Edgecam 4/5 Axis

Simultaneous Milling
Training
4/5 Axis Simultaneous

Copyright
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Contents
Contents ................................................................................................................................3
License Restrictions ................................................................................................................7
Example Part Files ..................................................................................................................7
System Requirements and Supported Operating Systems .....................................................7
Edgecam Knowledge Base......................................................................................................... 7
Conventions Used in This Guide.............................................................................................8
Terminology................................................................................................................................ 8
Pre-Requisites ......................................................................................................................10
Licensing Requirements ........................................................................................................... 10
Before You Start ...................................................................................................................10
Setting Your Defaults................................................................................................................ 10
Five Axis Machining Overview ..............................................................................................11
The Shift Towards 5 Axis ......................................................................................................12
Advantages of working with 5 Axis cycles ................................................................................. 12
Disadvantages of 5 Axis ........................................................................................................... 12
Five Axis Postprocessors ......................................................................................................13
Machine Tool Configuration ..................................................................................................16
Five Axis Toolpaths .................................................................................................................. 16
Possible Five Axis Machine Tool Configurations ..................................................................17
What is Edgecam Machine Simulator? .................................................................................18
Horizontal Borer, with Rotary Axis ........................................................................................19
Exercise 0 – Solid Machine Tool Simulation Set Up ..................................................................... 19
Machine Tool Kinematics ......................................................................................................21
Exercise 0a – Horizontal Borer – Machine Kinematics.................................................................. 21
Machine Tool Simulator ........................................................................................................23
Exercise 0b - Machine Tool Kinematics ........................................................................................ 23
Five Axis Machine Tool NC code format ...............................................................................26
Multi-plane Coordinate System Output ..................................................................................... 26
CPL Coordinates ...................................................................................................................... 26
Machine Coordinates................................................................................................................ 26
Multi-plane Nutated Output ....................................................................................................... 27
Orthogonally Aligned ................................................................................................................ 27
Machine Axis Aligned ............................................................................................................... 27
Five Axis Coordinate System ................................................................................................27
Absolute coordinate Tooltip ...................................................................................................... 27
Absolute coordinate Pivot Point ................................................................................................ 27
Part Coordinates ...................................................................................................................... 27
Exercise 1 - Multiplane Output...................................................................................................... 28
Exercise 2 – Pivot about tooltip .................................................................................................... 30
Exercise 3 – Aligning Rotary Axis ................................................................................................. 32
Conclusion ............................................................................................................................... 33
Multi-Plane Nutated Output ...................................................................................................34
Orthogonally Aligned (CPL) ...................................................................................................... 34
Machine Axis Aligned (MC) ...................................................................................................... 34
Exercise 4 – Nutated Indexing Coordinates .................................................................................. 34
Exercise 5 – Five Axis Coordinates .............................................................................................. 37
Absolute Tool Tip ..................................................................................................................... 37
Part Coordinates ...................................................................................................................... 37
Five Axis Simultaneous - Turning .........................................................................................38
Absolute Coordinates - Tool Tip or Pivot Point ......................................................................... 38

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B Axis Coordinates................................................................................................................... 38
Five Axis Positioning (3 + 2) and Simultaneous.................................................................... 39
Exercise 5a – 3+2 and Simultaneous ........................................................................................... 39
3+2 Positional .......................................................................................................................... 40
Simultaneous ........................................................................................................................... 40
Conclusion ............................................................................................................................... 40
Component Positioning......................................................................................................... 41
Exercise 6 – Part Positioning ....................................................................................................... 42
Five Axis Tool Length Compensation ................................................................................... 44
5 Axis Operations ................................................................................................................. 45
Four Axis Rotary ...................................................................................................................... 45
Five Axis Blend ........................................................................................................................ 45
Five Axis Swarf ........................................................................................................................ 45
Five Axis Curve ........................................................................................................................ 45
Five Axis Finishing ................................................................................................................... 45
3 to 5 Axis Cycle ...................................................................................................................... 46
Five Axis Milling cycle .............................................................................................................. 46
CAD Preparation .................................................................................................................. 47
Drive and Check Surfaces........................................................................................................ 47
Drive Curve .............................................................................................................................. 47
Drive Surfaces ......................................................................................................................... 47
Check Surfaces........................................................................................................................ 47
Setting the Surface Side to Machine ........................................................................................ 47
Exercise 7- Surface Normals........................................................................................................ 49
Understanding the Five Axis Cycle ....................................................................................... 52
Solid Models ............................................................................................................................ 52
Drive Surfaces ......................................................................................................................... 52
Direct Picking ........................................................................................................................... 52
Check Surfaces........................................................................................................................ 52
Swarf Cut – Operation .......................................................................................................... 53
Exercise 8 – Preparing a Solid Model .......................................................................................... 54
Turn Milling ........................................................................................................................... 60
Exercise 9 – Four Axis Rotary Operation ..................................................................................... 60
Conclusion ............................................................................................................................... 63
Exercise 10 – Five Axis Curve Operation ..................................................................................... 64
Exercise 11 – Five Axis Blend Between Operation ....................................................................... 68
Exercise 12 – Five Axis Finishing Operation ................................................................................ 72
Five Axis Cycle ............................................................................................................................ 77
The Five Axis Cycle .............................................................................................................. 78
Toolpath Pattern ................................................................................................................... 79
Parallel Slice ............................................................................................................................ 79
Exercise 13 - Parallel Slice .......................................................................................................... 79
Normal to Curve ................................................................................................................... 81
Exercise 14a – Normal to a Curve................................................................................................ 81
Exercise 14b – Blend Between Two Curves ................................................................................. 83
Exercise 14c – Parallel to Curve .................................................................................................. 85
Project onto Curve ................................................................................................................ 89
Exercise 14d – Project onto Curve ............................................................................................... 89
Blend Between Two Surfaces ............................................................................................... 91
Exercise 14e – Blend Between Two Surfaces .............................................................................. 91
Exercise 14f – Parallel to Surface ................................................................................................ 94
Exercise 15 - PCI Templates........................................................................................................ 98
Tool Axis Control ................................................................................................................ 101
Tilt Strategy ............................................................................................................................ 101

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Output Type............................................................................................................................ 101

Tool Axis Control Tilt Strategy - Normal .................................................................................. 101
Exercise 16 – Normal and Relative to Cut Direction ................................................................... 102
Exercise 16a – Tilt Strategy - Axis control .................................................................................. 104
Exercise 16b – Tilt Strategy - Through a Fixed Point .................................................................. 106
Exercise 16c – Tilt Strategy- Away From a Fixed Point .............................................................. 109
Exercise 16d – Tilt Strategy - Tilt to a Curve ............................................................................... 111
Check ..................................................................................................................................114
Exercise 17 - Check Surfaces .................................................................................................... 115
Exercise 17a - Multiple Check Surfaces ..................................................................................... 117
Exercise 17b - Check Surfaces .................................................................................................. 121
Exercise 17c - Check Surface Options ....................................................................................... 123
Exercise 18 - Typical Five Axis Cycle set-up .............................................................................. 125
Conclusion ............................................................................................................................. 134
The Depth Tab Settings ......................................................................................................135
Exercise 19 – Depth Settings ..................................................................................................... 136
Exercise 20 – Retract Setting ..................................................................................................... 138
Angular and Axis Limits .............................................................................................................. 139
Exercise 21 – Angular Limits ...................................................................................................... 140
Conical Limits......................................................................................................................142
Exercise 22 - Conical Limits ....................................................................................................... 142
Exercise 23 – Selecting an Axis ................................................................................................. 144
Lead Control .......................................................................................................................146
Exercise 24- Lead Parameters ................................................................................................... 147
Link Control .........................................................................................................................151
Exercise 25 – Link Control .......................................................................................................... 151
Exercise 26 - Long Links ............................................................................................................ 152
Gap Control.........................................................................................................................153
Exercise 27 – Gap Parameters................................................................................................... 154
Exercise 28 – Depth, Leads, Links and Multi-Cuts ...................................................................... 155
Exercise 28a - Spiral Solid with Table Tilt.ppf ............................................................................. 158
Exercise 28b - Spiral Solid with Head Tilt.ppf ............................................................................. 158
Exercise 28c - Spiral Solid with Mill Turn.ppf .............................................................................. 159
Optimised Feedrates ...........................................................................................................160
Inverse Time Feedrate ........................................................................................................... 160
Miscellaneous Parameters ..................................................................................................162
Exercise 29 - Point Separation and Angle change ...................................................................... 162
Exercise 30 - Preferred Rotary Solution ..................................................................................... 164
Exercise 31 - Round Corner Modifier.......................................................................................... 165
Exercise 32 – Round Corner External ........................................................................................ 167
Exercise 33 - Round Corner example ......................................................................................... 168
Exercise 34 - Start Margin and Tool Axis Shift ............................................................................ 170
Taper Tools ............................................................................................................................ 170
Method 1 – Known Taper Angle ............................................................................................. 170
Method 2 – Taper Angle not Known ....................................................................................... 170
Side Tilt Definition (Tool Axis Control) ................................................................................171
Example 35 - Side Tilt Examples ................................................................................................ 171
Roughing in Five Axis Simultaneous Machining .................................................................172
Exercise 36 - Multiple Passes and Depths.................................................................................. 172
Exercise 37 – Roughing In Four Axis Simultaneous Machining .................................................. 174
3 to 5 Axis Cycle .................................................................................................................177
Exercise 38 - 3 To 5 Axis ............................................................................................................ 178
Workshops ................................................................................................................................. 182
Swarf Cutting (Workshop 1)........................................................................................................ 182
Trimming (Workshop 2) .............................................................................................................. 185

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Rotary CAMS (Workshop 3) ....................................................................................................... 188

Blade machining (Workshop 4) .................................................................................................. 193
Machine Tool: 5ax training - 4axcybs b axis tool tip positional only.tcp................................... 197
Port (Workshop 5) ...................................................................................................................... 201
Lacing the Port ....................................................................................................................... 208
Impeller Floor machining (Workshop 6) ...................................................................................... 211
Face Features ........................................................................................................................ 212
Worm (Workshop 7) ................................................................................................................... 217
Create Sequence ................................................................................................................... 219
Machine Simulator (Workshop 8) – 4 Axis CYB Sub Spindle Lathe............................................ 222
Document Revision ................................................................................................................ 225

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License Restrictions
You may discover that you are unable to work with some of the exercises due to license restrictions.
In order to remove any license restrictions, you can set Edgecam to run in Homework Mode. To
activate Homework Mode, Right click over the CLS in the windows task bar notification area, and
select the option from the menu.
Homework Mode enables the user of a licensed system to run Edgecam with access to all
functionality except for NC code generation.
 Homework mode emulates the educational Homework license.
 Useful when training for example, to evaluate higher levels of license than currently in
use.

Homework Mode allows you to experience all available licenses in Edgecam. This feature will allow
you to save files. The file extension is not a standard .PPF extension but is an .EPF.
You will not be able to re-load an .EPF file into a licensed version of Edgecam.

 You cannot generate CNC data from an .EPF File.

Example Part Files

There are a number of sample part files mentioned within this training guide. This data can be
accessed either from a Training CD or specified folder.
If selecting from a USB Stick this will generally be E:\ Miscellaneous Files\Five Axis Simultaneous
License Parts.

 Some files may not be opened away from the classroom due to licensing
restrictions.

System Requirements and Supported Operating Systems

For the latest up to date information visit http://www.edgecam.com/systemrequirements.

Edgecam Knowledge Base

Tips on FAQ http://www.edgecam.com/faqs/

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Conventions Used in This Guide

To enable you to use the information in this guide effectively, you need to understand the used in the
guide to represent different types of information.
 Buttons on the screen are represented as the button text in bold within square brackets.
For example: Click on [OK].
 Keys on the keyboard are represented as bold lettering in between <> characters.
For example: Press <Enter>.
 Menu options are represented as a path with the main and sub menus in Bold and
Capitalised and separated with ►.
For example: Select File ► Open.
 Field names are represented as bold text. And the value to be entered will be
represented by Bold Text.
For example: Enter the value 50 in the Offset field. Or
 When prompted for the X, Y or Z values type X100Y50Z0 <Enter>.
Denotes a Left Mouse Button Click
Denotes a Right Mouse Button Click

 This is a note. It contains useful or additional information.

 This is a reference. It directs you to another area or document.

This is a thought box. It is generally used in exercises and contains a question for
you to consider.

 This is a warning, it contains information that you must not ignore.

 This is a tip. It is generally used in exercises and offers further advice.

1. This is the first line of a number list item

2. This is the second item of the numbered instructions, which you must

3. Follow in sequence.
 This is a list
 of items, in which
 The order is not important.

Terminology
Whilst reading this manual some of the terminology and terms maybe new to you.
Examples of these are:

Pick = Select = Left Click.

Construction Plane (CPL) = Origin = Datum
Confirm your selection = Tick or Right Click

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Trainee Notes

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Pre-Requisites
Depending on your level of License, this lesson assumes that you have previously completed training
in,
 Getting Started
 Wireframe Essential Design would be advantageous
 Essential Milling
 Standard Milling
 Advanced Milling
 Ultimate Milling
 Essential Turning
 Standard Turning C/Y
 Advanced Turning 4BSS

 You must successfully complete these all your license lessons before beginning work on
the following exercises.

Licensing Requirements
This manual is aimed at users with the Edgecam 4 Axis Simultaneous Milling License
(Edgecam_EN040-S) or Edgecam 5 Axis Simultaneous Milling License (Edgecam_EN050-S) and
used in conjunction with a Solid Machinist License.
Before You Start
Setting Your Defaults
Before starting these exercises ensure that you have set Edgecam to a suiTable mill default.

 Refer to the Getting Started manual for more information on Defaults.

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Five Axis Machining Overview

Edgecam provides a comprehensive range of simultaneous 4- and 5-Axis milling strategies designed
for the production machining requirements of industries such as :-
 Aerospace
 Turbine Blades
 Medical
 Automotive
 Motor Sport
 Marine
 Mould & Die
 Sub-Contract
 Oil & Gas
Among the advantages of 5-Axis machining are the ability to reduce cycle time by machining
complex components using a single set-up and improved surface finish by tilting the tool to maintain
the optimum tool to part contact point at all times.

Additionally, improved access to undercuts and deep pockets through tilting the tool or component
allows shorter series tooling to be employed further improving the surface finish and eliminating the
need for secondary set-ups.

5-Axis strategies include Swarf cutting for machining variable taper walls and sophisticated multi-
surface finishing with inbuilt, automatic collision avoidance. Additional strategies are available to
handle applications such as machining of impellor type components and the de-flashing of plastic
moulded components.

In addition to the range of 5-Axis strategies, the requirements of 4-Axis rotary machining are
addressed with a range of cycles that handle the machining of automotive and aerospace
components such as camshafts, blades and rotary dies

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The Shift Towards 5 Axis

Five Axis Machining has become increasingly popular over the past number of years. This is due to
many factors, such as:-
 Technology advance in Machine tools
 Affordability of Machine Tools
 One Operation Manufacturing
 Reduced Set-ups / Reduced Batch Size
 Reduced Lead Times
 Improved Accuracy
 Less Scrap/Damage
 To remain Competitive
 Changing Practice (Solid)

Advantages of working with 5 Axis cycles

 Manufacturing Trends
 One Operation Manufacture
 Increased Flexibility
 Made From Solid
 Greater Accuracy
 Better Cutting Conditions than 3 Axis
 Shorter Tools (more rigidity)
 Less Need for Fixtures

Disadvantages of 5 Axis
 High Value Machine
 Unable to Programme Manually
 Longer set-up Time
 Education
 Collision Rich Environment

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Five Axis Postprocessors

It is essential that you not only understand the behaviour of the Five Axis Cycle and Operations, but
also the composition of the postprocessor.
Edgecam supports a variety of Five axis machine tools controllers, including multiple configurations.
The term configuration refers to the arrangement of axis on the machine tool – both rotary and linear.
Remember, Five axis machine tools are used for both Positional machining (3 + 2, multi-plane) and
Simultaneous.
Herewith a list of Five Axis Machine tool configurations supported by Edgecam.
 Table/Table
 Head/Head
 Head/Table Horizontal or Vertical Intersecting Table/Table
Edgecam Code Wizard will provide the tools for setting up the postprocessor. Within the Machine
Parameter stage, you may set your Machine type which allows you to determine the correct type of
Five Axis capability.
The example below uses a Vertical spindle, where, Rotary Head is B and Rotary Table is A.

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The above configuration allows rotary movement on the Table as well as the head – a Table/Head
machine tool set-up.

The Machine Elements window shows the correct machine tool configuration has been achieved.
Furthermore, it will empower the user to determine the amount of linear and rotary movement used
by a particular axis. The same window allows the user to customise the graphic image.
Selecting a different machine Type will yield a completely different machine tool configuration. The
example below uses a Vertical spindle, where, Rotary Head is B and Rotary Table is C.

The above configuration creates the machine tool shown below.

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The Default Parametric Graphic images can be replaced by bespoke solid models. The image below
shows the same configuration except the standard graphic images have been replace by custom
designed solid models.

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Machine Tool Configuration

The previous chapter introduced the importance of the code wizard and the role it plays when setting
up Five Axis Machine tools. You should pay particular attention to the set up aspect of the machine
tool configuration – in the case of the Code Wizard the Machine Elements window.
Users are no doubt fully conversant with the Simulate machining software used frequently
alongside every machining session within Edgecam. Using the Machine Elements window to its full
capacity, firstly allows the user to fully understand the kinematics of the machine tool. Moreover, a
user can also address the toolpath moments produced by CAM instructions.

Five Axis Toolpaths

Due to the complexity of five axis machining, users rely heavily on the support of a CAM system. The
style of machining promotes a collision rich environment where programmers need to be extra
vigilant. By offering full machine tool Simulation, Edgecam allows the user to:-

 Reduce prove out time

 Reduce lead time

 Reduce work in progress

 Reduce manufacturing costs

 Reduce delivery time to customer

 Remove toolpath collisions and thus, potential scrap

 Reduce machine tool damage and thus maintenance down time.

 Increase Productivity and thus profits

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Possible Five Axis Machine Tool Configurations

Head Table Trunnion Configuration

Head Table Machine Tool

Vertical Intersecting Table/Table

Vertical Head/Head

Vertical Non Intersecting Table/Table

Vertical Offset Head/Head

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What is Edgecam Machine Simulator?

Edgecam Simulator offers full simulation of the machine tool and machining process for lathes and
milling machines. This enables you to visualize the interaction between the various elements of the
machine tool helping to avoid expensive collisions, optimise the cutting process and reduce cycle
time.
Simplified block graphics are created for you by default and their dimensions can be parametrically
adjusted to suit your machine tool configuration.
Optionally, you can substitute the parametric graphics with your own fully detailed graphics by
modeling the machine tool in a solid modeler such as Edgecam Part Modeler. Elements of the
machine tool such as heads and turrets are represented as graphics. The 'Machine tree' provides an
easy-to-use method of controlling the display and kinematics of each machine tool component. The
graphics are positioned in an axis configuration built into the Machine Tree (such as upper ATC on
the B Axis, B Axis on the Y Axis and so on, or Table on the C Axis, C Axis on the A Axis and so on).
There are also graphics for fixtures, such as tool mounting blocks, and chucks, that you can store in
a library for use in the machine tool simulation.
The Machine Simulation setup is contained in the code generator; as created in Code Wizard. For
correct simulation you need to specify details such as the axis configuration and the Home positions.

 Edgecam Simulator has now been developed to include full collision checking between all
elements of the machine.

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Horizontal Borer, with Rotary Axis

The following exercise explains how to set up Machine Tool graphics for a Horizontal Borer with a
Rotary axis.

Exercise 0 – Solid Machine Tool Simulation Set Up

1. In Edgecam, open the file ’0 - Machine Assembly.ppf’ Study the part file, the
dimensions and layers. Observe (on the dimensions layer) the Y & Z axis values of
1300mm and 595mm.

 Note how the Solid Machine Tool is already correctly aligned in X, Y and Z within
Edgecam.
2. In Code Wizard open the file ‘0 - Horizontal B.cgd’. This post processor has already
been configured but no graphics have been set.
3. Returning to the ’0 - Machine Assembly.ppf’, from the Features Window, select all
the solid features that make up the Assembly by Window dragging all the items, Right
Click and select, Output Model.

4. Returning to the Code Wizard, ‘0 - Horizontal B.cgd’, ensure that you are in the
Machine Set Up window. Right Click and select, Paste Model.

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5. Select each solid in turn, then, In the Properties window, Re-name the Five Graphics
using basic descriptions.
 Head Y Axis
 Column X Axis
 Base
 Table Mount Z Axis
 Table B Axis

6. Select Datum Location. In the Properties window, observe the location to reflect the true
sizes of the machine tool from the Spindle Datum to the centre of the Table.
 X axis: 0mm
 Y axis: -1300mm
 Z axis: -585mm

 Note the positions of the CPL markers and negative values used.

7. Save as ‘0 - Completed Horizontal Borer.CGD’.

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Machine Tool Kinematics

In the Machine Tree, we now must place the various solids onto the correct axis and ensure that the
linear and/or rotary movements of these solids are correct. The four axes are X, Y, Z and B.
 As the Code Wizard does NOT offer an Undo facility or Auto-Save it is strongly
recommended that you regularly save your document.

Exercise 0a – Horizontal Borer – Machine Kinematics

1. In Code Wizard, carry on with the previous .CGD file or open ‘0 - Completed
Horizontal Borer.CGD’. Select the Machine Setup Window.
2. Drag & Drop the graphic Head Y Axis on top of the Y Axis. This will cause the graphics to
mimic the movement of the Y-Axis

3. From the Properties window, slide the Position drag bar. Observe how the Y Axis
Graphic moves, the motion is now correct.

4. Drag & Drop the remaining solids onto the relevant axis.

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5. In a real life scenario the Min and Max limits for all the axes would then be changed to suit
the specific machine tool.

6. Re-save as ‘0 - Completed Horizontal Borer.CGD’.

 See Workshops for more complex examples.

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Machine Tool Simulator

As in all cases, the most accurate check of the toolpath is through the Machine Simulator. This is a
must when considering the Five Axis cycle. As seen in the last exercise, the kinematics of the
machine tool must allow the axes to index to the extremities of the cycle.

Exercise 0b - Machine Tool Kinematics

1. Open the file ‘0b - Out of Limits.ppf’.

2. Select the Machining ribbon and on the sequence window, Regenerate the Five Axis
cycle. You will be informed an error on regeneration. Select [OK]. To dismiss and [OK] to
accept the cycle. The error message, The A axis minimum limit has been exceeded,
will then be displayed in the Feedback window.

3. Select [OK], to dismiss and cancel the Cycle.

4. In Code Wizard, open the file ’0b - Out of Limits.cgd’.
5. Inspect the A-Axis values, the Table can only move a full 180°.

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6. Edit the A Axis Table values.

 Minimum: -80 Maximum: 100

7. Compile the Code Wizard document.

8. Return to the Edgecam and the file ‘0b - Out of Limits.ppf’. From the Machine Tree,
Right click in the Machine Tree and select Reload Machine. The new values are now
imported to the file.

9. Regenerate the toolpaths. Notice how the error message has disappeared.
 If error messages persist select Machining ► Miscellaneous ► Delete Cache and then
regenerate.

10. Launch the Simulator.

 See how collisions are detected against the Spindle and Table.
11. Save as ‘Completed 0b - Out of Limits.ppf’.

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Five Axis Machine Tool NC code format

Having esTablished the machine tool configuration and graphics, the CNC output must be
considered.
With a Five Axis Machine tool you will need to consider two co-ordinate systems. One for Five Axis
Simultaneous and the other for positioning (3+2). Both these systems are separate and independent.
When considering a Table/Table machine tool configuration for Multiplane output, only CPL Co-
ordinates are supported. Code Wizard should really grey out any other option. CPL co-ordinates can
be likened to the 3 + 2 output that Edgecam has always supported.
Table/Table configuration: Always CPL Coordinates
Head/Head configuration: Machine Coordinates
Part Coordinates with IJK output generally for TNC and the part positioning is not critical within
Edgecam.

 Certain options will grey-out owing to the fact that they are exclusive to the Mill/Turn
configurations.

Multi-plane Coordinate System Output

CPL Coordinates
Edgecam will output a new workplane in which the tool is aligned with Z again, along with a new
datum. The workplane would correspond to the CPL you indexed to in Edgecam.

Machine Coordinates
The alternative to CPL Coordinates is to set Multi-plane Coordinate System Output to Machine
Coordinates, which is a system that always corresponds to the machines X, Y and Z linear axes.
As normal, you work in different CPLs in Edgecam (that you index to), but Edgecam converts the
moves into the fixed machine coordinate system for output.

 Under this setting, hole canned cycles are only supported in a CPL that is in the same
plane as the initial CPL

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Multi-plane Nutated Output

Orthogonally Aligned
The toolpath is output as for a normal orthogonal machine, and the machine tool handles the
required transformations for Nutated movement.

Machine Axis Aligned

The toolpath is output in true machine axis coordinates.
Five Axis Coordinate System
Absolute coordinate Tooltip
The toolpath is for the tip of the tool, in absolute coordinates

Absolute coordinate Pivot Point

The toolpath is for the pivot point of the tool, in absolute coordinates. An option for B-Axis lathes and
head-head milling machines.

Part Coordinates
The toolpath is for the tip of the tool, output in 'part space'.

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Exercise 1 - Multiplane Output

The following exercise shows the difference in NC output for Multiplane machining scenarios.
Edgecam will offer either CPL Coordinates or Machine Coordinates.
1. Open the file ‘1 - Nozzle Head Head MPL.ppf’.

2. Inspect the part file, specifically concentrating on the Move Index commands
3. In Code Wizard, open the file ‘Gantry CA Offset.cgd’. (Five Axis Training Posts Folder).
4. Inspect the Machine Parameters. The Multi-plane Coordinate System Output has been
set to CPL Coordinates.

5. In Edgecam, Generate Code and inspect the resultant output. You will observe that,
as in the traditional manner, Edgecam has output X,Y & Z coordinates from the local CPL.
6. Edit the Code Wizard file, setting the Multiplane Coordinate setting to Machine
Coordinates.

7. Return to Edgecam, remembering to Reload Machine and Regenerate the sequence.

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8. Generate Code and inspect the resultant output. You will observe that the code has
increased significantly, due to the Code Wizard alteration.

CPL Coordinate Machine Coordinate

9. Save as ‘1 - Completed Nozzle Head Head MPL.ppf’.

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Exercise 2 – Pivot about tooltip

Using the same part file and postprocessor, the following exercise will demonstrate the usage of the
Pivot about Tooltip command.

Edgecam allows the user to set the default for this option (checked or unchecked) in the Code
Wizard. Pivot about Tooltip is found in the Move / Index command. If the option is not used within the
Code Wizard, the default condition for the command will be off.

1. Carry on with last file or open ‘2 - Nozzle Head Head MPL.ppf’.

2. The last CAM instruction was a Profiling cycle.

3. Select Machining ► Move Tool ► Rapid . Type in a Coordinate of IZ150.

4. Select Machining ► Move Tool ► Index .
General Tab
 Position To, Name: Top Pivot about Tool Tip: Un-Checked

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5. Select Machining ► Move Tool ► Move to Toolchange .

6. Observe how the Index command has caused the tool to move in an un-acceptable
manner.

7. Edit the Index command. Make Pivot about Tool Tip active.

8. Observe how the Index move is a lot more contained with this option.

9. Save as ‘2 – Completed Nozzle Head Head MPL.ppf’.

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Exercise 3 – Aligning Rotary Axis

The following exercise demonstrates the close relationship between postprocessor and
the Five Axis positional command. In both instances, Edgecam is using a Nutated Table
configuration (both rotary axis are shackled together)

 This exercise uses the same solid component so as the users can make comparisons
between each method.
1. Open the file ‘3 - Trunnion Table - CPLs.ppf’.

2. Observe the machine tool graphic and the position of the part file.
3. In Code Wizard open the file ‘Solid Vertical AC Trunnion.cgd’.(Five Axis Training
Posts) Observe the Machine Parameters, notice how the Multi-plane Nutated Output is
set at Orthogonally Aligned.

 This machine tool is NOT a Nutated Machine Configuration, the graphic has been
purposely made this way for the sake of this exercise.
4. Using the slide bar found in the Machine Elements window, move the A & C axis.
Observe the machine tool movements.

5. In Edgecam, Select Machining ► Move Tool ► Index .

General Tab
 Position To, Name: Face 1 Trun

 Pivot About Tool Tip option is not available as this is only required on a rotary head
code generator.

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6. Edgecam executes the movement without any hesitation and realigns the CPL axis (X Y
& Z) in the correct orientation.
7. Close the current file and open the file ‘3a - Nutated Table - CPLs.ppf’.

8. In Code Wizard open ‘TNC - DMU 50 Evolution BC.cgd’. This is an example of a true
Nutated Table configuration.
9. Similar to the previous instruction, within Code Wizard, use the slider bar found in the
Machine Elements window to move the B & C axis. Observe the machine tool
movements.

Consider how Edgecam makes possible the fact that the B axis is capable of
rotating on a compound angle.

10. Returning Edgecam, Select Machining ► Move Tool ► Index .

General Tab
 Position To, Name: Face 1 Trun
11. On this occasion, as the CPL is incorrect for the configuration, Edgecam will work around
this problem by creating a clone CPL, correctly aligned, which the machine tool can use.
12. The copied CPL is now re-aligned to suit the machine tool configuration. Edgecam
creates a new CPL, Face 1 Trun.1, which is actually the original user defined CPL.
13. Finish off the exercise by creating a Rapid move to X0Y0Z50 and move into the
Machine Simulator. Take note of the Table movements.
14. Save as ‘3a - Completed Nutated Table - CPLs.ppf’.

Conclusion
The machine tool is limited in the amount rotation it can produce on the Y axis. The Table belongs to
a Nutated configuration and therefore is limited in the amount of movement available. Therefore, the
C Axis is used to compensate for the lack of Y axis rotary movement.

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Multi-Plane Nutated Output

Orthogonally Aligned (CPL)
The toolpath is output as for a normal orthogonal machine, and the machine tool handles the
required transformations for Nutated movement.

Machine Axis Aligned (MC)

The toolpath is output in true machine axis coordinates.

Exercise 4 – Nutated Indexing Coordinates

The following exercise demonstrates the difference between Orthogonal and Machine Axis Aligned.
The CPL’s on the part have been corrected, to allow the machine to index in the correct manner.
1. In Edgecam, open ‘4 - Nozzle-BC Nutated Table MPL.ppf’.

2. In Code Wizard, open ‘TNC - DMU 50 eVo BC-ABS.cgd’.( Five Axis Training Posts)
3. Inspect the Machine Parameters, in particular the Multi-plane Nutated Output option has
been set to Orthogonally Aligned.
4. This means that the co-ordinate output will be relevant to the local CPL (same as
traditional 3+2) indexing.

5. Return to Edgecam, select the CPL Face 1. Observe the direction of the X Y & Z axis.
Bearing in mind what was learnt on the previous exercise, the CPL axes are correct for
the machine.

 The Y Axis represents the length of the pocket. The X Axis represents the width of the
Pocket. This axis configuration of this CPL mimics the clone CPL created in the previous
exercise.

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6. Select Generate NC code. Observe the values of X & Y.

7. Returning to the Code Wizard, switch the Multi-plane Nutated Output option to Machine
Axis Aligned Re-compile the code wizard
8. This means that the NC output will be relevant to the machine tool datum and not the CPL
that has been indexed to.
9. Return to the Edgecam part file. Re-load the machine and re-generate the code.
10. When you Generate Code on this occasion the vales of X & Y axis will be swapped
around.

Orthogonal Aligned Machine Aligned

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 Five Axis Coordinates

 Absolute or Part coordinate
 Absolute Coordinates (Typically Fanuc)
 ABC Angles
 IJK Output
 Typically – Fanuc Output

In the diagram above, imagine the component part remaining stationary and the tool moving
underneath the part. The tool moves up and down depending on its positions on the part – observe
how the Y axis does not move
 Part Coordinates
 Typically – TNC Output (Some Fanuc)

Opposite to the previous illustration, here, the component part is stationary, but, the tool moves
around the part.
Therefore the CPL moves with the part.

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Exercise 5 – Five Axis Coordinates

The following exercise will demonstrate the difference between to the two Five Axis output methods.
1. Open the file ‘5 - Five Axis Coordinates.ppf’.

2. In Code Wizard open ‘Solid Vertical BA Table Unit.mcp’( Five Axis Training Posts).
Check the Five Axis Coordinates setting. You will see it set to Absolute Coordinates
Tooltip.

3. Return to the Edgecam and Generate NC .

4. Return to the Code Wizard and swap the Five Axis Coordinates setting to Part
Coordinates. Re-Compile the file.

5. Return to the Edgecam part file. Re-load the machine and re-generate the code.
6. When you generate code on this occasion the vales of X & Y axis will be very different to
the first setting – notice how angular co-ordinates are being used.

Absolute Tool Tip Part Coordinates

7. Save as ‘5 - Completed Five Axis Coordinates.ppf’.

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Five Axis Simultaneous - Turning

 Absolute Coordinates Tooltip/ Pivot point
 B Axis Coordinates Tooltip/ Pivot point

When working with Absolute Coordinates Edgecam offers two methods, Tool Tip or Pivot Point. If
you are working with Pivot Point, you must ensure that the Z Gauge Length and Flute Length values
contained in Edgecam accurately represent the true value on the machine tool. You will notice that
the Z Axis remains aligned along the natural Z Axis of the machine tool.

Absolute Coordinates - Tool Tip or Pivot

B Axis Coordinates
Point

You will observe a difference in the Z Axis output value whilst working with B Axis Coordinates.

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Five Axis Positioning (3 + 2) and Simultaneous

With a Five Axis Machine tool one will need to consider the two primary uses:
 Five Axis Simultaneous
 Positioning (3+2)
Both these systems are separate and require a different approach when applying toolpath inside
Edgecam.
The following exercise demonstrates the difference between 3+2 and simultaneous.

Exercise 5a – 3+2 and Simultaneous

1. Open the file ‘5a - 3+2 and Simultaneous.ppf’.

2. Simulate the Toolpath. Observe the machine tool movements.

3. Exit the Simulator and take a closer look at the machine sequence

 Notice how T2 is indexing to different CPL’s to carry out each profiling cycle.

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3+2 Positional Simultaneous

Conclusion
The previous exercise clearly shows how 3+2 differs from Simultaneous, both when setting up CPLs
and Features, to when configuring a Sequence. You will have seen how Simultaneous is not reliant
upon user CPL’s being defined prior to creating Face Features and Edge Loop features.
 In the Five Axis cycle you may directly pick Faces and edges to machine.
CAD Preparation will be discussed in more detail in the next section.

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Component Positioning
The following section addresses the subject of position the Component onto the machine tool Table.
In previous chapters we learnt that Edgecams Code Wizard offers the ability to build the full machine
tool from solid models, so as more accurate and realistic machining simulation can be achieved.
During the building of the machine tool, Edgecam allows the user to state the position of the
Component Location – this is set inside the Machine Elements tree.

You are offered the ability to mate the component to the Component Location during the initial set up
of the Machining Sequence.

Having stated the mating location, Edgecam allows you to move the component around the Table by
way of editing the Machining Sequence and Mating Offset
When working with Five Axis Simultaneous machine tools, the Component position in relationship to
the machine tool datum can be critical. Some Machine tools will insist on outputting the program co-
ordinates in relationship to the Machine Datum as opposed to the Local Datum.

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Exercise 6 – Part Positioning

1. Open the file ‘6 - Cone and Vice MC.ppf’. This uses ‘Solid Vertical AC
Trunnion.mcp’ as it’s postprocessor.

2. Observe the component, in particular the position of the component to the Machine Tool
Table.

3. Select the Simulator and observe the machine tool movements. Notice how, that once
machining is under way, the Table does not need to move because of the central position
of the component part.

 The Initial CPL is located directly over the machine tool datum

4. Generate NC Code and observe the NC output. Notice how Edgecam produces a
large amount of C axis output code.
5. In Edgecam, edit the machining sequence and move the 50mm in the X Mating Offset.

6. In Simulator and observe the machine tool movements. Notice how the Table must
move in both X and Y to cope with the position of the component.

7. Regenerate and Generate NC code.

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8. You will notice how Edgecam now has to output further X, Y and Z moves in order to
compensate for the latest position of the machine tool.

On Centre Off Centre X50mm

9. Save as ‘6 - Completed Cone and Vice MC.ppf’.

 When setting up on certain Five-axis Machine tools, the need to know the offset positions
BEFORE machining the part is important. This is another example of where 5 Axis
Simultaneous differs from 3-Axis machine tools.

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Five Axis Tool Length Compensation

A number of Five Axis Controllers use G43.4 (typical, Fanuc) when machining in Five Axis
Simultaneous. This is usually an option that needs to be activated on the Controller itself. A number
of controllers classify this function as 5-Axis Compensation.
G43 (Absolute Co-ordinate output and ABC angles)
G43.4 Part Co-ordinates and ABC angles

 You will find that other CNC controllers will use G43.5, in this instance use IJK angle
output
High Speed Block Look Ahead (HPCC)
 G5 P1000 switched the option on
 G5 P0 switches the option off
This option is crucial when producing Five Axis Simultaneous toolpaths. Without it, the resultant
surface finish and texture of the component part is very poor due to the controller not being able to
read the part program positions fast enough. The machine tool will jerk from position to position,
leaving a witness mark on the part.
As thousands of lines of NC data are typically being produced, the controller needs the ability to look
ahead and pre-calculate the toolpath. By allowing this to happen, the toolpath is smoothed into one
continuous flow.
The P value represents the tolerance for smoothing.

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5 Axis Operations
Similar to all previous Edgecam configurations, the 5-Axis licence offers a set of Five Operations
which are designed to make programming simpler.
The operations will cater for all permutations of 5-Axis machining and, can be edited to expose the
full 5-Axis cycle.
Select Machining ► More (In the Mill Operations panel).

 The 5-Axis Operations are influenced by Machining ► More ► Operation Preferences.

Four Axis Rotary

Cutting which can be parameterised by the radial distance of the tool from an axis of rotation for the
part. Typically used for machining camshafts etc.
Five Axis Blend
Cutting between two drive curves along a specified surface. Typical used on Worms or helical flutes.
Five Axis Swarf
Cutting using the side of the tool, with the tool being laid flat against the surface.

Five Axis Curve

Runs the tool once along a curve, with the tool axis parallel to a drive surface. Useful for de-flashing,
for example.
Five Axis Finishing
Similar to Parallel Lace, except with the extra facility of the tool tilt being driven by the surface

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3 to 5 Axis Cycle
Select Machining ► Milling Cycles ► 3 to 5 Axis

Allows the conversion of an existing 3 Axis Cycle into a 5 axis cycle.

Five Axis Milling cycle

Select Machining ► Milling Cycles ► Five Axis
The Five Axis Milling cycle allows you to simultaneously drive the tool in Five Axes (that is 3 linear
axes and two rotary axes). This means for example that the tool can always be kept normal to a
surface, to improve the finish, or that the tool can be fed into complex cavities, being tilted to avoid
gouging.
You can make the cycle emulate the traditional three axis cycles, such as producing a Parallel Lace
finishing pattern over a surface, but with the extra sophistication of being able to keep the tool always
normal to the surface.

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CAD Preparation
The Five Axis Machining module relies heavily on the user’s ability to create suitable CAD data. The
key to a successful toolpaths relies heavily on the CAD data.
Unlike the traditional 3-Axis strategies, the Five-Axis cycle does not offer Containment Boundaries.
Therefore, it is necessary to select and identify various regions on the component for 5-Axis
machining.
A further reason for this design preparation is that one would never wish to allow a 5-axis toolpath to
machine the entire surface area of a component. Therefore, the model is carved-up into machineable
regions.

Drive and Check Surfaces

The toolpath is controlled by three types of entity (each has its own prompt when you are selecting
geometry for the cycle):

Drive Curve
An entity (line, arc, and curve) which provides the tool with the basic pattern.

Drive Surfaces
This is the surface that produces the basic toolpath, and drives the tilt of the tool.
Check Surfaces
In general these are the surfaces you wish to protect from being machined, or gouged by the tool
and/or holder (you can also protect drive surfaces from gouging). The check surfaces modify the
basic toolpath.

Setting the Surface Side to Machine

If you are using face features as the surfaces for a Five Axis cycle, the correct side will always be
machined (this is because the face features are derived from solid models, so the 'material' side is
always known).
However if you are using surfaces, you might find the wrong side being machined, perhaps the
underneath rather than the top:

In this case you could use Setup ► Surfaces ► Surface Group , setting the side selection to
prompt.

After selecting the surface(s) to form the group, you would then click on the material side (here this is
the top face, as indicated by the red lines):

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If you then select this surface group as the drive surface for the cycle, the machining will be on the
correct side:
To view, select File ► Preferences
Surfaces Tab
 Normals, Length: Value Display: Checked

 The position of the Surface Normal can be switched by creating a Surface Group.

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Exercise 7- Surface Normals

1. Open the file ‘7 - Surface Normals.ppf’ this component originated as an IGES file. Inspect
the CAD entities, in particular observe the types of Surfaces.

2. Select the Machining ribbon. A Five Axis cycle has already been created.

3. You will notice that the tool is machining the incorrect side of the top surface. There are no
edits in the Five axis cycle that can rectify this.

4. The Five Axis toolpath has placed the toolpath on the Normal side of the surface. In this case,
the Normal needs to be corrected.

5. Select File ► Preferences.

Surfaces Tab
 Normals, Length: 10 Display: Checked

6. Show only the Upper Surface layer. The Surface Normals are pointing in the wrong direction.
This surface is being used by the Five Axis Cycle.

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7. Select Setup ► Surfaces ► Surface Group.

General Tab
 Side Selection: Prompt

 Ensure that you have an active layer on display whilst creating the Surface Group.

8. Select [OK]. Follow the prompt

 Select first surface for new surface group. Select the upper surface. Tick or
Right Click.

 Select default side for surface. Left Click to toggle the Surface Normals until they
point upwards. Tick or Right Click twice.

9. On the Machining Ribbon, Show all Layers, in the Layers Window.

10. Edit the Five Axis cycle.

 Reselect Geometry and Coordinate input: Checked

11. Select [OK]. Follow the prompt.

 Select drive surfaces, First de-select all picks. Select the Surface Group. Tick or
Right Click.

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 Select check surfaces, ignore. Tick or Right Click.

12. The toolpath is now at the correct side of the surface. The clearance position though is now
incorrect.

13. Edit the Five Axis cycle.

Depth Tab
 Clearance Plane Height: 5 Associative: Checked

14. Select [OK].

15. Check the toolpath in the Simulator.

16. Save as ‘7 – Completed Surface Normals.ppf’.

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Understanding the Five Axis Cycle

Solid Models
The topology of the solid model comprises of Loops; Faces and Vertices.
When using the Five Axis Cycle you will be prompted to pick Drive Surfaces, Curves and Check
Surfaces depending on the type of cycle applied. These Surfaces can be represented by Face
Features. The model can be prepared on the Features ribbon by manually creating these features.
To create Drive or Check Surfaces
Select Features ► Face

To create Curves to machine.

Select Features ► Edge Loop

 Wireframe Geometry may also be used for Curves.

Drive Surfaces
The Five Axis Cycle will require Drive Surfaces. These can either be represented by Face Features
or Surface Groups. A Drive Surface is the area that you wish to machine on. The Tilt Angle of the
tool is measured from this surface.

Direct Picking
It is possible to directly pick Faces and Edges off a Solid model to machine within the Five axis cycle,
without the need to create Features.

 If using a Five Axis Operation, Features must be used prior to 2016 R1.

The cycle itself has three main areas which determine the resultant toolpath:-
Strategy: There are seven differing strategies. Each strategy will not only create a unique toolpath
pattern, but will require different CAD inputs.
Tool Axis Control: There are three output methods 3, 4, or 5 Axis, along with eight different Tilt
Strategies.

Check Surfaces
Is an area that you wish to avoid machining on or, force the tool not to machine across.
 You may also drive the tool around a Check surface, if required.

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Swarf Cut – Operation

Side Wall Axial Relief Feed or Flank Milling.
In flank milling the material removal is done with the side of the cutter in comparison to point milling
where the cutting is done with the bottom edge of the cutter. Flank milling shapes the design surface
based on the trajectory it follows and the shape of the tool.
Flank milling is the crucial feature offered by a five-axis NC machine. Compared with bottom-edge-
based machining, machinability can be greatly enhanced by flank milling in that the side cutting edge
is mainly used.
Consider the simple part component used in the following exercise. The aim of the machinist is to
generate the taper side wall. This has always been possible within Edgecam, using a 3-axis
machining cycle. The cycle would have been controlled by a cusp height and would have taken many
passes in order to fully machine the sidewall.
Using the 5-Axis cycle, the SWARF cut the component part. In this instance the side of the cutter is
in constant contact with the side wall of the component.

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Exercise 8 – Preparing a Solid Model

 Swarf Operation uses the Parallel to Curve strategy and sets Tool Axis Control to Relative
to cut Direction Tilt Angle 90.

1. Open the file ‘8 - Five Axis Swarf Operation.ppf’.

2. Create a New Layer called Wall.

3. Select Features ► Face.

General Tab
 Name: Wall

4. Select [OK]. Follow the prompt.

 Select individual faces. Select Conical face . Tick or Right Click.

5. Repeat the above steps to create another Face Feature.

6. Create a New Layer called Floor.

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7. Select Features ► Face.

General Tab
 Name: Floor

8. Select [OK].

9. Change to a different colour.

10. Follow the prompt.

 Select individual faces. Select Freeform Radius and Planar face. Tick or Right
Click.

11. Create a New Layer called Drive Curve.

12. Select Features ► Edge Loop.

General Tab
 Name: Drive Curve Copy From: Edges

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13. Select [OK].

14. Change to a different colour.

15. Follow the prompt.

 Select or chain-select edges. Select Freeform Radius and Planar face. Tick or
Right Click.

16. In the Features window there will be three features.

17. A Machine sequence has already been created.

18. Select Machining ► More… ► Five Axis Swarf.

19. Follow the prompts.

 You may only pick Features when using an Operation.

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 Select drive curve, Select the Edge Loop Feature. Tick or Right Click.

 Select cycle start point, Ignore. Tick or Right Click.

 Select wall geometry, select the Face Feature called Wall. Tick or Right Click.

 Select floor geometry, select the Feature called Floor. Tick or Right Click.

 You may find it easier to pick the Features from the Features window.

20. The Five Axis SWARF Operation dialog box will open. Fill in the modifiers.

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General Tab
 Mill Type: Clockwise Number of Cuts: 4 Cut Distance: 2
 Offset: Blank Lead Radius: 5 Side Tilt Definition Type: Follow Surface

Tooling Tab
 Select [Find…] Select a 12mm Long Series Ballnose Mill – LS Position: 1

Depth Tab
 Clearance Plane Height: 5 Associative: Checked Safe Distance: 5

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Multiple Cuts Tab

 As below

21. Select [OK]. A toolpath will be created.

22. Edit the Five Axis Swarf Operation altering, in turn, the modifiers below in order to learn
more about the influence each has on the toolpaths.

General Tab
 Number of Cuts: 1 One single pass will be created.
 Cut Distance: .5 This will have no influence as the number of cuts is one.
 Mill Type: Optimised As the number of cuts is set to one this will have little influence,
re-set number of cuts to 2 and the toolpath will lace cut.
Depth Tab
 Tool Axis Shift: -3 This parameter is used to move the toolpath in an up/down
direction. The negative value should push the tool further down, however this will be
prevented by the Check surface.

23. Save as ‘8 - Completed Five Axis Swarf Operation.ppf’.

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Turn Milling
The next Five Axis Operation will demonstrate the Four-Axis Rotary toolpath. This method of
machining is very common on Mill/Turn machines where Constant Offset and Cut Width Control will
produce a perfectly Flat Face.

Exercise 9 – Four Axis Rotary Operation

The aim of the following exercise is to highlight the functionality of Drive and Check Surfaces.
Usually, the Check Surface is used to prevent the tool from entering various regions on the
component.
The Drive Surface is used to produce the basic toolpath (for example 'parallel lace' cuts across the
surface), and also drive the tilt of the tool.
 The role of these two Surfaces can sometimes be swapped.
1. Open the file ‘9 - Four Axis Rotary Operation.ppf’.

2. Select Machining ► More… ► Four Axis Rotary.

3. Follow the prompts.

4. You may only pick Features when using an Operation.

 Select cycle start point, Type in a Coordinate of X100Z10Y0. Select [OK].

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 Select drive geometry, select the large Face Feature. Tick or Right Click.

 Select model geometry, Ignore. Tick or Right Click.

5. The Operation dialog box will appear. Fill in the modifiers

General Tab
 Mill Type: Climb Cut Distance: 6 Tool Contact Point: Automatic
 Front Shift: Null Tolerance: .01 Lead Lag Angle: 0
 Offset: Null Lead Radius: 5 5th Axis Lock: Null

Tooling Tab
 [Find…] Select a 12.0 mm x 1mm rad End Mill Position: 1

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Depth Tab
 Clearance Radius: 5 Associative: Checked
 Safe Distance: 5 Tool Axis Shift: Blank

Multiple Cuts Tab

 Ignore
6. Select [OK].
7. Observe the toolpath, it is far from satisfactory. The tool is driving itself around the
feature, staying Normal to it (at 90 deg). Due to the shape of the feature, the tool has
difficulty in driving itself around the enclosed area.

8. Show the Layer called Surface Fix and Hide Clover CAM - 001.

9. You will see a cylindrical surface positioned centrally inside the solid. Even though we do
not wish to physically cut this shape, the surface will now act as the Drive Surface. The
original Face Feature will act as the Model Geometry (Check Surface).

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10. Edit the Four Axis Rotary Operation. Reselect Geometry and Coordinate Input:
Checked. Select [OK]. Follow the prompts.

 Select cycle start point, ignore. Tick or Right Click.

 Select drive geometry, select the Ruled, cylindrical surface. Tick or Right Click.

 Select model geometry, Select the Face Feature. Tick or Right Click.

11. Select [OK] to dismiss the dialog.

12. The shape of the toolpath is being produced by the Drive surface. The Face Feature acts
as the Check surface, preventing the tool moving through the component.
13. Save as ‘9 – Completed Four Axis Rotary Operation.ppf’.

Conclusion
The exercise demonstrates that the Drive and Check Surfaces are of paramount importance to the
successful outcome of the toolpath. Usually the Drive Surface influences the direction of the toolpath,
the Check Surface determines which areas are not machined. However, there are certain exceptions
to this rule, this example demonstrates this.
Further CAD entities would be required for this, in this instance, a Ruled surface.
As you work through this manual you will other examples.

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Exercise 10 – Five Axis Curve Operation

P = Parallel To Curve
T= Relative to cut Direction @ 0°
C= Tool
The Operation will drive a cutter once along a curve, with the tool axis parallel to a drive surface.
Useful for de-flashing.

 5 Axis Drive Curve Operation uses the Parallel to Curve strategy and sets Tool Axis
Control to Relative to cut Direction Tilt Angle 0º

1. Open the file ’10 - Five Axis Curve Operation.ppf’. Inspect the part paying special
attention to the Features that have been created.

2. Select Machining ► More… ► Five Axis Curve.

3. Follow the prompts.

 You may only pick Features when using an Operation.

 Select drive curve, Select the EdgeLoop Feature. Tick or Right Click.

 Select drive geometry, select the Face Feature. Tick or Right Click.

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 Select model geometry, ignore. Tick or Right Click.

4. Select [OK].
 Selecting the Features from the Features window will avoid any possible errors when
selecting.

5. The dialog box will open. Fill in the modifiers.

General Tab
 Mill Type: Clockwise Number of Cuts: 1 Reverse Cut: Un-Checked
 Cut Distance: 10 Cut Order: Standard Lead Radius: 5
 Tolerance: .01 Start Margin: Null

Tooling Tab
 [Find…] Select a 16.0 mm Multi-Flute End Mill Position: 1

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Depth Tab
 Clearance Plane Height: 100 Associative: Checked Clearance Type: Plane
 Clearance Axis: Z Axis Retract Distance: 10
 Safe Distance: 5 Tool Axis Shift: Null

Multiple Cuts Tab

 Ignore

6. Select [OK].

7. Edit the Operation.

General Tab
 Start Margin: 3

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8. The centre of the tool is now driven further up from the Drive curve.

Consider what effect the Tool Axis Shift parameter has on the toolpath.

9. Save as ’10 - Completed Five Axis Curve Operation.ppf’.

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Exercise 11 – Five Axis Blend Between Operation

1. Open the file ’11 - Blend Between 2 Curves Operation.ppf’.

2. Select Machining ► More… ► Five Axis Blend.

3. Follow the prompts.

 You may only pick Features when using an Operation.

 Select first curve, Select the EdgeLoop Feature. Tick or Right Click.

 Select second curve, select EdgeLoop Feature. Tick or Right Click.

 Select drive geometry, ignore. Tick or Right Click.

 Select model geometry, ignore. Tick or Right Click.

4. Select [OK].
 Selecting the Features from the Features window or turning off the rendering will avoid
any possible errors when selecting.

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5. The dialog box will open. Fill in the modifiers.

General Tab
 Mill Type: Clockwise Cut Distance: 10 Number of Cuts: 10
 Reverse Cut: Un-Checked Offset: Blank Lead Radius: 5
 4th Axis: Z Axis Cut Order: Standard Tolerance: .1
 Output Axis: 5-Axis Start & End Extensions: Null

Tooling Tab
 [Find…] Select a 20.0 mm x 2mm rad End Mill Position: 1

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Depth Tab
 Clearance Radius: 30 Associative: Checked Clearance Type: Plane
 Clearance Axis: Z Axis Retract Distance: 50
 Safe Distance: 5 Tool Axis Shift: Null

Multiple Cuts Tab

 Ignore

6. Select [OK].

7. A toolpath will be created. Check in the Simulator.

8. Note the many collisions. Exit the Simulator.

9. Edit the Operation. Select [OK].

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General Tab
 Start and End Extension: 11

10. Select [OK].

11. The toolpath has been extended 11mm at either end.

12. Check in the Simulator.

 The Start and End Extension options are ideal for open shapes where you wish to start
and finish off the component.

13. Save as ’11 - Completed Blend Between 2 Curves Operation.ppf’.

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Exercise 12 – Five Axis Finishing Operation

 It is essential that your 5 Axis postprocessor is correctly aligned for this, and all
other examples.

1. Open the file ’12 – Five Axis Finish Operation.ppf’.

2. Select Machining ► More… ► Five Axis Finishing.

3. Follow the prompts.

 You may only pick Features when using an Operation.

 Select cycle start point, ignore. Tick or Right Click.

 Select drive geometry, select the Face Feature. Tick or Right Click.

 Select model geometry, ignore. Tick or Right Click.

4. Select [OK].

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5. The dialog box will open. Fill in the modifiers.

General Tab
 Mill Type: Climb Angle In XY: 0 Angle From Z: 90
 Cut Distance: 6 Cut Distance: 6 Tolerance: .1
 Lead Radius: 5

Tooling Tab
 [Find…] Select a 12.0 mm Ball Nose Mill Position: 1

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Depth Tab
 Clearance Plane Height: 2 Associative: Checked Clearance Type: Sphere
 Clearance Axis: Z Axis Retract Distance: 1 Safe Distance: 5
 Tool Axis Shift: Null

Multiple Cuts Tab

 Ignore

6. Select [OK].A Toolpath will be created.

7. Concentrate on the Lag and Tilt angles. Activate the Toggle Toolpath Normals. This will show
the angular position of the tool in respect to the Drive Surface.

8. The Normals will now be visible. These show where the tool will be at 90 degrees to the Face
as it machines it.

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9. Edit the Five Axis Finishing Operation and in turn change the Tilt Angle.
General Tab
 Tilt Angle: 5 / 10 / 15 / 20 (Observe how the tool gradually leans backwards).

10. Select [OK].

11. Edit the Five Axis Finishing Operation and change the Lead Lag Angle.
General Tab
 Lead Lag Angle: 15

12. Select [OK].

13. Edgecam will display an error message as the machine tool cannot index its axes to the
require positions.

14. The Sequence will not work in the Simulator as the cycle has now failed.

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15. Undo the last edit.

16. Expand the Five Axis Finishing Operation. Inspect the contents of the CAM instructions. Edit
the Five Axis Cycle in order to view the command dialogs.

17. Save as ’13 - Completed Five Axis Finish Operation.ppf’.

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Five Axis Cycle

We have previously looked at Operations to place our Five Axis cycles onto the components. As with
all Operations these place a safe working toolpath down but have limited capability.
On opening the Five Axis cycle you will be presented with many more options.
The next set of exercises will gradually introduce the cycle’s commands, breaking-down the
modifiers and explaining each of the relevant parameters.

 Break the cycle down into three stages, Pattern, Tilt and Check.
 Do not attempt to create the command exactly right first time. Gradually build up the
cycle’s components, adding extra modifiers and fine tuning the command as you finally
reach a satisfactory conclusion.

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The Five Axis Cycle

Pattern
Select an appropriate Toolpath Pattern.

Tilt
Define how the tool will lean relative to the surface or axis.

Check
Control the toolpath against Drive and Check Surfaces

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Toolpath Pattern

Parallel Slice
Similar to the Parallel Lace cycle, the tool stripes forms a series of parallel planes which intersect the
drive surface. The Cut Distance sets the distance between the planes. The Angle in XY and Angle
from Z sets the orientation of the planes.
This is used for general finishing.
 Ideal for producing a Parallel Lace or Water-line pattern.

Exercise 13 - Parallel Slice

This exercise concentrates solely on the Parallel Slice pattern and the Angle modifiers that control
the pattern of the toolpaths.

 The Angles are measured from the Current CPL Z- axis.

1. Open the file ‘13 – Parallel Slice Modifiers.ppf’.

2. In turn, Edit the Five Axis cycle.

General Tab

3. Angle In XY: 45, 90 and 135.

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4. In turn, Edit the Five Axis cycle.

General Tab
 Angle In XY: 0 Angle From Z: 0, 45, 90 and 135

5. Edit the Five Axis cycle.

General Tab
 Angle In XY: 0 Angle From Z: 90 Cusp Height: .1
 Cusp Height can be used as an alternative to setting a Cut Distance.

6. Select [OK]. View the Toolpath.

7. Close the part without saving.

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Normal to Curve
The cuts are normal, 90 Degrees, to a curve which you specify.

Exercise 14a – Normal to a Curve

This pattern is generally used when you wish the toolpath pattern to radiate away from an edge or
cut normal to a flow curve. An example could be Port machining, where a backbone is defined.

1. Open the file ‘14a - Normal to Curve.ppf’.

2. Edit the 5-Axis Cycle and Reset all Picks.at the top right of the dialog box.

3. Select [OK].

4. Show only Layers, 10.0 mm Ball Nose Mill & Aero Cover in Vice - 001.

5. Follow the prompts.

 Features or Directing picking of the model is possible in the cycle.
 Pick Lead Curve, select curved edge. Tick or Right Click.

 Select drive geometry, select the Top Cylindrical Face. Tick or Right Click.

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 Select check surfaces, ignore. Tick or Right Click.

6. Experiment with the Mill Type parameter. For example, try some of the following settings:
 Reverse Cuts: Forces the start position of the cycle pattern to begin at the opposite
edge.
 Cutting Range: Standard Cuts or Exact Surface

Consider why Exact Surface does not machine the complete surface.
 A continuous exists on the Layer, 1-New Lead Curve. Use this as the Lead curve to
extend the Toolpath.

7. Save as ‘14a - Completed Normal to Curve.ppf’.

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Exercise 14b – Blend Between Two Curves

Good for machining along flow surfaces either normal (fillet) or Swarf (blend between top and bottom
edges)

1. Open the file ‘14b - Blend Between Two Curves.ppf’.

2. Edit the 5-Axis Cycle and Reset all Picks.at the top right of the dialog box.

3. Select [OK]. Follow the prompts.

 Features or Directing picking of the model is possible in the cycle.
 Pick first Curve, select the Top Edgeloop. Tick or Right Click.

 Select second Curve, select the Bottom Edgeloop. Tick or Right Click.

 Select drive surfaces, select the Face Feature. Tick or Right Click.

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 Select check surfaces, ignore. Tick or Right Click.

 You may select Features from the Feature Window.

 Switching the order in which the Curves are selected will influence the toolpath.

4. Save as ‘14b - Completed Blend Between Two Curves.ppf’.

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Exercise 14c – Parallel to Curve

1. Open the file ‘14c - Parallel To Curve.ppf’.

2. Edit the 5-Axis Cycle and Reset all Picks.at the top right of the dialog box.

3. Select [OK]. Follow the prompts.

 Features or Direct picking of the model is possible in the cycle.
 Pick Single Edge Curve, select the Continuous. Tick or Right Click.

 Select drive surfaces, pick the Face Feature. Tick or Right Click.

 Select check surfaces, ignore. Tick or Right Click.

 You may select Features from the Feature Window.

4. Simulate the toolpaths.

5. Edit the cycle.

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General Tab
 Start Margin: 2 Reverse Cuts: Checked

Tool Axis Control Tab

 Tool Axis Control: Tilt Angle: 90

6. Simulate the Five Axis Cycle. The toolpath is the same as the Swarf Operation. (See previous
exercises). Indeed the Strategy (Pattern) has been set to the same as the first sequence, yet
the toolpath is totally different.

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Consider why the two toolpaths are so dis-similar, yet the same Strategy has been
selected.

7. Re-set the Tilt Angle: 0.

8. Inspect the Check parameters. Both Check 1 and Check 2 have been activated and
parameters have been set.

9. De-activate all the Check parameters and observe the effect this has on the toolpaths. You
might want to use Simulate Machining to view the toolpaths because the error may not be too
apparent in normal Play mode.

Before continuing this exercise, consider why the tool has gouged in certain place.

10. The original cycle contained a stringent Check Surface criteria. Used in this example, is
acceptable, although if the component part had been larger, the time used to produce the
cycle would have been extended. .

11. Checking is clearly required on this cycle, activate the Check Tab and only set the following
parameters.

12. You will now find that the gouge in the corner has been removed because the tool is told to
Retract if it comes into contact with the component part.

13. Select Machining ► Miscellaneous ► Transform ► Rotary Rotate, which will create three
extra 5-Axis cycles to machine the remainder of the components.

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14. Simulate the toolpaths.

15. Save as ‘14c - Completed Curve Cutting.ppf’.

 Some machine controls could fault out when using this to copy toolpath, if so use the
Rotate options within the cycle itself on the Multiple cuts Tab.

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Project onto Curve

Etching text or patterns onto a freeform shape. Driving a tool form along a surface or Morphing a
pattern onto a given surface area.

Exercise 14d – Project onto Curve

1. Open the file ‘14d - Project Onto Curve.ppf’.

2. Edit the 5-Axis Cycle and Reset all Picks at the top right of the dialog box.

3. Select [OK]. Follow the prompts.

 Features or Direct picking of the model is possible in the cycle.
 Pick Projection Curves, pick all the Spline Curves that make up the text. Tick or
Right Click.

 Select drive surfaces, pick the Face Feature. Tick or Right Click.

 Select check surfaces, ignore. Tick or Right Click.

 You may select Features from the Feature Window.

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4. Edit the cycle.

 Offset: –.5

5. The toolpath will now be deeper.

6. Save as ‘14d - Completed Project Onto Curve.ppf’.

 The Spline Curves were created in design by creating text and projecting down onto a
ruled surface which in turn creates surface curves. This geometry is then exploded into
spline curves.

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Blend Between Two Surfaces

Ideal for machining the floor space between Impellor blades.
Internally, Edgecam creates two drive curves, and the cuts are blended between each curve. The
curves mark the intersection between Edge surfaces and the Drive Surfaces.

Exercise 14e – Blend Between Two Surfaces

1. Open the file ‘14e - Blend Between Two Surfaces.ppf’.

2. Edit the 5-Axis Cycle and Reset all Picks at the top right of the dialog box.

3. Select [OK]. Follow the prompts.

 Features or Direct picking of the model is possible in the cycle.
 Pick Tilt Curve, Select the Continuous entity. Tick or Right Click.

 Select drive surfaces, pick the Face Feature. Tick or Right Click.

 Select check surfaces, ignore. Tick or Right Click.

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 Select first edge surfaces, pick the Wall A Face Feature. Tick or Right Click.

 Select second edge surfaces, pick the Wall B Face Feature. Tick or Right Click.

4. Simulate the toolpaths.

5. Edit the cycle. In turn alter the following parameters.

Leads Tab
 Start Extension: 5 End Extension: 5
 Lead Type: Radius Tangential Angle: 45 Lead Radius: 5
Links Tab
 Long Link: Rapid Feed Safe Distance: 10

Consider why the Start and End Margin parameters have been used.

6. Notice how the tool moves past the Nose section of the Impeller Assembly. This can be
prevented by using a Check surface.

7. Show the Layer called New Check you are looking at a surface group.

8. Edit the cycle.

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 Reselect Geometry and Coordinate Input: Checked

Check 1
 Check: Both Against: Check Surface Strategy: Remove Toolpath

9. Select [OK]. Edgecam will prompt for the same information. Ignore all prompts except.
 Select check surfaces, Pick the Surface Group. Tick or Right Click.

10. Observe how the toolpath is removed when the tool comes into contact with the Check
Surface.

 You will learn more about Check Surfaces later in this training guide.

11. Save as ‘14e - Completed Impellor Floor-Blend Between two Surfaces.ppf’.

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Exercise 14f – Parallel to Surface

This method is very similar to SWARF cutting (Parallel to a Curve) except, a Surface is used.
The cuts are calculated using Cut Distance and are calculated to a specified surface. The toolpaths
morph the contour of the surface.

1. Open the file ‘14f - Parallel To Surface.ppf’.

2. Select [OK]. Follow the prompts.

 Drive Surface, Side wall Feature (named Drive)
 Check Surface, Ordinarily this would be the solid model but on this occasion, ignore the
prompt.
 Single Edge Surface, The face feature on the base (named Edge).

3. Edit the 5-Axis Cycle and Reset all Picks at the top right of the dialog box.

4. Select [OK]. Follow the prompts.

 Features or Direct picking of the model is possible in the cycle.
 Pick drive surfaces, Select the Continuous entity. Tick or Right Click.

 Select check surfaces, ignore. Tick or Right Click.

 Select single edge surfaces, pick the Wall A Face Feature. Tick or Right Click.

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5. Enter the Simulator and observe not only the toolpaths but also the movements of the
machine tools head configuration.

6. Edit the cycle, In turn changing the following modifiers.

Leads Tab
 Add Start and End Extension values.
 Type: Radius Tangential Angle: 45 Lead Radius: 5

Links Tab
 Long Links: Rapid Feed

As a result of the Link Type being altered, the tool now gouges the part. Before
continuing the exercise, think why this condition is being produced.

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7. The gouging issue can be addressed by altering either the Link method or Safe Distance
values. As an alternative, and as a way of illustrating another aspect of the five axis cycle, we
will use Check.

8. Currently the cycle has not be instructed to Check for collisions (The Check prompt was not
inputted nor, Check method instigated in the cycle)

9. Edit the cycle and set the Check 1 Parameters accordingly. Furthermore, activate Coord
input.
 Reselect Geometry and Coordinate Input: Checked
Check Tab
 Check: Both Against: Check Surfaces Strategy: Retract

10. Select [OK]. Edgecam will prompt for the same information. Ignore all prompts except.
 Select check surfaces, Pick the Solid Model, Parallel to Surface. Tick or Right
Click.

11. The tool no longer is in collisions but the cycle time may increase due to the excessive
amount of movement.

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12. Edit the cycle and switch off the Check 1 Parameters (you do not need to re-select the
entities).
Check Tab
 Check1, Check: None
Links Tab
 Long Link Type: Clearance

13. You may have already noticed that the machine tool spindle is potentially in collision with the
vice. One solution to avoid this condition is to swap the tool over for a Long Series cutter,
however this would increase the possibility of chatter due to lack of tool rigidity.

14. To remove collisions, the Tilt method will be altered.

15. Edit the Five Axis cycle.

Tool Axis Control Tab
 Tilt Strategy: Relative to Cut Direction Tilt Angle: 15

16. Simulate the toolpaths.

17. Save as ‘14f – Completed Parallel To Surface.ppf’.

Conclusion
The last exercise demonstrated the final of the Pattern methods Parallel to Surface. In doing so,
hopefully the exercise has made you aware of the other two Five Axis cycle components, Tilt and
Check.
Both Tilt and Check were used to offset various undesirable aspects of the toolpaths, so proving that
all three components are inter-twined with one another.
Lastly, the exercise proved that knowledge of the kinematics of the machine tool is essential. The
Machine Tool set-up allowed the tool to reach into certain positions, thus leading to a collision. This
was eventually repelled by both Check and Tilt options.

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Exercise 15 - PCI Templates

Once you have adjusted the 5 Axis Cycle, it can be saved away to be used on a similar component.
A template can be used to:
 Automate 5 Axis cycles
 Create niche Operations
 Simplify demonstrations
 Speed up programming time
 Minimise mistakes
If you know you are going to create similar 5-Axis toolpaths on a family of component parts, the PCI
Template is an ideal tool.
PCI Templates can be used in all aspects of Edgecam, but are especially useful where the 5-Axis
cycle is concerned due to the large amount of command dialog options.
Having created an optimum 5 Axis Cycle toolpath, save the CAM instructions as a PCI Template.
When the template is re-run the toolpath is easily and reliably produced on similar components.

1. Open the file ’14b - Blend Between Two Curves.ppf’.

2. On the machining Ribbon, Highlight the four CAM instructions in the Sequence Window.
Right click and select PCI Template.

3. Select [Browse]. Save the file as 5 Axis Template.js on the Desktop.

4. Select [OK].

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5. Edgecam will display the pre-selected CAM instructions.

 If any of the CAM instructions are highlighted, the command dialogs will show when the
macro is run.

6. Open the file ’15 - PCI Template.ppf’.

7. Select File ► Macro, [Browse] for and select the name of your PCI file, created in the
previous instructions.

8. Select File ► Macro ► [Run].

9. Follow the prompts.

 Pick first Curve, Select the First curve. Tick or Right Click.
 Pick second Curve, Select the Second curve. Tick or Right Click.
 Select drive surfaces, Select the Drive curve. Tick or Right Click.
 Select check surfaces, ignore. Tick or Right Click.

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 Pick the Features from the Feature Window.

10. The toolpath will be created on a different component.

11. Save as ’15 – Completed PCI Template.ppf’.

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Tool Axis Control

Tilt Strategy
The Tilt method influences how the tool is presented to the workpiece. The Lead Lag and Tilt Angles
are crucial. We shall look first at the eight methods of Tilt Strategy.

 It is desirable to control the tool axis because:

 Zero cutting on Centre of Tool: best surface speed achieved from side of tool.
 Reduced reach required: improved rigidity and so no tool chatter.
 Access: reach in to area of a component that would be difficult for standard cycle.
 Improved Toolpath Shape.

 Depending upon which method is selected, will determine how many command prompts
are created.

Output Type

Output type is dependent upon your Edgecam Licence. Selecting 3-Axis will force the cycle to
behave like Slice Machining or Parallel lace cycle.
4-Axis will be selected when dealing with cylindrical parts, especially lathe work.

Tool Axis Control Tilt Strategy - Normal

The tool axis stays normal to, 90°, the drive surface. This is the most restricted manner of holding the
tool where the majority of sub-modifiers will not be effective.

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Exercise 16 – Normal and Relative to Cut Direction

In this exercise you will observe that the majority of Tool Axis parameters are greyed out.
 The Check commands cannot over-ride the Tilt functions

1. Open the file ’16 - Tilt Part.ppf’.

 You will be familiar with this part as it has been used in the previous Pattern examples.

2. The tool is constantly presented to the drive surface at 90°(Normal). Using this method would
mean that the best cutting surface speed is not being achieved as the centre of the tool is
constantly in contact.

3. Edit the existing Five Axis cycle.

Tool Axis Control Tab
 Tilt Strategy: Relative to Cut Direction
 Tilt Angle: 20

4. Edit cycle.
Tool Axis Control Tab
 Lead Lag Angle: 20

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5. View the toolpath and witness both the tool and machine tool movements in the Machine
Simulator.

6. The tool is rotated from its surface normal orientation in two planes, by specified angles.
 Lead Lag Angle: Leaning the tool forwards or backwards relative to the cut direction.
 Side Tilt: Leaning the tool sideways, at 90° to the cut direction.

7. Save as ’16 - Completed Tilt Part.ppf’.

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Exercise 16a – Tilt Strategy - Axis control

The last example demonstrated the usage of Tilt and Lead angles applied to the Cutter. Furthermore,
you should now be familiar with the concept and meaning of Normal in terms of Edgecam strategy.
In this next method the tool is tilted away from the Surface Normal by the Tilt Angle. A Tilt Axis can
be specified (X, Y or Z). The applied tilt reduces once the tool is parallel to the Tilt Axis.
 You must specify a Tilt Axis when using Relative Angle.

1. Open the file ‘16a - Tilt Relative Angle.ppf’.

 The Pattern strategy is Blend between Two Curves.

2. Edit the existing Five Axis cycle. The Relative Tilt Angle is currently set to Tilt Angle 30°
Tool Axis Control Tab

3. Alter the angle from 10° through to 55° - observe the differences.

10 Deg 55 Deg

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4. Alter the Tilt Axis: X, Y or Z.

5. The tool is tilted from the normal by the angle about the specified Axis. If the Tool’s natural
Tilt becomes less than the Tilt Angle, then the Tool Follows the Surface Normal.

6. Edit the cycle setting the strategy to Fixed Angle to Axis.

7. Let the Tilt Axis remain as Z-Axis, however set the Tilt angle to 30°.

Relative Angle Fixed Angle to Axis

 Relative Angle: The tool is tilted from the surface normal by the Tilt Angle you specify,
towards the Tilt Axis you specify (X, Y or Z).
 Fixed Angle to Axis: The tool is tilted from the Tilt Axis you specify (X, Y or Z) towards
(or past) the surface normal.

8. Activate the Toolpath Normals to illustrate the differences between these two methods.

9. Save as ’16a - Completed Tilt Relative Angle.ppf’.

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Exercise 16b – Tilt Strategy - Through a Fixed Point

The tool axis is constantly pointing towards a point entity. Regardless where the tool sits on the
component, the tool always looks towards the point.

 This next method will demand extra Coord input data.

Through a Fixed Point Away from a Fixed Point

1. Open the file ‘16b - Dimple - Through A Fixed Point.ppf’.

 The Pattern strategy is Parallel to Curve.

2. This particular Tilt method affords good accessibility for machining deep pockets. Without this
ability the tool would have to remain perpendicular to the work piece so fouling sections of the
tool.

3. The Five Axis cycle has no Tilt Strategy applied. You will witness some gouging. The
optimum tool speed is not being achieved due to always cutting on the centre of the tool.

4. Simulate the current toolpaths. The toolpath is unsatisfactory due to there being no tilt
strategy.

5. Edit the existing Five Axis cycle.

Tool Axis Control Tab

 Reset All Picks.

 Reselect Geometry and Coordinate Input: Checked
 Tilt Strategy: Through a Fixed Point

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 Tilt Axis: Z Axis Looking along the tool from flutes to shank, the tool always points
towards a specified point.

6. Select [OK]. Follow the prompts.

 Pick Single Edge Curve, Select the Drive Curve, EdgeLoop Feature. Tick or
Right Click.

 Input Tilt Fixed Point, Select the point entity located above the part.

 Select drive surfaces, Select the hemisphere shaped Face Feature. Tick or
Right Click.

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 Select check surfaces, Select the flat Face feature. Tick or Right Click.

7. You have fixed the toolpath by not altering the Pattern but by merely correcting the Tilt.

8. Edit the cycle, this time selecting a different point entity (the point entity is on layer Point B)
Observe the different tilt on the tool axis.

Centre Tilt Point Offset Tilt Point

 You might have to regenerate the CAM sequence after each edit.

9. Tilt Angle and Tilt Axis are still effective when Through a Fixed Point is active. The Tilt angle
is measured to the tool axis and therefore the tool is tilted within its own environment.

Tilt Angle Through a Fixed Point

Will the Check Surface Feature have any bearing on the toolpath?

10. Save as ‘16b – Completed Dimple - Through A Fixed Point.ppf’.

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Exercise 16c – Tilt Strategy- Away From a Fixed Point

Opposite to the previous method, the tool axis constantly points away from a point entity.

1. Open the file ‘16c - Dome – Away From A Fixed Point.ppf’. Note the Features, Stock
and machine tool set-up.

 The Pattern strategy is Parallel Slice.

2. Simulate the current toolpaths. The toolpath is unsatisfactory due to there being no tilt
strategy.

3. Edit the existing Five Axis cycle

Tool Axis Control Tab

 Reset All Picks.

 Reselect Geometry and Coordinate Input: Checked
 Tilt Strategy: Away From a Fixed Point
 Tilt Axis: Z Axis

4. Select [OK]. Follow the prompts.

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 Input Tilt Fixed Point, Select the point entity located above the part.

 Select drive surfaces, Select the Dome shaped Face Feature. Tick or Right
Click.

 Select check surfaces, Select the flat Face feature. Tick or Right Click.

5. The tool now points down, towards the point entity. The tool is not pivoting through a point
(e.g. previous example) rather, it is consistently pointing inwards.

In the Simulator, how do we stop the Fixture and Stock Rotating?

6. Edit the cycle

Tool Axis Control Tab
 Tilt Angle: 20 This will have the effect of further constraining the tool angle.

7. Edit the cycle.

Tool Axis Control Tab
 Tilt Angle: Null
 Conical Limits, Conical Minimum: 0 Conical Maximum: 15
 Cone Axis: Z Axis

8. Save as ‘16c - Completed Dome – From A Point.ppf’.

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Exercise 16d – Tilt Strategy - Tilt to a Curve

The following tilt strategy will constrain the tool axis to a pre-drawn arc or curve entity.
 The ‘curve’ entity can be an arc, spine, or continuous.

1. Open the file ‘16d - Tilt To Curve Dovetail.ppf’. The sidewalls possess a negative draft
angle which would ordinarily cause issues with tool access.

 The Pattern Strategy is Blend between Two Curves.

 This example uses an arc entity to control the tilt strategy. The creating of the arc entity
was created on the Setup Ribbon.

2. Edit the existing Five Axis cycle.

 Note the Tilt Strategy: To Curve.

 Reset All Picks.

3. Select [OK]. Follow the prompts.

 Pick first Curve, select the Edge Loop Feature. Tick or Right Click.

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 Pick second Curve, select the Edge Loop Feature. Tick or Right Click.

 Select Tilt Curve, Select the Arc. Tick or Right Click.

 Select drive surfaces, Select the Drive Surface Face Feature. Tick or Right
Click.

 Select check surfaces, Ignore. Tick or Right Click.

4. Observe the toolpath. The tool is carried by the arc entity.

5. Edit the cycle.

Tool Axis Control Tab
 Curve Tilt Angle: Angle From Curve Tilt Angle: 10

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6. The tool may now tilt 10 degrees off the Tilt curve.

What would a Normal to Curve type of strategy do for this part?

7. Save as ‘16d - Completed Tilt To Curve Dovetail.ppf’.

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Check
The purpose of this parameter is to control the toolpath against Drive and Check Surfaces.
You will have noticed that the Five Axis cycle does not use containment boundary therefore,
the Check option is used to ensure the tool does not machine unwanted areas.
There are several conditions to the Check function. What item, tool or holder, is checked
against what condition, Drive and/or Check Surfaces.
Furthermore, there are permutations for the type of evasive action the cycle must take if it
detects any form of collision.

It is not necessarily true that the Check command is used to prevent the tool from machining a
surface. This is a common misconception probably nurtured by the fact that other Edgecam cycles
use Check to behave in the manner (Parallel Lace & Profiling Cycles)
The checks cascade from Check 1 to Check 4. Each check is applied to the toolpath resulting from
the previous check, starting at Check 1. This allows you to apply different gouge avoidance
strategies for the tool as opposed to the holder, or for individual check surfaces.
Check Tab
Shank and Holder Offset: Apply values to these two fields to effectively increase the size of that
particular item for checking. This has the effect of proving additional clearance.
Against: The surface to be protected from gouging: Surfaces (drive), Check Surfaces or Both.
Check: Choose from, Tool, (tool) Holder, Both (tool and holder) or None (no checking).

 Tool is defined as Flutes only. Holder is Shank & Holder.

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Exercise 17 - Check Surfaces

 Initially, try not to use the Check conditions. This will speed up the progress of the
command.

1. Open the file '17 - Swarf Impellor Blade.ppf’.

 The Strategy pattern is Parallel to Curve.

2. Simulate the toolpath and observe the progress of the tool.

3. Edit the Five Axis cycle, inspecting the Pattern and Tilt. The tool is using an Edge Loop
feature for its Drive Curve. The Face Feature provides the (blade, sidewall) represents the
Drive Surface. Similar to the Swarf cutting command the tilt is set to Relative angle.

4. A Check Surface has not been selected, and so the cycle has been allowed to gouge the
floor of the impellor. This is caused by the Check parameters also not being set.
Check Tab

 Reset All Picks

 Reselect Geometry and Coordinate Input: Checked
 Check 1, Check: Tool Against: Check Surfaces
 Tolerance: .01 Strategy: Retract

5. Select [OK]. Follow the prompts.

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 Pick Single Edge Curve, select the Edge Loop Feature. Tick or Right Click.

 Select drive surfaces, Select the Drive Surface Face Feature. Tick or Right
Click.

 Select check surfaces, Ignore. Tick or Right Click.

 The Features have been named and placed on separate layers.

 When the cycle was originally created, the Check Surface parameters would not have
been employed.

6. The cycle no longer gouges into the floor. The cycle is now being told to retract the tool if the
Check conditions are met.


7. Save as ‘17 – Completed Swarf Impellor Blade.ppf’.

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Exercise 17a - Multiple Check Surfaces

There are multiple gouges on this part. We shall look at some of the Check options before removing
these gouges one by one.

1. Open the file ‘17a - Swarf Blade.ppf’.

 The Strategy pattern is Parallel to Curve.

2. Simulate the toolpath and observe the progress of the tool. Clearly, the holder gouges the
part. Furthermore, the tool cuts into the root of the blade.

3. Edit the Five Axis cycle.

Check Tab

 Reset All Picks

 Reselect Geometry and Coordinate Input: Checked
 Check 1, Check: Tool Against: Check Surfaces Strategy: Retract

4. Select [OK]. Follow the prompts.

 As the Check Surface is the root of the blade, this first alteration will prevent the tool from
gouging this area.

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 Pick Single Edge Curve, select the Drive Curve Edge Loop Feature. Tick or
Right Click.

 Select drive surfaces, Select the Drive Surface Face Feature. Tick or Right
Click.

 Select check surfaces, Pick the Check Surface Face Feature. Tick or Right
Click.

5. Observe how the cycle no longer gouges the root of the blade. The cycle is now being told to
retract the tool if the Check conditions are met.

6. Edit the cycle.

Check Tab
 Strategy: Stop Calculation

7. Observe the toolpath, the cycle will miss out the entire last cut, because it detects the gouge.

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8. Edit the cycle.

Check Tab
 Check: Both Against: Both

 Both the Tool and its Holder is checked against Both the Surface and Check Surface.

9. The cycle will now only produce two passes because if it travels any further down the blade, a
collision is detected.

10. Clearly, the cycle cannot be left in this condition, the part will not be machined otherwise. The
next set of instructions will introduce a more acceptable method of taking evasive action if
indeed the cycle is found to gouge. Your next strategy will be Tilt Away. The tool will be
angled away from the collision area, you are allowed to specify how much it moves away.

11. Edit the cycle.

Check Tab
Check 1
 Shank Offset: 2 Holder Offset: 10 Clearance is introduced
 Check: Holder Against: Both Strategy: Tilt Away
 Tilt Direction: Side Tilt Tilt Sign: Either
 Check 1 conditions prevent the tool and holder colliding with the blade sidewall.

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Check 2
 Check: Tool Against: Check Surfaces Retract if gouge is detected
 Strategy: Retract
 Check 2 these conditions re-instate our first set of Check conditions, preventing the tool
from gouging the root of the blade.

12. Observe the resultant toolpath. The holder will no longer gouge as it is forced to tilt away from
the component. The tool should not strike the base of the blade due to the earlier checking
conditions.

 Note the machine is not collision checked against in the cycle.

13. Save as ‘17a - Completed Swarf Blade.ppf’.

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Exercise 17b - Check Surfaces

1. Open the file ‘17b - Move Along Vector.ppf’.

2. Simulate the toolpath and observe the progress of the tool. Clearly, the tool gouges the part
in the boss area.

3. Edit the Five Axis cycle.

Check Tab
 Check (1): Tool Against: Check Surfaces Strategy: Retract
 Reselect Geometry and Coordinate Input: Checked.

4. Select [OK]. Follow the prompts.

 Select drive surfaces, Select the Drive Surface Face Feature. Tick or Right
Click.

 Select check surfaces, Pick the Check Surface Face Feature. Tick or Right
Click.

 The resultant toolpath has now removed the gouging but is still not ideal.

5. Edit the cycle.

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Check Tab
 Strategy: Move Along Vector Vector Direction: Optimised XY

6. Observe how the tool now stays in contact with the drive surface, moving along the vector to
avoid the check surface.

7. Save as ‘17b - Completed Move Along Vector.ppf’.

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Exercise 17c - Check Surface Options

1. Open the file ‘17c - Avoid Gouge Remove Toolpath.ppf’.

 The Pattern Strategy is Parallel Slice.

2. Simulate the toolpath. Clearly, the toolpath is not acceptable; collision checking is currently
not set on the cycle.

3. Edit the Five Axis cycle.

Check Tab
 Shank & Holder Offset: 5
 Check 1, Check: Both Against: Both Strategy: Remove Toolpath

4. Select [OK]. Follow the prompts.

 Re pick only if you reset all picks.

 Select drive surfaces, Select the Drive Surface Face Feature. Tick or Right
Click.

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 Select check surfaces, Pick the solid Model. Tick or Right Click.

5. The cycle no longer gouges the part.

6. Save as ‘17c - Completed Avoid Gouge Remove Toolpath.ppf’.

 STL files can be used in Five Axis cycles but only as Check Surfaces.

Think what effect a different Check Strategy would do. Apply Tilt away Strategy with
Tilt direction set to Lead/Lag and Tilt sign to Either.

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Exercise 18 - Typical Five Axis Cycle set-up

In this exercise we will initially set up the cycle crudely then incremental change to make good.
Keep in mind the principal of Pattern, Tilt and Check, the finishing touches are made to the cycles
through the Check 2 commands.

1. Open the file ’18 - Bottle Base.ppf’.

2. Inspect the Features and Layers windows. In particular concentrate on the Features.

3. Select Machining ► Milling Cycles ► Five Axis.

4. Fill in the modifiers.

General Tab
 Strategy: Parallel Slice Mill Type: Climb Cutting Range: Exact Surface
 Angles In XY & Z: 0 Cut Order: Standard Tool Contact Point: Automatic
 Tolerance: .1 Cut Distance: 1

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Depth Tab
 Clearance Type: Plane Clearance Axis: Z Axis
 Clearance Plane Height: 5 Associative: Checked Retract: 5

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Tool Axis Control

 Tilt Strategy: Normal

Check Tab
 All Checks: None
Leads Tab
 Type: Radius Vertical to Tool Axis Lead In, Angle: 90 Lead Radius: 5

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Links Tab
 Short Links: Follow Surface Short Link Distance: 10
 Long Link Clearance: Clearance Safe Distance: 2 Gap Link Distance: 1

5. Select [OK]. Follow the prompts.

 Select drive surfaces, Select the Drive Surface Face Feature Item B. Tick or
Right Click.

 This is actually the wrong Drive Surface but is probably what a novice user would have
chosen because it represents the required shape.

 Select check surfaces, Pick the Check Surface Face Feature. Tick or Right
Click.

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 The resultant toolpath is very erratic due to the extreme deviations in the Drive
Surface. Despite selecting a Check Surface the tool has gouged the base because
no Check conditions have been stipulated inside the cycle.

6. Edit the cycle, activating a Check Condition.

Check Tab
 Check 1, Check: Tool Against: Check Surfaces

7. The tool is pushed away from the Check Surface and the cycle no longer gouges through the
base. However, the cycle is still too erratic. This due to the Drive Surface.

8. Edit the cycle.

 Reset All Picks.

 Reselect Geometry and Coord Input: Checked.

9. Select [OK]. Follow the prompt.

 Select drive surfaces, Select the Drive Surface Face Feature Item C. Tick or
Right Click.
 Turn off Rendering or Item A Layer.

 Select check surfaces, Pick the Check Surface Face Feature. Tick or Right
Click.

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 The Dome shape acts as the Drive Surface tilting the toolpath. Obviously this is the wrong
type of shape. The next alteration will explain why this has been done.

10. The cycles Tilt is now too erratic. Edit the cycle.
Tool Axis Control

 Reset All Picks.

 Reselect Geometry and Coord Input: Checked.
 Tilt Strategy: Away from a Fixed Point Tilt Axis: Z Axis

11. Select [OK]. Follow the prompt.

 Select Input Tilt Fixed Point, Select the point beneath the part (Point Layer).

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 Select drive surfaces, Select the Drive Surface Face Feature Item C. Tick or
Right Click.

 Select check surfaces, Pick the Check Surface Face Feature. Tick or Right
Click.

12. The Toolpath are now slightly better, the tool is held at more acceptable angle. However the
basic pattern to the toolpath is very wrong. The Dome is creating the basic shape and gives a
consistent, smooth toolpath. However, it is clearly the wrong shape.

13. Edit the cycle

Check Tab

 Reset All Picks.

 Reselect Geometry and Coord Input: Checked.
 Check 2, Check: Tool Against: Check Surface
 Strategy: Stop Calculation Select Checked Surfaces: Checked

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 Select the drive surface, select the Hemisphere shape Feature (ITEM C). Tick or
Right Click.

.
 Select Check Surfaces, Select Item A. Tick or Right Click.

 Select Check Surfaces (2), select the flat base Face Feature (ITEM B). Tick or
Right Click.

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14. Select [OK]. Follow the prompt.

 Select Input Tilt Fixed Point, Select the point beneath the part (Point Layer).

 Select drive surfaces, Select the Drive Surface Face Feature Item C. Tick or
Right Click.

 Select check surfaces, Pick the Item A Face Feature. Tick or Right Click.
 Show Layer Item A.

 Select check surfaces (2), Pick the Item B Face Feature. Tick or Right Click.

15. On this occasion the toolpaths are acceptable.

16. Save as ’18 - Completed Bottle Base.ppf’.

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Conclusion
The exercise has been deliberately structured to show the cycle being incrementally altered in
stages, which then shows a gradual improvement to the toolpaths.
The principal of Pattern Tilt and Check are clearly defined throughout the exercise thus enforcing the
knowledge accumulated during the early stages of the training guide.
The use of the Dome shape as the Drive surface clearly demonstrates the need to understand and
manipulate CAD data.

1. Open the ’18 - Completed Bottle Base.ppf’ from your completed folder of your USB
stick. This shows a 3rd check in place on the top star like face. As the area is quite shallow
five axis is not required in this area. Constant Cusp has been used for finishing instead.

1. Open the part file ‘18a - Dino.ppf’ for another example of using Edgecam Surface Entities
as a Drive Surface and a STL Model as the Check.

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The Depth Tab Settings

Plane Cylinder Sphere

The depth settings are similar to that of a standard 3-Axis cycle. For example the Clearance value,
or beyond it, is a position where the tool is free to move without collisions.
Associative: Uncheck this for clearances to be measured from the CPL origin/principle axes. Check
this for clearances to be measured from points on the part geometry. For a clearance plane, for
example, the Clearance Plane Height would become an increment from the top-most point on the
part. For a Clearance Radius, this would be the smallest separation between points on the clearance
surface and the part.
Retract: From the Retract Distance the tool is given the appropriate tilt for the start of the cycle, and
moved to the start of the Lead In move (or to the start of the first cut if no Leads are specified).
Similarly at the end of the Lead Out move the tool retracts to the Retract Distance.

Tool Axis Shift: Introduces an offset into the toolpath.

The offset is produced by moving the tool along its axis by this Tool Axis Shift distance. Positive
values move away from the cutting end, negative values move towards it.

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Exercise 19 – Depth Settings

The following exercise demonstrate the various settings used in the Depth Tab.

1. Open the file ’19 - Air Vent - Clearance.ppf’.

 The dimensions Layer displays the 30mm plane.

2. With the Clearance Plane setting and Z axis, the 30mm value is adequate. The tool does not
collide.

3. Edit the Cycle.

Depth Tab
 Clearance Type: Sphere Clearance Radius: 30

4. The Toolpath retract movements are far too excessive.

5. Edit the Cycle.

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Depth Tab
 Clearance Type: Plane Clearance Axis: Z Axis
 Retract: 2 Plane Height: 10

6. The Clearance is more acceptable.

7. Save as ’19 – Completed Air Vent - Clearance.ppf’.

 Note with a Clearance plane it is easy to control the tool clearance, sometimes with
cylinder & Sphere, retract can be in the opposite direction to what you were expecting.

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Exercise 20 – Retract Setting

1. Open the file ’20 - Undercut.ppf’.

2. Currently, the cycles have no Retract value. Enter the Simulator and observe how the tool
gouges the side wall.

3. Edit the Five Axis cycle.

Depth Tab
 Retract: 25

4. In the Simulator and check that the collision has been removed.

5. Save as ’20 – Completed Undercut.ppf’.

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Angular and Axis Limits

Previous exercises have demonstrated the strategies found in the Tool Axis Control Tab. The
various strategies allow the user to hold or present a tool during machining so as the best tilt angles
are achieved.
Sometimes the tilt or lean the tool can exceed either the physical capabilities of the machine tool or,
a collision is created.
The following exercises demonstrate how to interpret and execute the commands.

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Exercise 21 – Angular Limits

The Angular limits commands can also be used to act as a containment boundary. In the last
example, the command was used to protect the machine tool. In this next example, the machine is
capable of indexing and tilting the Table, however the toolpath requires constraining because a
collision has been created.

1. Open the file ’21 - Knee Joint Machined.ppf’.

2. In Simulator, note the collisions points.

3. Edit the cycle

Tool Axis Control Tab
 XZ Minimum: 5 XZ Maximum: 175

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4. In the Simulator, note that the collisions points have been removed.

5. Save as ’21 - Completed Knee Joint Machined.ppf’.

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Conical Limits
The previous example, demonstrated limiting rotation angles along a plane. This is acceptable
provided the component is being machined in one plane. Using Conical Limits is a far better method
when machining all the way around a Circular component.

Exercise 22 - Conical Limits

1. Open the file ’22 - Bottle Bottom - Conical Limits.ppf’.

2. You will already be familiar with this part and how the machining cycle was developed. For
the purposes of this exercise, the Tilt method has been set to Normal (not Fixed through a
point). The base of the component has not been used as a Check surface.

3. Due to the manner in which the Five Axis cycle has been created, the tool is constantly
perpendicular to the Drive Surface. This causes the tool to move too far down the part and so
colliding with the base.

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4. Edit the cycle.

Tool Axis Control Tab
 Conical Minimum: 0 Conical Maximum: 45 Cone Axis: Z axis

5. Note the alteration in the attitude of the tool.

6. Save as ’22 - Completed Bottle Bottom - Conical Limits.ppf’.

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Exercise 23 – Selecting an Axis

The previous exercises described how to limit the movement in a particular axis. The Five Axis
cycles offers the ability to rotate around all three axes (X, Y and Z). It’s sometimes desirable to inhibit
a rotary axis, normally where there is excessive machine tool Table movement or where the part is
relatively simple and therefore require a less sophisticated toolpath.

1. Open the file ’23 - Limit Axis.ppf’. Inspect the part and cycle attributes.

2. In the Simulator and witness the erratic swing of the machine tool Table as it rotate the C
axis.

3. Edit the Five Axis cycle.

Tool Axis Control Tab
 Output Type: 4-Axis Axis: X Axis

4. In the Simulator, a smoother toolpath with less rotation is produced.

5. Edit the Five Axis cycle.

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Tool Axis Control Tab

 Output Type: 4-Axis Axis: Y Axis

6. In the Machine Simulator, a smoother toolpath is produced with rotation being around the Y
axis

7. Edit the Five Axis cycle.

Tool Axis Control Tab
 Output Type: 4-Axis Axis: Z Axis

8. In the Machine Simulator, the toolpath is now rotating around a Z axis (machine spindle) this
is probably not what we required.

9. Save as ’23 - Completed Limit Axis.ppf‘.

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Lead Control
Lead In/Out parameters largely operate in the same manner as a standard cycle but with more
options.

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Exercise 24- Lead Parameters

1. Open the file ’24 - Lead Control.ppf’. Currently there are no leads applied.

2. Edit the cycle.

Lead Tab
 Type: Radius Horizontal to Tool Axis Equal lead Moves: Checked
 Angle: 90 Lead Radius: 15

 The angle is applied Horizontally.

3. Edit the cycle.

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Lead Tab
 Type: Radius Tangential Equal lead Moves: Checked
 Angle: 90 Lead Radius: 15

 The angle is measured tangentially to the side of the component.

4. Edit the cycle.

Lead Tab
 Type: Radius Vertical to Tool Axis Equal Lead Moves: Checked
 Angle: 90 Lead Radius:15

 As the Tilt angle on the tool is Relative to Cut Direction you will not witness any alteration.

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5. Edit the cycle.

Lead Tab
 Type: Linear Tangential Equal Lead Moves: Checked Length:15

 The length is always tangential to the Toolpath.

6. Edit the cycle.

Lead Tab
 Type: Linear Normal Equal lead Moves: Checked Length:15

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 The length is always Perpendicular to the Toolpath.

7. Edit the cycle.

Lead Tab
 Start Extension: 10 End Extension: 10

 The toolpath is extended by 10mm at its beginning and end.

8. Save as ’24 - Completed Lead Control.ppf’.

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Link Control
Link control behaves very similar to the standard cycles. The Link move itself is the 3D distance the
tool moves after it has Lead Out and before in Leads In. Moreover, one further needs to consider the
Cut Distance and Mill Type.

Exercise 25 – Link Control

1. Open the file ’25 - Short Link Control.ppf’.

2. Edit the cycle.

Links Tab

3. Select each Short Link method in turn to see the differences.

 If Short Link Distance is less than Cut Distance, then Long Link is used.

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Exercise 26 - Long Links

The next exercise demonstrates how to save cycle time by using another Link type.

1. Open the file ’26 - Link Type.ppf’.

2. Simulate the toolpaths and take note of the cycle time.

3. Note the excessive amount of lift that the tool goes through during each successive pass.

4. Edit the cycle.

Links Tab
 Long Links: Rapid Feed

5. Simulate the toolpaths. Notice how the tool now remains at the same level. This will save
cycle time as the tool does not need to continually move up to the Clearance position.

6. On larger parts, the cycle time can be quite significant.

7. Save as ’26 – Completed Link Type.ppf’.

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Gap Control
Gaps are defined as a void in a drive surface (for example you might have selected two distinct
surfaces to form the drive surface, which have a gap between them). As with links, there are Short
Gaps and Long Gaps with an adjustable threshold between them.

 Gap Link Distance: Gaps shorter than this value are classed as Short gaps. Where the
Gap is longer than this value, it is classed as a Long gap.

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Exercise 27 – Gap Parameters

1. Open the file ’27 - Gap Link Control.ppf’.

 The cycle is using the Parallel Slice Pattern and Normal as its Tilt control.

2. The current Gap setting is 1mm therefore, the gaps will behave as Long Gaps.

3. Edit the Five Axis cycle and in turn change the Gap Links, Long Gap Settings

4. Edit the Five Axis cycle .Change the Safe Distance setting to 20mm this value is somewhat
impracticable as the tool will move up to this value instead of Clearance.

5. Set the Gap Link Distance: 50 (greater than the void between the Drive Surface). Short Gaps
would now be used on the part.

6. Save as ’27 - Completed Gap Link Control.ppf’.

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Exercise 28 – Depth, Leads, Links and Multi-Cuts

The following exercise combines the contents of the previous examples.
The task is to produce acceptable toolpaths to machine the spiral flute.

1. Open the file ’28 - Spiral Solid.ppf’.

2. The machine tool/code wizard used in this example is Fanuc vertical Table b-120 25 a.cgd.
This uses a Vertical, Table/Table configuration.

3. Edit the Five Axis Cycle, inspecting the Output Type and 4th Axis.

Consider the current status of Pattern, Tilt and Check. Would you have chosen the
same settings?

4. Beginning with the Depth parameters, alter the following settings, the aim is to keep the tool
as close to the part during non-cuts.
 Clearance Type: Plane Clearance Axis: Z-Axis Clearance Plane Height: 10
 Clearance Type: Sphere Clearance Radius: 5
 Clearance Type: Cylinder Clearance Axis: X-Axis Clearance Radius: 5

5. Try different values in Retract value: 1mm, 5mm and 10mm

6. Experiment with the Lead Values. The aim is to allow the tool as smoother entry into the part
as possible.
 Type: Linear Tangential Length: 10 Height: 10
 Type: Linear Normal Length: 10 Height: 10
 Type: Radius Tangential Angle: 45 Length: 10 Lead Radius: 10
 Switch the colour of Leads File ►Colours. This will allow you to easily identify the
toolpath determined by Lead settings.

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7. Experiment with the Start and End Extensions. The toolpath needs to engage the component
prior to full machining.

 Ideally, some of the original model features could be suppressed in order to enlarge the
drive curves and surface allowing the toolpath to run more smoothly.

8. Links Tab. The aim being to keep the tool from excessive movements. Use as many
combinations of Long and Short Link, you may find that due to your Mill Type and Depth
parameter settings, the Link parameters do not play a large part.

9. It may be necessary to rough-out the part prior to finishing.

10. Edit the cycle.

Multiple Cuts Tab
 Rough Passes: 3 Cut Distance: 3 Sort by: Passes

11. Note how the first series of cuts are wasteful and do not touch the part.

12. You may re-adjust the Cut Distance but this may leave large depths of cut still.

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Multiple Cuts Tab

 Stock Type: Current Stock

13. This will trim the excess toolpaths.

14. Edit the Cycle to machine the other flutes.

Multiple Cuts Tab
 Stock Type: Current Stock

15. Save as ’28 – Completed Spiral Solid.ppf’.

 Two further part files have been prepared in order to demonstrate how the tool could be
tilted.

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Exercise 28a - Spiral Solid with Table Tilt.ppf

1. Open the file ‘28a - Spiral Solid with Table Tilt.ppf’.

 This is the same part file in the exercise, except a Tilt angle has been introduced.

2. The tool doesn’t actually tilt, the Table inclines to allow the tool further clearance.

Exercise 28b - Spiral Solid with Head Tilt.ppf

1. Open ‘28b - Spiral Solid with Head Tilt.ppf’.

 This is the same solid as before except a different postprocessor.

2. The workpiece remains horizontal, the tool axis inclines.

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Exercise 28c - Spiral Solid with Mill Turn.ppf

1. Open the file ‘28c - Spiral Solid with Mill Turn.ppf’.

 This is the same solid as before except a different postprocessor.

2. Create the same toolpath as in the previous configurations. You will need to prepare the Cad
geometry as follows:

3. Ensure that the Axial CPL is active then create the following geometry.
 Remember to turn off Layers that are not required.
 2 Edge Loop Features
 1 Drive Surface (Face Feature)
 No Check Surfaces (we are not going to use any Check Surfaces)

Consider the application of Pattern, Tilt and Check based on the knowledge gained
from the previous examples. Would it be easier to start with an Operation?

4. Save as ‘28c – Completed Spiral Solid with Mill Turn.ppf’.

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Optimised Feedrates
Modifies the feed rate based on the surface curvature. The surface curvature is calculated at each
toolpath position where the surface contact point of the tool is known. This prevents excessively
rapid tool angle changes when machining tight curves.

Inverse Time Feedrate

When moving in 4 or 5 axes the controller needs to synchronise all axes. Without the Inverse Time
Feedrate function, one would discover that an axis would reach its destination before the remaining
axis.
Calculating the F-Code
The constant used to calculate the inverse time code is normally 1 minute, such that the equation is:
F = 1(minute) / (distance / mm/min))
– F(code) = 1(minute) / (time = 3D distance/velocity)
The 3D distance of the move is calculated in model coordinate space at the NC control point, not in
machine coordinate space and not necessarily at the tool tip. For example, a 5mm move at 50
MMPM takes 5 50ths of a minute, yielding an inverse time calculation of 1/.1 and an F-code of F10.
The same 5mm move at 700 MMPM would be 1(minute) / (time = 5 / 700) or (1/(5/700)) or
(1/.0071428) or F1400.168
1 / (distance / mm/min) Feedrate = 100 mm/min
Travel 1mm = 1/(1/100) = F100
Travel 2mm = 1/(2/100) = F50
Travel 10mm = 1/(10/100) = F10
Feedrate = 50mm/min
Travel 1mm = 1/(1/50) = F50

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 Ensure that your Code Wizard supports Inverse time Feed.

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Miscellaneous Parameters
The following series of exercise sets out to explain some of the remaining Five Axis cycle modifiers
that contribute to the successful creation of a toolpath.

Exercise 29 - Point Separation and Angle change

1. Open the file ’29 - Angle Change.ppf’.

2. Alter the View to Front. Select Machining ► Miscellaneous ► Toggle Toolpath Normals
and zoom into the top left hand section of the component.

3. This exercise concentrates solely on the influence of the Maximum Point Separation on the
General Tab and Maximum Angle Change on the Tool Axis Control Tab.

4. Edit the Cycle.

General Tab
 Maximum Point Separation: 10. Observe the effect this has on the toolpath.

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Tool Axis Control Tab

5. Edit the cycle.

 Maximum Angle Change: 10. Observe the effect this has on the toolpath.

6. Select NC Code ► Generate NC . You will see changes in the length of code when these
modifiers are altered.

7. Save as ’29 – Completed Angle Change.ppf’.

 Note default values are set at 5mm and 5 degrees respectively

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Exercise 30 - Preferred Rotary Solution

1. Open the file ’30 - Alt Solution.ppf’.

2. Enter the Simulator and view the Toolpath.

3. You will see that the Toolpath is hidden by the machine graphics. Close the Simulator.

4. Edit the 5 Axis cycle. At present the preferred Rotary Solution is set at Positive. Change this
to Negative.

5. Return To Simulator and check the toolpath.

6. Save as ’30 – Completed Alt Solution.ppf’.

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Exercise 31 - Round Corner Modifier

Use this setting to remove fishtails. Fishtails are extra sharp corners that are introduced into the
toolpath as the tool rounds a corner. The command is commonalty needed when tiny radii or internal
sharp corners are found on the drive surface. Using the command can be perceived as an automatic
fillet command.
The fillet is proportional to the radius of the current tool.
The Round Corner value is a radius value at which to trim back the toolpath from the surface corner.
This leaves a gap, which is then treated according to the 'Gap Link' settings in the Links Tab.

 Refer to Edgecam On-line Help for more information regarding Round Corners.

1. Open the file ’30 - Round Corners.ppf’.

2. Simulate the Sequence. Observe the bottom corner of the toolpath. Currently the Round
Corner setting is set to zero.

3. Edit the Five Axis Cycle.

General Tab
 Round Corners: Null The toolpath now demonstrates Fishtails.

4. The Fishtails are causing gouges, but the Check removes these.
 Check the Tool Against the Surface Strategy: Retract
 This last edit proves the connection between Checks & Links

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5. Edit the Cycle.

General Tab
 Round Corners: 1 The toolpath now has a Radius.

6. Save as ’30 – Completed Round Corners.ppf’.

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Exercise 32 – Round Corner External

A further example of this application can be seen from the following part file. You will appreciate why
the Round Corner setting defaults to zero. This component part presents with a sharp corner within
the toolpath. This may be a design error or may need Pencil machining afterwards. Never the less,
without the Round Corner command the Five Axis Cycle will struggle.

1. Open the file ’32 - Fish Tails.ppf’.

2. Enter the Simulator and observe the toolpaths.

3. Edit the cycle.

General Tab
 Round Corners: Null

4. In the Simulator, observe the toolpaths.

5. The toolpath can be altered by Check Surfaces, similar to the previous example.
Check Tab
 Check 1, Check: Both Against: Both Strategy: Retract

6. Taking this action should further emphasise the meaning of Fish Tails.

7. Save as ’32 - Completed Fish Tails.ppf’.

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Exercise 33 - Round Corner example

Use this example as good way of understanding the Round Corner setting plus, how an Operation
can prevent the best toolpath output.

1. Open the part ’33 - Shaker.ppf’.

2. You will create a Swarf Operation using the prepared Features. You will discover that the
toolpath is not satisfactory.

3. Select Machining ► More… ►Five Axis Swarf Operation.

 Select Drive Curve: Select the Edge Loop Feature. Tick or Right Click.
 Select Cycle Start Point: Ignore. Tick or Right Click.
 Select Wall Geometry: Select the Feature called Wall. Tick or Right Click.
 Select Floor Geometry: Select the Feature called Floor. Tick or Right Click.
General Tab

Tooling Tab

4. Select a 16.0 mm Multi-Flute End Mill-LS.

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Depth Tab

5. You will discover that only a small proportion of the component is actually machined. This is
due to the Round Corner option. The Swarf Operation will always set the modifier to zero.

 Round Corner set a zero is removing fishtails, however the shape of his part would
not induce a fishtail because there is no Sharp corners.

6. Expand the Operation and Edit the cycle.

General Tab
 Round Corner: Null

7. The toolpath is now corrected.

8. Save as ’33 – Completed Shaker.ppf’.

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Exercise 34 - Start Margin and Tool Axis Shift

The previous example demonstrates that by using an Operation, one can find that an unsatisfactory
toolpath is produced. However, one should always appreciate that an Operation is purposefully
designed to keep the dialog box brief and simple.
This next example actually demonstrates the opposite effect by NOT using an operation, the toolpath
is not correct.

Taper Tools
In this example, a taper tool cutter has been used in order to avoid the possibility of scaring the flat
base of the component part. If a regular square corner end mill had been used, the tilt angle will
cause the tool to be in collision with the base..
Instead of using the normal 90° Tilt angle when swarf cutting, observe that a different angle has been
employed. The Tilt angle is proportional to the tools taper value.
In this case 85° ((90-(included angle/2))
Taper tools used with the 5 axis cycle are not automatically compensated for. You will need to adopt
one of the following methods -

Method 1 – Known Taper Angle

 If the Tools Included Taper angle (18 Deg)
 Edit the Five Axis Cycle
 Go to the Tool Axis Control page, Edit the Tilt Angle: (90 – Taper Angle) = (90 – 9)=81

Method 2 – Taper Angle not Known

 Edit the Five Axis Cycle
 Go to the Check page, Check 1, Check - Tool, Against - Surface, Strategy - Tilt away,
Tilt Direction - Side Tilt, Tilt Side – Either

1. Open the file ’34 - Start Margin.ppf’.

2. The cycle generated by the Swarf Operation, will always default to placing 0.1mm into the
Start Margin and -0.13 (negative) into the Tool Axis Shift. This is done in order to remove any
mathematical anomalies in the cycle’s algorithms.

3. The tool is ascended by 0.1mm (Start Margin). This would result in the toolpath being out of
position. To counteract this action a negative value is used to place the tool back into
position, this is achieved by Tool Axis Shift.

4. Simulate the toolpath and see sections of toolpath are missing.

5. Edit the Cycle.

General Tab Depth Tab

 Start Margin: 0.1  Tool Axis Shift: -0.13

6. The fault will be rectified.

7. Save as ’34 – Completed Start Margin.ppf’.

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Side Tilt Definition (Tool Axis Control)

Side Tilt Definition is used to decide if the tool will follow the Surface, or the Drive curve, the default
is follow Surface.
The setting decides the manner in which the tool is tilted and become extremely important when
milling with the side of the cutter (flank milling)

Example 35 - Side Tilt Examples

1. Open the file ’35 - Side Tilt.ppf’. Observe that there are two machining sequences. You
can experiment with both of the Five Axis cycles.

2. Enter the Simulator. Selecting the first sequence (Radial Faces) The toolpath is ok.

3. Edit the Cycle. Select in turn the different options for Side Tilt Definition.

Tool Axis Control Tab

 Normal to First Edge Normal to Cut Direction Use Spindle Direction
 In this example Follow Surface is best option.

4. Select Second Sequence: Flat faces

 The Best option here is: Use Spindle Direction

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Roughing in Five Axis Simultaneous Machining

Using the Multi-cuts Tab, the Five Axis Cycle allows you to rough out bulk material. You add extra
cuts to the basic surface/curve based toolpath.
Multiple Passes/Depths allow you to create extra cuts by creating copies of the basic toolpath cuts,
projected along the surface normal (Passes) or along the tool axis (Depths).
Areaclear collapses a single loop cut into a series of cuts filling the enclosed area.

Exercise 36 - Multiple Passes and Depths

1. Open the file ’36 - Roughing 5 Axis.ppf’.

2. Edit the cycle, concentrating on the. Initially enter the following into the Multiple Pass area.
Multiple Cuts Tab
 Multiple Pass, Rough Passes: 5 Cut Distance: 2

3. Five extra cuts are now created.

4. Edit the cycle

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Multiple Cuts Tab

 Multi Depth, Rough Passes: 8 Cut Distance: 5

5. Set Multiple Pass to Slices and Multiple Depth to Passes and experiment.

6. Put in extra passes and use Current Stock to complete the part.

7. Save as ’36 - Completed Roughing 5 axis.ppf’.

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Exercise 37 – Roughing In Four Axis Simultaneous Machining

1. Open the file ’37 - Rotary CAM.ppf’.

2. Select Machining ► More… ►Four Axis Rotary Operation.

 Select Cycle Start Point: Select the Point entity.
 Select Drive Geometry: Select the Face Feature. Tick or Right Click.
 Select Model Geometry: Ignore. Tick or Right Click.

3. Fill in the modifiers.

General Tab
 Mill Type: Climb Cut Distance: 5 Tool Contact Point: Front Edge
 Lead Radius: 10 4th Axis: X axis

Tooling Tab
 Select a 20.0 mm x 2mm rad End Mill from the Tool store and place in position 1.

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Depth Tab
 Clearance: 5 Associative: Checked Safe Distance: 5

4. A finish pass only has been applied.

5. Due to the size of the stock, the tool is currently experiencing some very heavy cuts. The tool
will probably burn out or worse, break.

6. Roughing cuts are required.

7. Edit the Operation.

Multiple Cuts Tab
 Rough Passes: 10 Cut Distance: 3

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8. Select [OK] and observe the new toolpath. Extra cuts are being applied but there is a lot of
fresh-air machining. The Operations needs to consider the stock.

9. Edit the Operation.

Multiple Cuts Tab
 Stock Type: Pick

10. Pick the Stock solid from the Features Window.

11. Check the resultant toolpaths. The surplus tool movements have been trimmed back to the
Stock model.

12. Save as ’37 - Completed Rotary CAM.ppf’.

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3 to 5 Axis Cycle

You may convert an existing finishing 3 axis cycle to a 5-axis cycle by using the 3 to 5-Axis
Cycle command. The cycle is available with Ballnose tools and
 Allows you to use shorter tools for improved stability
 Protects the shank and holder from collisions
 Offers an easy method to create a 5-axis cycle

The supported cycles are as follows:-

 Profiling
 Parallel Lace
 Constant Cusp
 Rest Finish
 Flow Surface
 Project Boundary Collapse
 Project Flow Curves
 Project Circular Pattern
 Pencil Mill

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Exercise 38 - 3 To 5 Axis

1. Open the file ‘38 - 3 To 5 Axis.ppf’.

2. Select the Machining Ribbon where a 6mm Ballnose cutter has been pre-selected and the
part has a 3mm root radius around tapered wall.

3. A Pencil Mill cycle has already been applied to the part, simulate this part from the window of
Edgecam and observe the clash with the body of the tool holder. Right Click on the Pencil
Mill cycle from the sequence window and Simulate.

4. To rectify this problem we could hang the cutter out further but we have a 5 axis machine so
we can tilt the tool over and maintain the rigidity of the tool.

5. Select Machining ► Milling Cycles ► 3 To 5 Axis and use the following information to
tilt the tool over.
General Tab
 Tilt Angle: 15 Maintain Tilt Angle: Checked Tolerance: .1 Shank Offset: 2

6. Select [OK]. Follow the prompt.

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 Select Check surfaces, Pick the Face Feature that represents the tapered walls.
Tick or Right Click.

 Toggle features to show more clearly.

7. Simulate the resulting 3 To 5 Axis toolpath, the tool now tilts over and the collision is avoided.

8. Move to Toolchange.

9. Take the part in to Simulator to check the results.

10. Select Machining ► Milling Cycles ► Constant Cusp Finishing, use the following as a
guide.
General Tab
 Mill Type: Optimised Direction: Inside Out % Stepover:25

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Depth Tab
 Clearance: 50 Level: 49.5 Depth: None

Lead Tab
 Type: Normal Equal Lead Moves: Checked
 Lead In Angle: 90 Length: 4 Radius: 2

11. Select [OK]. Follow the prompts.

 Select surfaces to machine, Pick the Solid, Tick or Right Click.

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 Select containment boundary entities (Finish for none), in the layers Window, show
the layer called boundary and select the continuous. Tick or Right Click.

 Select single drive curve (Finish for none), Ignore. Tick or Right Click.

12. Simulate the resulting toolpath and observe that the tool holder collides with the solid in the
same way as the previous pencil mill cycle.

13. Copy the 3 to 5 Axis cycle and put it below the Constant Cusp cycle.

14. The tool now tilts to clear.

15. Move to Toolchange.

16. Take the part in to Simulator to check the results.

 Conclusion, the 3 to 5 Axis now has many uses and can be applied to a wide variety of
finishing cycles in order to tilt the tool to avoid any possible clashes with the part.

17. Save as ‘38 – Completed 3 To 5 Axis.ppf’.

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Workshops
Swarf Cutting (Workshop 1)
In this example we are going to SWARF cut (Side Wall Axial Relief Feed or Flank Milling) the side
walls of the pockets.
Pattern: Parallel to Curve.
Tilt: Relative to Cut Direction with 90° Tilt.

1. Open the file ‘Workshop 1 - Spreader.ppf’.

 This is a Lathe, you should be in the AXIAL CPL.

 Hide the Stock Layer before picking.
Geometry Required:
Check
Edge Loop Feature Face Feature
Surface

Interface N/A

Name Drive Curve Wall N/A

Layer Drive Curve Wall N/A
Colour User Defined User Defined N/A

Picks N/A

2. Select Machining ► More… ► Five Axis Swarf.

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3. Follow the prompts.

 Select Drive Curve: Pick the Edge Loop Feature.
 Select Start Point: Ignore.
 Select the Wall Geometry: Select the Face Feature.
 Select the Floor Geometry: Ignore.

4. Fill in the modifiers.

General Tab

Tooling Tab

Depth Tab

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Multiple Cuts Tab

5. Observe the Toolpath in the Simulator.

 Note how the tool only just about touches the base of the pocket.

6. Edit the Operation.

 Tool Axis Shift: -3

7. Check in the Simulator.

8. To machine the remaining Pockets we can either, repeat the above process or alternatively
use the Rotary Rotate command:

9. Save as ‘Workshop 1 - Spreader.ppf’.

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Trimming (Workshop 2)

1. Open the file ‘Workshop 2 - Sheetmetal Trimming.ppf’.

Pattern: Parallel to Curve
Tilt: Relative to the Cut Direction
Check: Both Tool and Holder

Geometry Required:
Check
Edge Loop Feature Face Feature
Surface

Interface N/A

Name Drive Curve Drive Geometry N/A

Layer Drive Curve Drive Geometry N/A
Colour User Defined User Defined N/A

Picks N/A

2. Select Machining ► More… ► Five Axis Curve.

3. Follow the prompts.

 Select Drive Curve: Pick the Edge Loop Feature.
 Select the Wall Geometry: Select the Face Feature.
 Select Model Geometry: Ignore.

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4. Fill in the modifiers.

General Tab

 Without Start Margin the tool would be on the Edge of the component.
Tooling Tab

Depth Tab

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Multiple Cuts Tab

5. Observe the Toolpath in the Simulator

6. The Component can also be machined using a Swarf Operation – Have a go.

7. Save as ‘Completed ‘Workshop 2 – Sheet metal Trimming.ppf’.

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Rotary CAMS (Workshop 3)

1. Open the file ‘Workshop 3 - Rotary CAMS MillTurn.ppf’.

Pattern: Parallel to Curve
Tilt: Relative to the Cut Direction
Check: Both Tool and Holder

 This is a Lathe you should be in the AXIAL CPL.

 Turn off the Stock Layer to aid Picking.

2. Create 2 Wireframe Points at X40Y40Z-130 and X-60Y20Z-70. These shall be the start
points on the first prompt of the Operation.

Geometry Required:
2 Face Features Check Surface

Interface N/A

Name Drive Geometry 1 and 2 N/A

Layer Drive Geometry N/A
Colour User Defined N/A

Picks N/A

3. Select Machining ► More… ► Four Axis Rotary.

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4. Follow the prompts.

 Select Start Point: Select Point entity.
 Select Drive Geometry: Select a Face Feature.
 Select Model Geometry (Check Surfaces): Ignore.

5. Fill in the modifiers.

General

 Tool Contact Point: Front Edge. The tool axis tilt is adjusted just sufficiently so that the
edge of the end flat section that is leading in the cut direction contacts the surface. Note
that gouging by the tool edges is possible, so you might need to make settings in the
Check Tab.

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Tooling Tab

Depth Tab

 The Tool Axis Shift is offsetting the tool away from the work piece.


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Multiple Cuts Tab

6. Select [OK]. Observe the Toolpaths.

7. Copy the Operation and Edit.

 Tool Axis Shift: 0

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8. Copy both Operations and Edit Coord input and select the second cam geometry.

9. Save as ‘Workshop 3 – Completed Rotary CAMS MillTurn.ppf’.

What other ways could you rough and finish the part?

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Blade machining (Workshop 4)

Turning Application
 Path : Parallel Slices
 Tilt: Relative to Cut Direction
 Checking: Both
Machine Tool: 5ax training - 2axcy.tcp.

Similar to previous machine tool BUT has a B Axis. This Post is also POSITION ONLY. You will see
this evidence of this in the Tilt modifiers – NO ‘Lock 5th Axis’ and ONLY 3 & 4 Axis output.

 The postprocessor is very important in this example.

1. Open the file ‘Workshop 3 – Rotary Blade - 2axCY.ppf’.

2. Isometric View

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 You must activate the Axial CPL

 Create a point to act as the start point
 Reference to (tip of the blade)
 X10mm

3. Create Face Features

 These features are eventually used in the CAD selection.
 Create Layer: Features
 Use different colours for each separate Features.
 Create Face Feature for Blade Wall (4 Faces) Green
 Create Face Feature on Radius at the root of the Blade (4 Faces) Light Blue

4. Select the Manufacturing Ribbon.

5. Select Planar Mode or 5 axis cycle is not available.

6. Ensure the correct tool Orientation.

 NOTE: Due to Post – no Angle modifier.

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7. Select Five Axis Cycle – Set the following.

 Parallel Slice: The tool Pattern will follow the feature (water-line)
 Angle in XY & Z determines the pattern of the slice.
 Exact Surface as Cutting Range: The tool will fall exactly on the Feature.
 Cutting Order: Standard front to back.

Depth Tab
 Clearance Type: Cylinder Axis, Clearance Z axis. Around the centre-line of the spindle.

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Tool Axis Control

 Tilt Strategy: Relative to Cut Direction. The tool will follow the pattern of the cut.
 Lead Lag: 0º angle so as the tool will not lean over.

Checks
 Check 1, Check: Both Tool & Holder are checked against ALL items (Drive & Check)
 Strategy: Retract away if collision.

Leads

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8. Select [OK].
 Select the Point entity as the Start Point.
 Drive Surfaces: Select the Drive Feature.
 Select the Check Surfaces: Select the Check Feature.

9. Observe the toolpaths.

What happens if the Start Point is not selected?

10. Generate NC Code .

Machine Tool: 5ax training - 4axcybs b axis tool tip positional only.tcp

11. Open the file ‘Rotary Blade - 4axCYBS Positional.ppf’.

12. Similar to previous machine tool BUT has a B Axis. This Post is also POSITION ONLY. You
will see this evidence of this in the Tilt modifiers – NO Lock 5th Axis and ONLY 3 & 4 Axis
output.

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13. In the Toolchange you can now Index the B Axis, once you have indexed, you don’t need to
select planar milling.

 The Five Axis Co-Ordinates is set to Absolute Co-ordinates Tool Tip.

14. Open Code Wizard - Load File - 5ax Training - 4axCYBS B Axis Tool Tip Positional Only.cgd.

 Create the 5-Axis cycle exactly like the previous cycle.

 Generate code: Observe the output.

15. Generate NC Code. One B Axis output.

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16. Swap the Five Axis co-ordinates out.

17. Re-compile

18. Reload

19. Regenerate

20. The CNC Program is now X Y Z co-ordinates.

21. Load File – ‘Rotary Blade - 4axCYBS.ppf’.

22. The Machine Tool is Machine Tool ‘5ax training - 4axcybs b axis tooltip.tcp’.

23. Set the 5 Axis cycle as before, except this time look at the Tool Axis Control. It allows 5 Axis
as the Output Type.

24. Set up the cycle.

25. Re-Run the Simulator.

26. Observe the Fluid movements to the toolpath.

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Port (Workshop 5)
This is a Milling Example.
This example could use Blend between two Curves, Parallel Slice or Normal to Curve as its Pattern,
and for the Tilt Strategy we could use, Relative to Cut Direction at 90deg, Through a fixed point or To
Curve.
For this Port we are going to be using.
 Pattern: Blend Between Curves Strategy
 Tilt: Either Through a fixed point or To Curve

1. Open the file ‘Workshop 5 - Manifold Assembly.ppf’.

Geometry Required:-
 2 Edge Loops
 1 Drive Surface (Face Feature).
 No Check Surfaces (we are going to use the entire model).
How to Create the Edge Loops.

2. Create a layer called Loops.

3. Ensure you are in TOP CPL.

4. Select Edge Loop Feature, Select the Top loop.

Create the Bottom Loop.

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5. Creating the Drive Surface (Face Feature).

6. Create a new Layer, Drive.

7. Create the Drive Surface.

8. This is a Face Feature comprising of four Faces.

9. Your Feature window will look like this:

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10. Select Machining Ribbon. The Machine Tool is solid vertical ba Table unit.mcp.

11. A 10mm Lollipop Cutter has already been selected.

12. Select the 5 Axis Cycle.

General Tab

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Depth Tab

Tool Axis Control Tab

13. For now we will set the tilt Strategy to Relative to cut Direction, with a 90 Deg tilt, just like
SWARF Cutting. We will come back and alter this later.
 Angular Limits, XZ Minimum: 0 XZ Maximum: 90

Check Tab
 None, Currently no Checking

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Leads Tab

Links Tab

Edgecam Inputs
 Pick First Curve: Bottom Edge Loop
 Pick second Curve: Top Edge Loop
 Select Drive Surfaces: Drive Face Feature
 Select Check Surfaces: Ignore

14. If you now simulate the Toolpath in Edgecam, the tool is now perpendicular to the surface,
but it is still Gouging the part. So we now need to Introduce Gouge Checking.

15. Edit the 5 Axis Cycle. Select the Check Tab.

 The Shank & Holder Offset are critical!

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 Note Input Data must be re-picked

 Pick First Curve: Bottom Edge Loop
 Pick second Curve: Top Edge Loop
 Select Drive Surfaces: Drive Face Feature
 Select Check Surfaces: The whole of the Solid Model

 Make sure the correct solid model is selected! DON’T PICK THE STOCK.

16. Simulate in Edgecam.

17. Try Changing the Check Strategy from Remove Toolpath to Stop Calculation.

18. On Stop Calculation, as soon as tool needs to lift off the surface to get to the next area, the
toolpath is trimmed back to this point.

19. But if we look at the Toolpath it does not go down the bore very far, so we need to possibly
look if using an alternative Tilt Strategy, would give us more access.

20. The first strategy we will try is Through a Fixed Point, for this we will need to add a point.

21. On the Setup ribbon, draw a point in the centre of the bore 20mm above it.

22. Edit the 5 Axis cycle. Select the Tool Axis Control Tab.

23. Change the Tilt Strategy to Through a Fixed Point.

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 Note Input Data must be re-picked

 Pick First Curve: Bottom Edge Loop
 Pick second Curve: Top Edge Loop
 Select the Start Position: Ignore
 Input Tilt Fix Point: Select the point entity that you have just created
 Select Drive Surfaces: Drive Face Feature
 Select Check Surfaces: Solid Model

24. Let’s now see if trying a different Tilt Strategy gives us any further advantages, so now we
can try To Curve.

25. For this strategy we must create a curve, for this we will need to add a Circle.

26. On the Setup ribbon, draw an Ø10mm Circle in the centre of the bore 20mm above it –use
the centre point as the arc centre.

27. Edit the 5 Axis cycle, select the Tool Axis Control Tab.

28. Change the Tilt Strategy to To Curve.

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 Input Data must be re-picked.

Pick First Curve: Bottom Edge Loop
Pick second Curve: Top Edge Loop
Select Drive Surfaces: Drive Face Feature
Pick the Tilt Curve: Select the ARC entity
Select Check Surfaces: Solid Model

29. If we look at the new toolpath, we will see that the tool is able to get a little bit further around
the bore, but it is very similar to through a point.

30. Simulate in Edgecam.

31. In practicable terms you may not wish for the tool to go all the way down the port because the
chuck can be indexed and you can machine the bore from the other side. To ensure that the
tool only passes down say 60% of the port, use a check surface (Check 2)

32. The Strategy we have applied so far is great if we want to machine around the bore in Z
Slices, but some port manufactures prefer to flow up and down the bore, so we will now
change the Toolpath Strategy to reflect this.

Lacing the Port

33. If we now try changing the Toolpath Strategy from Blend Between Two Curves, to Normal to
Curve.

34. Edit the 5 Axis Cycle

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General Tab

Depth Tab
 As before
Tool Axis Control Tab
 As before
Check Tab

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Leads Tab
 As before
Links Tab

 Re-Pick - Edgecam Inputs

 Pick lead Curve: Top Edge Loop
 Select Drive Surfaces: Drive Face Feature
 Pick the Tilt Curve: Select the ARC entity
 Select Check Surfaces: Solid Model

35. Now we can see that the toolpath is lacing up and down the bore vertically.

36. Now have a go and apply a 5 Axis toolpath to the other bore.

37. Save as ‘Workshop 5 – Completed Manifold Assembly.ppf.

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Impeller Floor machining (Workshop 6)

Mill XY Environment

1. Open the file ‘Workshop 6 - Impeller Floor.ppf’.

2. View from Top

 Pattern: Blend between to Two Surfaces
 Tilt: To Curve, we will need to create the centre-line between the two blades.
 Check: Introduce Check later.

3. Create a New Layer, and a Tilt Curve using Geometry from Edges .

4. Select Geometry from Edges, Select top edge of blade (1).

5. Transform Rotate curve about Z (360/No. of blades/2) 18 deg.

6. Move the Curve upwards, (Translate radially by 20mm) using the following method:

7. Draw a Construction line by setting the Z-Level to 35mm (back edge of the continuous).

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8. Draw single line from X0 Y0 to the tip of the Continuous

 Check that the line is flat. Lies at Z0mm

9. Edit, Extend the line by 20mm (The line is 100mm Long, make it 120mm).

10. Dynamically Translate the Continuous onto the end of the extended line.

Face Features

11. Create a new Layer called, Floor and create a Face Feature called Floor (2)

12. Create a new Layer called, Blade Wall and create a Face Feature called Blade Wall 1 (3)

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13. Create Face Feature called Blade Wall 2 (4).

14. In the Toolstore , Select an 8.0 mm Ball Nose Mill. Place in Position 1.

15. The size of the Ballnose cutter is important, due to Start& End Margins.
 Remember, Z Gauge for Loading into Simulator.

16. Machine Tool: sample mill vertical ac trunnion mm.mcp.

17. Select the Five Axis Cycle , See following screen shots.
General Tab
 Tilt: Blend between Two Surfaces, the two Face Features Start & End Margin: 4
 Cut Order: In to Out Cut Distance: 3 Tolerance: 0.1 Mill Type: Climb

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Depth Tab

Tool Axis Control Tab

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No Checks?

Leads Tab

18. Select [OK].

 Pick Tilt Curve, Select the Continuous Entity.
 Select Drive Surfaces, select the Floor Feature.
 Select Check Surfaces. Ignore.
 Select First Edge Surfaces.
 Select Second Edge Surfaces.

19. Observe the toolpaths

20. Observe toolpaths. The tool rides over the lower end of the cone. Try to prevent this by using
Checks.

Can Checks be added?

21. On the setup Ribbon create/position surfaces.

22. Create a New Layer called Checks.

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23. Top CPL & TOP View. Z-Level 100.

 Primitive won’t work unless in static View

24. Create Slab.

25. Position at X-30Y0.

26. Move back to the Cycle & Edit. Activating the Check.

27. Select the top Ruled Surfaces.

 Now use a SWARF strategy to finish the blade walls

 Try creating a .PCI to use for the blade walls

28. Save as ‘Workshop 6 – Completed Impeller Floor.ppf’.

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Worm (Workshop 7)
This is a Turning Example
A milling example may use Parallel to Curve as it Pattern, Around 4th Axis as its Tilt.
This type of screw form can be manufacture using
 Pattern: Blend Between Curves Strategy
 Tilt: Fixed Angle to Axis

1. Open the File ‘Workshop 7 - Screw.ppf’. or if you wish to skip the design stage, load
‘Workshop 7 - Screw Design Prepared.ppf’.

2. Create Machining geometry

 2 - Curves
 1 – Drive Surface
 No Check Surfaces

3. Create Layer, Drive 1.

4. Change CPL to Axial.

5. Select the First Loop .

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6. Create the 2nd Loop

 Where selecting the Edge Loop Feature becomes difficult, try editing the Feature several
times.

7. Create the Drive Feature.

8. Create a new Layer Driver.

9. Create the Drive Surface.

10. This is a Face Feature comprising of three Face features.

11. The two Drive Curves straddle the Drive Surfaces

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Create Sequence

12. Machine Tool: 5ax training - 4axcybs b axis tooltip.tcp.

13. Planar Mode is already selected.

14. Create a Five Axis Cycle using the screen shots over to help.
General Tab

Depth Tab

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15. Start and End Margins are very important to prevent the tool from tipping over the edge of
the drive surfaces.

16. The Tool is Tilted by 20º in order to maintain surface speed. The Fixed angle to axis is
reference to the Z Axis.

17. No Checks, keep time calculations down.

Lead Tab

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Links Tab

18. Select [OK].

19. Follow the Prompts:

 Pick 1st curve, Select the first EdgeLoop feature
 Pick 2nd curve, Select the second EdgeLoop feature
 Select start position, ignore
 Select drive surface, select the Face Feature
 Select check surfaces, ignore

20. Experiment with the Leads & Links to tidy up the toolpath.

What influence does the Cut Order have on the part?

Why is the Drive Curve geometry so important?

21. Save as ‘Workshop 7 – Completed Screw.ppf’.

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Machine Simulator (Workshop 8) – 4 Axis CYB Sub Spindle Lathe

1. Open the file ‘MX2500ST Oriented.ppf’ OR ‘MX2500ST.pmod’ if you would like to try
and orientate the solid prior to Copying and pasting into Code Wizard.
 Alternatively you can use Kitamura Orientated.ppf and 5 Axis Table Table.cgd.

2. Select/highlight all items found in the Features window. Right Click and select Output Model
You will now use these models inside the Code Wizard in order to represent the machine
tool.

3. In Code Wizard, open ‘MX2500ST.cgd’.

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4. Select Machine from Setup/Machine Element window. Right Click and select Paste Model
Observe that images are now displayed, and listed by name.

 Observe the position of the Datum within the Code Wizard. You may increase the
Translucency of each model to gain a clearer view.

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Index
D P
data .......................................................................................... 4 part .......................................................................................... 2

E S
Edgecam ........................................................................ 2, 4, 7 standard ..................................................................................4
example .................................................................................. 5 Standard .................................................................................7

I T
in Edgecam ............................................................................ 4 text ........................................................................................... 5
Text .......................................................................................... 5
M
W
Milling...................................................................................... 7
windows ..................................................................................4
Windows .................................................................................2

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Document Revision
 Rev 3.0 April 2007, Re-written in line with new product version.
 Rev 4.0 Sept 2007, Screen Shots updated for V11.75.
 Rev 5.0 Nov 2007, Re-Written to include new configurations, parts and V12.0.
 Rev 6.0 January 2008, Re-Written to include new configurations and parts.
 Rev 7.0 April 2008, Re-Written in line with V12.50.
 Rev 8.0 May 2008, Miscellaneous Updates.
 Rev 9.0 February 2011, Updated for V2011 R1 too many changes to list. SBL.
 Rev 10.0 July 2011 Updated for V2011 R2, Screenshots updated. AWA
 Rev 10.1 July 2012 Replaced Planit for Vero, Digitise for Select. Removed Front Page.
SBL.
 Rev 11.0 Jan 2015 Updated for V2015 R1.Too many changes to list SBL.
 Rev 12.0 Dec 2015 Updated for V2016 R1.Too many changes to list SBL.
 Rev 12.1 Feb 2016. 3 to 5 axis exercise added. Workshops updated. Too many changes
to list SBL.
 Rev 12.2 Feb 2016. Incorrect screen shots. Resized many images.Too many changes to
list.SBL

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