Feature command 3-3, 3-13, 3-20 renaming 4-41
Insert 3 Axis Feature dialog box 3-4, 3-13, 3-20 reorganizing 4-27
Insert Avoid Area 2-12, 2-19 suppressing 4-27
Insert Contain Area 3-28 using attributes 4-11, 4-22, 4-39
Insert Hole Operation command 1-43 Machine (mill) 1-4, 1-5, 1-19
Insert Hole Operation dialog box 1-43 adding in TechDB 6-2
Insert Operation command (mill) 2-11, 3-24 Machine (turn) 4-4, 4-5
Insert Operation dialog box 2-11

ii
 Index

Machine dialog box operations (mill)

Controller tab 1-7, 1-21, 3-2, 4-7, 4-21 adding tool overlap on open air edges 2-18
Machine tab 1-19, 4-5 changing machining parameters 1-14, 1-42, 2-12,
opening 1-5 2-15, 3-17, 3-21
Parameters tab 1-7, 1-21, 4-7, 4-21 changing tools 1-43, 3-5, 3-8, 3-17, 3-21
Tool Crib tab 1-6, 1-20, 4-6, 4-20 combining 1-33, 2-6
Machine Parameters form (TechDB) 6-3, 6-10 deleting 1-43
Machining Depth form (TechDB) 6-25 generating operation plan 1-13, 1-26, 1-34, 1-42,
machining direction 3-4, 3-16
changing 1-39, 4-48 generating toolpaths 1-15, 1-34, 3-6, 3-24
defining 3-3, 4-35 inserting 1-43, 2-11, 3-24
machining island tops 2-4 inserting avoid areas 2-12, 2-19
Machining Parameters dialog box (mill) 1-14, 1-42, inserting contain area 3-28
2-12, 3-5, 3-21 modifying 1-14, 1-42, 2-12
NC tab 2-20 post processing 1-17, 1-35
Z Level Edit tab 3-9 regenerating operation plan 1-26
Machining Parameters dialog box (turn) 4-14, 4-34 set up machining sequence in TechDB 6-15, 6-23,
Thread tab 4-42 6-26
N simulating toolpaths 1-15, 1-35
NC Planes, specifying for 2 axis operations 2-21 sorting 1-46, 2-4
NC program (mill) updating operation plan 1-26
file 1-18 operations (turn)
generating 1-17, 1-35 changing machining order 4-16
steps to generate 1-2 changing machining parameters 4-14, 4-34
NC program (turn) changing tools 4-35
file 4-17 deleting 4-14
generating 4-17, 4-29 generating operation plan 4-13, 4-23, 4-27, 4-42,
steps to generate 4-2 4-48
NC program, changing default file extension 4-17 generating toolpaths 4-15, 4-28
modifying 4-14, 4-34, 5-4
O
OD feature with protrusion, extracting 4-52 post processing 4-17, 4-29
OD feature, defining 4-12, 4-39 simulating toolpaths 4-15, 4-36, 4-44
OD Profile Parameters dialog box 4-11, 4-22 Options dialog box, Features tab 3-4, 3-17
OD rectangular groove feature, defining 4-33 Options dialog box, Features tab (turn) 4-53
Offset strategy, 3 Axis Finish operation 3-33 Options dialog box, General tab 1-11, 4-11, 4-16,
open air edges 4-29
changing 1-32, 1-40 origin (mill), changing 1-45, 2-5, 3-20
specifying tool overlap on 2-18 origin (turn)
Open dialog box, Solids option 1-3, 4-3 changing 4-35, 4-47, 4-48, 4-53
Operation Setup Parameters dialog box changing for double-chucking 4-50
Chuck Location tab 4-44, 4-50, 5-5, 5-6 origin (turn), changing 5-6
Chuck Parameters tab 4-44, 4-50, 5-5, 5-6 P
Origin tab 4-35, 4-43, 5-6 Parameters command 1-24
Operation tree (turn) 4-13 Parameters dialog box 1-24
Parasolid file
opening 4-3

iii
Index

Part Setup 1-10 program zero (mill), changing location 1-45, 2-5,
changing origin 1-45 3-20
defining machining direction 1-25, 2-5 program zero (turn), changing location 4-35, 4-53
inserting 1-29, 2-14, 3-3, 3-7, 3-20, 3-30 R
setting default rapid, clearance planes (TechDB) Radial strategy, 3 Axis Finish operation 3-32
6-11 Rapid plane 2-20
specifying Rapid and Clearance Plane 2-21 Recycle Bin 1-4, 1-29, 4-5
Part Setup dialog box 1-29, 2-14, 3-3, 3-20, 3-30 Report Database, customizing setup sheets 1-18, 4-18
Part Setup Parameters dialog box 1-45, 2-5, 3-20
S
NC Planes tab 2-21 save machining data 1-11, 4-11
parts used in exercises Save/Restore part option 1-11, 4-11, 4-29
mill2ax_1.x_t 1-3 setup sheet 1-7, 1-18, 4-18
mill2ax_11.pcii 6-15, 6-21 shortcut menus 1-5, 4-5
mill2ax_2.pcii 1-19 Simulate Toolpath command (mill) 1-15, 1-35, 3-6,
mill2ax_3.pcii 1-27 3-22
mill2ax_4.pcii 1-36 Simulate Toolpath command (turn) 4-15, 4-36, 4-44,
mill2ax_5.pcii 2-2 4-50, 5-7
mill2ax_6.pcii 2-8 sketch See cross section entity
mill2ax_8.pcii 2-17, 6-26 Slice strategy, 3 Axis Finish Mill operation 3-6
mill3ax_1.pcii 3-2 solid model file
mill3ax_2.pcii 3-7 opening 1-3, 4-3
mill3ax_3.pcii 3-12 setting units of measurement 1-3, 4-3
mill3ax_4.pcii 3-19 Solids
mill3ax_5.pcii 3-26 demonstration mode 1-35
mill3ax_6.pcii 3-30 machining trees 1-4, 4-4
millp1.pcii 2-22 menu 1-5, 4-5
millp2.pcii 2-23 Message Window 1-10, 1-17, 1-34, 4-10, 4-28
turn2ax_1.pcii 4-25 toolbar 1-5, 4-5
turn2ax_1.x_t 4-3 Solids Machining Feature tree (mill) 1-3, 1-10
turn2ax_3.pcii 4-19 Solids Machining Operation tree (mill) 1-14
turn2ax_4.x_t 4-30 Solids toolbar
turn2ax_5.pcii 4-37 Cross Section Entity command 1-36, 4-30
turn2ax_6.pcii 4-46 Sort Operations command (mill) 1-46, 2-4
turn2ax_7.pcii 4-52 Sort Operations dialog box 1-46, 2-4
turn4ax_1.pcii 5-2 Sort Operations form (TechDB) 6-13
Pattern feature 1-33 spindle centerline (turn)
Pencil Mill operation 3-24 changing direction 4-47, 4-53
Pocket strategy, 3 Axis Finish Mill operation 3-23 defining 4-53
Post Output File dialog box 1-17, 4-17 Spiral strategy, 3 Axis Finish operation 3-33
Post Process command 1-17, 1-35, 4-17, 4-29 Step Thru Toolpath command 1-16
Post Process Output dialog box 1-18, 1-35, 4-18 steps to generate NC program (mill) 1-2
post process, changing default file extension 4-17 steps to generate NC program (turn) 4-2
post processor (mill), parameters 1-7 stock See Workpiece (turn). See Workpiece (mill)
post processor (turn), parameters 4-7

iv
 Index

T Turn Setup 4-10

Technology Database defining chuck 4-43
adding mill machines 6-2 defining machining direction 4-35
attributes 6-13, 6-15, 6-26 displaying locating symbols 4-43
default operation parameters 6-12 U
default Setup parameters 6-11 Units dialog box 1-3, 4-3
default sort operations order 6-13 UV strategy, 3 Axis Finish Mill operation 3-31
defining taps & associated operations 6-23
W
selecting tools for operations 6-19
Workpiece (mill) 1-4, 1-8, 1-27, 2-8, 3-2
setting up machining sequences 6-15, 6-23, 6-26
Workpiece (turn) 4-4
tool cribs 6-8
defining as forging or casting 4-30
tools 6-5
defining bar stock 4-8
Tools Database form (mill) 1-21
defining from cross section entity for double-
thread (turn)
chucking 4-46
changing operation parameters 4-42
Workpiece Material dialog box 1-8, 4-8
generating operation 4-26, 4-39
selecting thread condition in TechDB 4-41 X
threading parameters (TechDB) 6-23 X Preset 4-8
tool (mill) Z
adding to TechDB 6-5 Z level pattern, 3 Axis Finish Mill operation 3-17
selecting for operation 1-43, 3-5, 3-8, 3-17, 6-19 Z level strategy, 3 Axis Finish Mill operation 3-10
selecting tool crib 1-6, 1-20, 6-10 Z levels, changing for 3 Axis Rough Mill operation
setting up tool crib in TechDB 6-8 3-9
tool (turn) Z Preset 4-8
adding tool to turret 4-21
selecting for turn operation 4-35
selecting tool turret 4-6, 4-20
Tool Crib form (TechDB) 6-9
Tool Selection form (TechDB) 6-19, 6-24, 6-29
toolpaths (mill)
customizing leadin/leadout 2-15
generating 1-15, 1-34, 3-24
post processing 1-17, 1-35
simulating 1-15, 1-35, 3-6
specifying areas to avoid 2-12, 2-19
stepping through 1-16
toolpaths (turn)
generating 4-15, 4-28
post processing 4-17, 4-29
simulating 4-15, 4-36, 4-44, 4-51, 5-7
Tools Database - Keyway form (TechDB) 6-27
Tools Database – Tap form (TechDB) 6-23
turn feature, inserting 4-12, 4-26, 4-38
Turn Section Plane dialog box 4-47

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Index

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