Rhino Cam Gettingstarted Guide

RhinoCAM 2.0 Getting Started Guide

Copyright 1998-2008, MecSoft Corporation, www.mecsoft.com 1

RhinoCAM® 2.0

Cutting edge manufacturing technology in Rhino ©

MecSoft Corporation



RhinoCAM Getting Started Guide Welcome to RhinoCAM Getting Started Guide ..................................................... 5

About this Guide......................................................................................... 5 Where to go for more help ........................................................................... 5

Tutorial 1: Machining a Gasket......................................................................... 6 Introduction............................................................................................... 7 Preparing the part for Machining ................................................................... 7 Create Tools .............................................................................................16 Create/Extract Regions...............................................................................19 Create Machining Operations .......................................................................21 2 ½ Axis Profiling.......................................................................................22 Creating a 2 ½ Axis Profile for the Outer Region.............................................33 Reports ....................................................................................................36 Post Processing .........................................................................................38

Tutorial 2: Machining a Slotted Gear ................................................................40 Introduction..............................................................................................41 Preparing the part for Machining ..................................................................42 Create Tools .............................................................................................49 Create Regions for Machining ......................................................................52 Create Machining Operations .......................................................................56 2 ½ Axis Profiling.......................................................................................56 Creating an Engraving Operation..................................................................68 Post Processing .........................................................................................74

Tutorial 3: Machining a Shaft Base ..................................................................76 Introduction..............................................................................................77 Preparing the part for Machining ..................................................................78 Create Tools .............................................................................................88 Create Machining Operations .......................................................................90 2 ½ Axis Facing.........................................................................................90 2 ½ Axis Pocketing ....................................................................................95 Hole Pocketing Operation ..........................................................................110 2 ½ Axis Engraving Operation ...................................................................121 2 ½ Axis Profiling.....................................................................................124 Post Processing .......................................................................................129

Tutorial 4: Simple V-Carving.........................................................................130 Introduction............................................................................................131 Preparing the part for Machining ................................................................132 Create Tools ...........................................................................................141 Create Machining Operations .....................................................................144 V-Carving ...............................................................................................144 Post Processing .......................................................................................153

Tutorial 5: Embossing..................................................................................156 Introduction............................................................................................157 Preparing the part for Machining ................................................................158 Create Tools ...........................................................................................169 Create Machining Operations .....................................................................173 V-Carving Roughing .................................................................................173 V-Carving ...............................................................................................182 Post Processing .......................................................................................188

Tutorial 6: Chamfering.................................................................................189



Introduction............................................................................................190 Preparing the part for Machining ................................................................190 Create Tools ...........................................................................................193 Create Machining Operations .....................................................................195 Chamfering.............................................................................................195 Post Processing .......................................................................................205

Tutorial 7: 3 Axis Milling...............................................................................207 Introduction............................................................................................208 Preparing the part for Machining ................................................................208 Create Tools ...........................................................................................219 Create Machining Operations .....................................................................221 3 axis Horizontal Roughing........................................................................222 3 axis Parallel Finishing ............................................................................229 3 axis Horizontal Finishing.........................................................................233 Post Processing .......................................................................................239

Tutorial 8: Profiling with Bridges (Tabs)..........................................................240 Introduction............................................................................................241 Preparing the part for Machining ................................................................241 Create Tools ...........................................................................................254 Create Machining Operations .....................................................................257 2 ½ Axis Profiling.....................................................................................257 Post Processing .......................................................................................270

Tutorial 9: Hole Making................................................................................272 Introduction............................................................................................273 Preparing the part for Machining ................................................................273 Create Tools ...........................................................................................282 Create/Extract Regions.............................................................................284 Create Machining Operations .....................................................................286 Hole Machining........................................................................................286 Creating the Drill operation for the 0.25” Holes ............................................297 Post Processing .......................................................................................299

Tutorial 10: Re-Machining a 3D Mold..............................................................300 Introduction............................................................................................301 Preparing the part for Machining ................................................................301 Create Machining Operations .....................................................................302 3 axis Pencil Tracing.................................................................................302 3 axis Valley Re-Machining........................................................................311 Post Processing .......................................................................................314

Tutorial 11: Machining a Ring .......................................................................316 Introduction............................................................................................317 Preparing the part for Machining ................................................................317 Create Tools ...........................................................................................330 Create Machining Operations .....................................................................332 4 axis Roughing.......................................................................................332 4 axis Finishing .......................................................................................340 Post Processing .......................................................................................344

Tutorial 12: Engraving on a Cylinder ..............................................................345 Introduction............................................................................................346 Preparing the part for Machining ................................................................346 Create Tools ...........................................................................................356 Create Machining Operations .....................................................................358 4 Axis Engraving......................................................................................359 Post Processing .......................................................................................367



Tutorial 13: Machining a Ring .......................................................................369 Introduction............................................................................................370 Preparing the part for Machining ................................................................370 Create Tools ...........................................................................................382 Create Machining Operations .....................................................................385 4th axis Roughing.....................................................................................386 4th Axis Roughing operation #2..................................................................393 4th axis Finishing......................................................................................398 Post Processing .......................................................................................402

Tutorial 14: Pocketing and Drilling on a Ring ...................................................403 Introduction............................................................................................404 Preparing the part for Machining ................................................................404 Create Tools ...........................................................................................415 Create Machining Operations .....................................................................418 4 Axis Drilling..........................................................................................418 4 axis Pocketing ......................................................................................428 Post Processing .......................................................................................435



Welcome to RhinoCAM Getting Started Guide Welcome to RhinoCAM and thank you for choosing one of most powerful and easy to use complete CAD/CAM packages on the market today. RhinoCAM is a unique CAM product plug-in that runs inside of Rhinoceros 4.0. Plug-ins can be considered as independent applications that can be loaded and unloaded on demand from the host program, which in this case is Rhinoceros 4.0 (Rhino). This fully integrated RhinoCAM plug-in seamlessly integrates Rhino’s CAD functionality with toolpath generation and cutting simulation/verification, in one package that is both easy and fun to use. You can work with the native Rhino design data as well as use any of the data types that can be imported into Rhino such as solids, surfaces and meshes. Then you can use RhinoCAM with its wide selection of tools and toolpath strategies to create machining operations and associated toolpaths. These toolpaths can then be simulated and verified, and finally post-processed to the controller of your choice.

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

Where to go for more help Apart from the on-line help system you can download tutorials and projects from MecSoft Corporation's web site at www.mecsoft.com. This will help you get started with using RhinoCAM. If you need additional help, or if you have any questions regarding RhinoCAM, you may contact us via e-mail at [email protected] MecSoft offers Online training as well as personalized full day training sessions. Please look up our website or email us at [email protected] for further details Please do continue to visit our home page to learn about the latest updates to RhinoCAM and any other help material.



Tutorial 1: Machining a Gasket



Introduction This tutorial will illustrate machining of a simple prismatic part such as this gasket using 2-1/2 milling operations. Even though we have created a 3-D representation of the gasket, it will be seen later on that we can machine this using just 2-D curves. The reason we are able to do this is because of the prismatic nature of this model. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the Gasket

• We will machine the Gasket by using a 2-½ axis machining operation called Profiling.

• The part will be machined out of a 8 ½ x 5 x ¼ inch poplar wood sheet using a ½ inch Flat End Mill.

• The wooden sheet will be held to the machine table or the spoil sheet on the table using double-sided tape.

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

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

coordinates • Create / Select the tool used for machining • Set the feeds and speeds • Set the clearance plane for the non-cutting transfer moves of the cutter • Select the machining regions for containing the cutter to specific areas to cut • Select the machining operations and set the parameters • Generate the toolpath • Simulate the toolpath.

You may have to repeat either all or part of these steps for subsequent operations.

Preparing the part for Machining Loading the Part Model “Part” refers to the geometry that represents the final manufactured product. You can create parts within Rhino.

To load a part:

1. Select File / Open from the Menu, or click the Open icon from the Standard bar.



2. From the Open dialog box, select the Gasket.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)

The imported part appears as shown below

Note: You can import solid models, Stereo-Lithography (both ASCII and binary) format files. Surfaces can be imported from IGES, STEP or Rhino 3DM. Faceted (triangulated) models can be imported from VRML, Raw Triangle, DXF / DWG facet data, or Rhino Mesh.



Setup Tab

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

2. Select Machine Setup from the setup tab.

3. Set the Machine type to 3 axis



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

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

Note: By default post processor files are located under

C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Posts



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

Create Stock Geometry

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



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

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



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

Locate Machine Zero

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

1. Select Locate WCS from the Setup tab



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



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

Align Part and Stock

In this process, we can align the part and the stock geometry. As we have set the Machine zero to the Stock Box, we will now move the part relative to the stock.

1. Select Align Part and Stock from the Setup tab

2. Set to Object to Move as Move Part, Z alignment to Top and XY alignment to Center



The part geometry is aligned to the center of stock in XY and top in Z. Click Save to save the work and specify a file name as Gasket-Rev1. The file is now saved with extension 3dm.

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

1. Go to the RhinoCAM-Tools browser that is located below the RhinoCAM-MOps browser and select Create/Edit Tools. Select the Tool Type to Flat End Mill.



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



Setting Feeds and Speeds

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

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

4. Use the following settings for feeds and speeds.

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

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

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



Create/Extract Regions

In order to machine the Gasket, we need to extract the curves from the 3d model to select them as machining regions.

1. Select the Layer Manager from the Standard bar.

2. The layer manager is now open. Set the Layer01 as the active layer.

3. Close the Layer Manager.

4. From the Curves menu under Rhino Toolbar menu select Curve from Objects and Duplicate Face Border.



5. The command bar will now prompt the user to select surfaces or faces for duplicate border.

6. Select the top face (surface) on the Gasket. A selection list will display the geometries that can be selected. Browsing through the selection tree will highlight the surface that corresponds to the selection.



7. Press the Enter key on your keypad to accept the selection.

8. The curves are now created and displayed in red on the part geometry.

Note: You can toggle the stock model display by selecting Stock Visibility that is located at the bottom of the RhinoCAM-MOps Browser

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

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



2 ½ Axis Profiling

1. Select 2.5 Axis Mill and choose Profiling

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

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

Regions



3. Now select the 3 inner circles by using the left mouse click starting from left to right.



4. Right mouse click or select enter from the keypad to complete the

selection. 5. The selected regions are now displayed under Machining Regions



Selecting the Tool

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

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



Set Feeds and Speeds 8. Click on the Feeds and Speeds tab.

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



Clearance Control 10. Switch to Clearance Tab.

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

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



Specifying Cut Parameters

12. Switch to Cut Parameters tab

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

14. Select the Cut Levels Tab and specify the Total Cut Depth = 0.125. The cut depth is always set as an absolute value.





Entry/Exit

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

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

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





Simulate Toolpath The generated toolpath can now be simulated.

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

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

3. The simulated part is as shown below.

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



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

Creating a 2 ½ Axis Profile for the Outer Region

1. Switch to the Create Operation tab.

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

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

4. Now click on Select Curves as Regions and select the Outer profile of the Gasket as the region.

5. Right mouse click to complete the selection.

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

7. Under Feeds/Speeds select Load from Tool.

8. Set the Clearance control to Automatic.



9. Switch to Cut Parameters tab, check Use Outside/Inside for Closed Curves, and set the Cut Start Side to Outside

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

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

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



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



Reports 1. Switch to Create Operations Tab.

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

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

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



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



Post Processing

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

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



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

End of Tutorial 1!



Tutorial 2: Machining a Slotted Gear



Introduction

This tutorial will introduce the usage of 2 ½ axis profiling and Engraving Machining Operations of RhinoCAM. We will be using the Gear.3dm part file.

It should be noted that, even though the part file contains a 3-D geometry representing the part, we could machine this entirely by using just 2-D curves due to the prismatic nature of this model. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. However, if you prefer to work straight through the steps without any additional reading, look for the following symbol:

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

• We will machine the gear completely using 2 ½ axis-machining operations. • We will use the Profiling operation to cut the outer shape of the gear and the

Engraving operation to cut the slots. The engraving option is preferred in situations where the cutter can be driven to create a slot that conforms to the shape of the tool trajectory. This is because of the computational efficiency as well as the accuracy of this method.

• The part itself will be machined out of a 3 inch x 3 inch x ½ inch poplar wood sheet.


• The part will be machined using a single ¼ inch flat end mill. Main Programming Steps In creating programs for each setup, the following steps will be followed:







To load a part:


2. From the Open dialog box, select the Gear.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)

The imported part appears as shown below.



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


3. Set the Machine type to 3 axis.



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

5. Set the current post processor that is on your controller. We will select Haas as the post processor for this exercise.






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



2. This brings up the Box Stock parameters. Set the Length (L) = 3.00, Width W = 3.00, and Height (H) = 0.25. Leave the other parameters as default, and click OK.





Locate Machine Zero

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

1. Select Locate WCS from the Setup tab.







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


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






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








Create Regions for Machining In the steps below we will extract regions from the 3D model and create curves for engraving.

1. Turn off stock model visibility from the RhinoCAM-MOps browser.

2. Select the Layer Manager from the Standard bar.

3. The layer manager is now open. Set Layer 01 as the active layer.




7. Select the top face (surface) on the Gear. A selection list will display the geometries that can be selected. Browsing through the selection tree will highlight the surface that corresponds to the selection.

The flat area curves are created and displayed on top of the part geometry.



8. Switch to the Top view and create a circle using Center and Radius. 9. From the Curves menu under Rhino Toolbar menu select Circle->Center,

Radius 10. Center of Circle

11. Specify 1.5,1.5 as the center coordinates and hit the enter key.

12. Specify 1.0 as the radius (or 2.0 as Diameter) of the circle and hit the enter key

We will now create lines, which can be selected for engraving the slots on the gear. 13. Turn on the Snap, Center Point and Quad Point snap from the status bar and

turn off the other snaps.

14. Switch to the Top view and select Line from the Curve menu and pick Create Line->Single Line.

15. For the first coordinate, snap to the quad point on the circle as show below.



16. For the second coordinate, snap to the center of the arc as shown below. A

line is now created at the center of the slot.



We will now array the line across other slots on the gear. 17. Select the line

18. Go to the menu at the top, and select Transform, Array->Polar 19. Use the following settings.

a. Center of polar array: 1.5,1.5 (hit enter)

b. Number of items: 6 (hit enter)

c. Angle to fill or first reference point: 360 (hit enter)

20. The lines created and shown below.



We have now created the regions for machining. Save the file using File->Save.

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


2 ½ Axis Profiling

2. Select 2.5 Axis Mill and choose Profiling.

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




Regions

4. Now select the inner circle first by using the left mouse click and then the outer circle.

Note: Hold the shift key down to select multiple regions. Use ctrl key to deselect a region



5. Right mouse click or select enter from the keypad to complete the selection. 6. The selected regions are now displayed under Machining Regions.



Selecting the Tool


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













13. Switch to Cut Parameters tab.

14. Set the Stock = 0, cut start Side as Determine using 3D Model.



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



Entry/Exit

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



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

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












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

Creating an Engraving Operation

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

1. Switch to the Create Operation tab.

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



Select Machining Regions

3. Under Machining Features/ Regions click on Remove All to deselect any regions that could have been selected from the previous machining operation.

4. Now click on Select Curves as Regions and select the 6 lines on the slotted gear as shown below.

5. Right mouse click to complete the selection.

6. The 6 selected regions are listed under the Machining Features/Regions



Select Tool

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

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

9. Set the Clearance control to Automatic. Specify Engraving Cut Parameters

10. Switch to Cut Parameters tab. Under Cut Depth Control, set the Total Cut Depth = 0.25, Rough Depth = 0.25, and Rough Depth/Cut = 0.125.



11. Click Generate to Create the Engraving Toolpath.

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





Simulate Toolpath

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



Post Processing

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

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




End of Tutorial 2!



Tutorial 3: Machining a Shaft Base



Introduction This tutorial will illustrate machining of a prismatic part such as this Shaft Base using 2-1/2 milling operations. Even though we have created a 3-D representation of the part, it will be seen later on that we can machine this using just 2-D curves. The reason we are able to do this is because of the prismatic nature of this model. This tutorial will introduce the usage of 2 ½ axis machining for a simple one sided part. We will use profiling, pocketing and hole pocketing operations. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the Shaft Base

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

• The starting material for the Shaft Base is soft wood and the size is 5.5 x 3.25 x 0.75 inches.


• The part will be machined using a single ¼ inch flat end mill. • Determining the sequence of machining operations

o As the part thickness is 0.625” thick and the available stock is 0.75” the first operation would involve reducing the thickness of the stock over the entire area from 0.75 to 0.625. To carry out this operation we will use the 2 ½ axis Facing Operation as the toolpath extends past the region.

o The next step would involve machining the areas around and inside the boss. As the thickness of material to be removed is not the same for both the areas we would have to use 2 separate operations to clear the material. We will use 2 ½ axis Pocketing Operation which is ideal removing material inside a specified region.

o We are now down to the level where the step holes need to be machined. As the holes are circular we will use 2 ½ axis Hole Pocketing operation to machine the holes to its depth in 2 separate operations.

o The 2 inner holes can be drilled using an engraving operation to its depth.

o Finally we will cut out the shape of the part from the rectangular using a contour toolpath. This is accomplished using a 2 ½ axis Profiling Operation which separates the finished part from the stock material.



coordinates • Create / Select the tool used for machining



• Set the feeds and speeds • Set the clearance plane for the non-cutting transfer moves of the cutter • Select the machining regions for containing the cutter to specific areas to cut • Select the machining operations and set the parameters • Generate the toolpath • Simulate the toolpath.



To load a part:


2. From the Open dialog box, select the ShaftBase.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)

3. The imported part appears as shown below



Setup Tab

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








C:\Program Files\Rhinoceros 4.0\ Plug-ins\RhinoCAM 2.0\Posts





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



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





Locate Machine Zero

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










Align Part and Stock During this step, we will align the part inside the stock geometry.

1. Select Align Part and Stock from the Setup tab.

In this step, we will position the part to the bottom of the stock and center in XY.

2. Use the following settings - Object to Move: Move Part, Z alignment: Bottom and XY Alignment: Center.



3. The part is now aligned inside the stock as shown below.

Front View

Top View



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


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












Create Machining Operations We will machine the Shaft Base using 4 different machining operations – Facing, Pocketing, Hole Pocketing and Engraving. The stock geometry has a thickness of 0.75” and the finished part is 0.625”. We will create a 2.5 axis facing operation to mill the 0.125” thickness of material from the stock geometry.


2 ½ Axis Facing

1. Select 2.5 Axis Milling and choose Facing.

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



Select Machining Features/Regions

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

2. Select the Rectangle and right mouse click to complete the selection. Region1 is now listed under Machining Features/Regions.

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

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

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



Specify Cut Parameters

1. Click on the Roughing tab. 2. Set the Tolerance to 0.01, Stock to leave to 0, Cut Pattern to Island

Offset Cuts, and Step Distance to 50 (% Tool Diameter).

3. Switch to the Cut Levels Tab.



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

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

Depth/Cut = 0.0625.

5. Switch to the Entry/Exit tab and set the Entry and Exit parameters to none. 6. Click Generate. The 2½ Axis Facing toolpath is now generated, and the

Operation is listed under the RhinoCAM-MOps browser.



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



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

Preparing the part for Pocketing

In Preparation for the pocketing Operation, we will now create regions by extracting curves from the 3D model.

1. Turn off the Stock Model and Toolpath Visibility from the RhinoCAM-MOps browser.

2. Open Layer Manager and Select Layer 01 as the Active Layer.






6. The command bar would now prompt the user to select surfaces or faces to extract the curves

7. Pick the flat area as shown below.

8. Curves are created and are on Layer 01.



We are now ready to create the pocketing operation for the inner region. 9. Switch to the Create Operations tab.



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

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


3. Select the curve and right mouse click to complete the selection. Region1 is now listed under Machining Features/Regions.

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






1. Click on the Cut Parameters tab.

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




4. Use the Following Settings. a. Location of Cut Geometry at Bottom (As the selected region is at the

bottom of the part, and we need to cut above it).

We will determine the Total Cut Depth from the 3D model by snapping at 2 points. b. Select the Depth measuring tool located to the right of Total Cut

Depth. This will minimize the Pocketing Operation parameters dialog.

c. Turn on the End Point Snap from the Status bar.

d. Pick the top of the boss as the start point and the bottom of the boss as the end point as shown below.

e. The pocketing operation dialog shows up and determines Total Cut Depth = 0.25.

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



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

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



5. Switch to the Entry/Exit tab. 6. Use the following settings for Entry/Exit. Make sure to check Apply Entry/Exit

at all cut levels.

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

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



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



Creating the Pocketing Operation #2 We will now create a 2nd pocketing operation for machining the region around the boss.

1. Switch to the Create Operations tab. 2. Open Layer Manager and select Layer 01 as the active layer. 3. From the Curves menu under Rhino Toolbar menu select Curve from

Objects and Duplicate Face Border. 4. The command bar would now prompt the user to select surfaces or faces to

extract the curves 5. Pick the flat area as shown below.



Copying a MOp 1. Switch to the Create operations tab. 2. Select the 2 ½ axis Pocketing Operation created from the previous step, right

mouse click, and select Copy. 3. Right click and select Paste.

4. This would create a copy of the 2 ½ axis Pocketing Operation listed below the

first pocketing operation as show below.



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

Features.



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

7. Select the rectangle and curve and right mouse click to complete the selection.



8. Region1 & Region2 are now listed under Machining Features/Regions. Click

Save to Close the Machining Regions Dialog. 9. Double click under Parameters and switch to the Cut Levels Tab. 10. Use the Following Settings.

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

Length = 0.1 and Angle = 0 e. Click Generate.

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



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



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

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

Preparing the part for Machining 1. Open the Layer manager and Make Layer 03 as the active layer. 2. From the Curves menu under Rhino Toolbar menu select Curve from


extract the curves



4. Pick the flat area as shown below.

5. Curves are created and are on Layer 03. We are now ready to create the

pocketing operation for the inner region. 6. Switch to the Create Operations tab.

Creating the Hole Pocketing Operation #1

1. Select 2 ½ Axis Milling and Hole Pocketing.


3. Select the 6 circles and right mouse click to complete the selection. Regions 1 to 6 are now listed under Machining Features/Regions.

4. Switch to the Tools tab inside the Hole Pocketing operation and select

FlatMill-0.25.







8. Use the following Settings

a. Tolerance to 0.001,

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

c. Hole Diameter (D) = 0.5,

d. Check Cleanup Pass at Each Z Level.

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

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

g. Cut Direction = Climb (Down Cutting).



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



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

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

12. The simulated part is shown below.





Creating the Hole Pocketing Operation #2

7. Switch to the Create Operations tab. 8. Open Layer Manager and select Layer 04 as the active layer. 9. From the Curves menu under Rhino Toolbar menu select Curve from


extract the curves 11. Pick the flat areas as shown below.

12. The curves are now created and are located on Layer 04.

Creating the Hole Pocketing Operation 13. Select the Hole Pocketing Operation created from the previous step, right

mouse click, and select Copy.



14. Right click and select Paste.

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

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

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

18. Select the 6 inner circles and right mouse click to complete the selection.



19. Regions 1 to 6 are now listed under Machining Features/Regions. Click Save to Close the Machining Regions Dialog.

20. Double Click under Parameters and set the Hole Depth = 0.1875, Hole Diameter = 0.315.

21. Switch to the Entry/Exit tab and set the Helix Diameter to 0.065



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

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





2 ½ Axis Engraving Operation

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

Preparing the part for machining Turn on the Center Point Snap from the status bar and turn off the other snaps.

1. From the Curve menu in Rhino, select Point Object-> Single Point 2. The command bar will now prompt the user to specify the location of point

object. We will now use the pick option by creating a point that snaps to the center of the circles as show below.

Creating the Engraving Toolpath

1. From the Create Operations tab, select 2 ½ Axis Milling and Engraving. 2. Go to the Machining Features/ Regions tab, click Remove All under Machining

Features, and click Select Curves as Regions. 3. Select the 2 points as regions for engraving. Right click to complete the

selection.



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



7. Switch to the Cut Parameters tab and use the following parameters - Tolerance = 0.001, Location of Cut Geometry At Top, Total Cut Depth = 0.375, Rough Depth = 0.375 and Rough Depth/Cut = 0.05.

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

9. Click Generate. The Engraving operation is now created. 10. Switch to Simulate tab, select Engraving, and click Simulate to run the

simulation.





2 ½ Axis Profiling

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

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

3. Select the outer curve. Right mouse click or select enter from the keypad to complete the selection.

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

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

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

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




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

a. Tolerance = 0.001,

b. Stock = 0,

c. Cut Start Side- Check Use Outside/Inside for closed curves and pick Outside.



9. Select the Cut Levels Tab and specify the Total Cut Depth = 0.25, Rough Depth/Cut = 0.05.

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


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



12. Switch to the Simulate tab in the RhinoCAM-MOps browser. Select the 2 ½ Axis Profiling Operation and click to Simulate.





To exit the Simulation mode, pause the Simulation, and click Exit Simulation.



Post Processing


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


End of Tutorial 3!



Tutorial 4: Simple V-Carving



Introduction This tutorial will illustrate machining a Sign using 2-1/2 axis-engraving operations. We can engrave the sign using 2-D curves. This tutorial will introduce the usage of 2-½ axis simple V Carving using V bit. V carving refers to a cutting strategy employed by sign makers to create sharp corners. V carving is performed using a tapered bit or conical tool (as shown below) usually known in the industry as a V Bit.

The V-bit is made to rise from the cutting depth to the top of the surface at the corners in such a way that the tapered sides of the cutter are always in contact with the corners. When the cutter finally reaches the top surface, only the bottom tip of the tool will be in contact with the corners, thereby creating clean and crisp cuts at the corners. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the part

• V carving is performed using the 2 ½ axis Machining Operation. • The part itself will be machined out of a 10.75 inch x 4 inch x ½ inch poplar

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

table using double-sided tape. Main Programming Steps In creating programs for each setup, the following steps will be followed:


coordinates • Create / Select the tool used for machining • Set the feeds and speeds



• Set the clearance plane for the non-cutting transfer moves of the cutter • Select the machining regions for containing the cutter to specific areas to cut • Select the machining operations and set the parameters • Generate the toolpath • Simulate the toolpath.



To load a part:


2. From the Open dialog box, select the V-Carve1.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)

The imported part appears as shown below.



Setup Tab










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





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







Locate Machine Zero














2. Set to Object to Move as Move Part, Z alignment to Top, and XY alignment to Center.



The part geometry is aligned to the center of stock in XY and top in Z. Click Save to save the work and specify a file name as VCarve-Rev1. The file is now saved with extension 3dm.


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

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

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



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




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








Create Machining Operations In this process we will create a 2.5 axis operation.


V-Carving

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

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




Regions.

4. Now, select the text by using the left mouse click, starting from left to right. Make sure to get the inner curves on the letters ‘e’ and ‘o’. Each curve is separate (by curves, not by letters) and must be selected separately. If the






Selecting the Tool

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

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








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

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





14. Set the Tolerance = 0.001, Cut Side = Inside, Location of Cut Geometry = At Top, Total Cut Depth = 0.25, Rough Depth = 0.25 and Rough Depth/Cut = 0.05.

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








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






Post Processing




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

The post by default is set to Haas as specified under the Post processor setup. You can change the post processor by selecting a different one from the drop down menu



in the list. The posted g code by default will be saved to the folder where the part file is located.

End of Tutorial 4!



Tutorial 5: Embossing



Introduction This tutorial will illustrate machining a Sign using 2-1/2 axis-engraving operations. We can engrave the sign using 2-D curves. This tutorial will introduce the usage of 2-½ axis V Carve Roughing with a Flat End Mill and V Carving using V bit. V carving refers to a cutting strategy employed by sign makers to create sharp corners. V carving is performed using a tapered bit or conical tool (as shown below) usually known in the industry as a V Bit.

The V-bit is made to rise from the cutting depth to the top of the surface at the corners in such a way that the tapered sides of the cutter are always in contact with the corners. When the cutter finally reaches the top surface, only the bottom tip of the tool will be in contact with the corners, thereby creating clean and crisp cuts at the corners. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the part

• Embossing is performed using the 2 ½ axis Machining Operations. • The part itself will be machined out of a 20 inch x 4 inch x 1 inch poplar wood

sheet • The part would be machined using a Flat End Mill and a V-Groove bit. • The wooden sheet will be held to the machine table or the spoil sheet on the


• Create the Part • Create the Stock geometry • Set the Machine zero point or Locate geometry with respect to the machine

coordinates • Create / Select the tool used for machining



• Set the feeds and speeds • Set the clearance plane for the non-cutting transfer moves of the cutter • Select the machining regions for containing the cutter to specific areas to cut • Select the machining operations and set the parameters • Generate the toolpath • Simulate the toolpath.


Preparing the part for Machining Creating the Part Model “Part” refers to the geometry that represents the final manufactured product.

To create a part:

1. Select File / New from the Menu, or click the New icon from the Standard bar. This creates a new session of Rhino.

2. Switch to the Top View by double clicking on the label Top under the Viewport.

3. Create a rectangle by selecting the Curve ->Rectangle Corner to Corner. 4. Under the Command bar, specify the First Corner of rectangle as 0,0. 5. Specify the Other Corner as 20,4. 6. Create a 2nd rectangle with the First Corner as 0.25,0.25 and Second Corner

as 19.75,3.75.

Create Text geometry

7. Select Text Object located under the Main1 toolbar in Rhino. By default this toolbar is located to your left side in Rhino. Alternatively you could type TextObject under the command bar.



8. This brings up Text Object Create Dialog. Use the Following Settings. 9. Text Size = 2.5, Font Name = Verdana, uncheck Bold & Italic. Select Curves

under Create. Check Group objects. Use Text to Create = RhinoCAM.

10. Click OK once you have the above settings. 11. The text would now appear on the screen and would expect the user to

specify the Start point of text.



12. Specify 1.25,0.75 as the insertion point under the command bar. The text is now created and displayed as shown below.

13. From the File Menu, select Save and save the file under the Tutorials Folder as Embossing1.3dm.

14. The part geometry is now created. We are now ready to generate toolpath to machine the part. We will now switch to the RhinoCAM-MOps browser.

Note: You can skip the above steps for creating the part geometry by loading Embossing.3dm file into Rhino. This is available under the Tutorials folder in RhinoCAM 2.0



Setup Tab

















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


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



Locate Machine Zero



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









2. Set to Object to Move as Move Part, Z alignment to Top, and XY alignment to Center.

The part geometry is aligned to the center of stock in XY and top in Z. Click Save to save the work and specify a file name as Embossing-Rev1. The file is now saved with extension 3dm.






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


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












6. Create a 2nd tool of type VeeMill.

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


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



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

Library. Click OK to close the dialog.



Create Machining Operations In this process, we will create two 2 ½ axis-machining operations.


V-Carving Roughing

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

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




Regions.

4. Now, select the inner rectangle and text by using the left mouse click, starting from left to right. Be sure to include the inner curves for the letters ‘R’ and ‘A’ as well as the dot for the letter ‘i’. Each curve is separate (by curves, not by letters) and must be selected separately.




Selecting the Tool

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

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














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

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

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



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








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





To exit the Simulation mode, pause the Simulation and click Exit Simulation. This switches back to the Create Operations tab. We will now generate V Carve Finishing to finish the sign with a Taper Tool.

V-Carving

1. Select 2.5 Axis Mill and choose V-Carving. This brings up the V-Carving Operations dialog. We will go over the steps for creating the toolpath.


2. Go to the Machining Features/ Regions tab. The regions from the previous operations stay selected and the Machining Features would list the 13 regions.

3. If the regions are not listed under Selected Machining regions use single select and select the inner rectangle and the Text as shown below. Right mouse click to complete the selection.

4. The selected regions are now displayed under Machining Regions

Selecting the Tool

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

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

Set Feeds and Speeds

7. Click on the Feeds and Speeds tab.













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

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







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

2. The Simulated part is as shown below.



Post Processing


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


End of Tutorial 5!



Tutorial 6: Chamfering



Introduction This tutorial is intended to show an easy way to chamfer and smooth sharp corners by using 2 ½ axis Chamfering operation. A tapered tool is suitable for this purpose. In this example, the chamfer is not modeled in the part. We plan to chamfer the edges of the part using a 30 degree taper tool that has 0 radius at the tip. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the part

• Chamfering is performed using the 2 ½ axis Chamfer Machining Operation. • The part would be machined using a single V-Groove bit. • The wooden sheet will be held to the machine table or the spoil sheet on the





Preparing the part for Machining Loading the Part Model “Part” refers to the geometry that represents the final manufactured product. You can create parts within Rhino..

To load a part:




2. From the Open dialog box, select the Chamfer.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)




Setup Tab

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



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

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

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













Create Machining Operations

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

Chamfering

1. Select 2.5 Axis Mill and choose Chamfering.

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



Select Machining Features/Regions 2. Go to the Machining Features/ Regions tab and click remove all if any

Machining regions are listed. 3. Click Select Curves as Regions.

4. Now, select the curve that follows the profile of the spanner as shown below.



5. Right mouse click or select enter from the keypad to complete the selection.

6. The selected region is now displayed under Machining Regions.



Selecting the Tool

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

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














14. Set the Tolerance = 0.001, Stock = 0, Chamfer Parameters use Chamfer Width = 0.125, Max Depth/Cut = 0.025, Cut Side = Outside. Click Generate. The Chamfering toolpath is now generated and the Operation is listed under the RhinoCAM-MOps browser.




Reorder a Machining Operation

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

1. Minimize all MOps inside the Mop Set1.

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

Chamfer toolpath is now generated and is displayed below.





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

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








Post Processing


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




End of Tutorial 6!



Tutorial 7: 3 Axis Milling



Introduction This tutorial will illustrate machining this Mold using 3 axis-milling operations. This tutorial will introduce the usage of several 3-axis operations such as horizontal roughing, parallel finishing, and horizontal finishing. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the mold

• We will machine the mold completely using 3 axis-machining operations. • The part itself will be machined out of a 5.5 x 6.5 inch x 1.25-inch wood

block. • The stock may be held to the machine table or the spoil sheet on the table

using double-sided tape or by clamps. • The part will be machined using 0.5” flat end mill, 0.25” & 0.125” ball end

mills. Main Programming Steps In creating programs for each setup, the following steps will be followed:





To load a part:




2. From the Open dialog box, select the 3Axis_Example1.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)




Setup Tab

















2. This brings up the Box Stock parameters. Set the Length (L) = 5.50, Width W = 6.50, and Height (H) = 1.25. Leave the other parameters as default and click OK.





Locate Machine Zero













In this step, we will position the part to the bottom of the stock and center in XY.

2. Use the following settings, Object to Move: Move Part, Z alignment: Bottom and XY Alignment: Center.




Front View

Top View



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









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


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

a. Tool Name: BallMill-0.25, Tool Number = 2.

b. Switch to Feeds & Speeds tab set Spindle Speed = 5000 rpm, plunge & approach feed = 35 ipm, approach feed = 40 ipm, cut feed = 45 ipm, retract and departure feeds = 50 ipm. Set the Transfer Feedrate to Use Rapid.

c. Click Save as New Tool.



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

d. Tool Name: BallMill-0.125, Tool Number = 3.

e. Switch to Feeds & Speeds tab set Spindle Speed = 5000 rpm, plunge & approach feed = 35 ipm, approach feed = 40 ipm, cut feed = 45 ipm, retract and departure feeds = 50 ipm. Set the Transfer Feedrate to Use Rapid.

f. Click Save as New Tool.


Create Machining Operations We will machine the mold using 3 different machining operations – Horizontal Roughing, Parallel Finishing, and Horizontal Finishing.



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


3 axis Horizontal Roughing

1. Select 3 Axis Milling and choose Horizontal Roughing.

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

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












8. Click on the Cut Parameters tab. 9. Set the Intol and Outol = 0.01, Stock to leave =0.025, Cut Pattern to

Stock Offset, Cut Direction = Mixed, Step over distance = 40 (% Tool Diameter).




11. Use the Following Settings. a. Step Down Control (dZ) = 50 (% Tool Diameter). b. Check Clear Flats under Cut Levels.

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

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



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



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

This is an efficient method of finishing or pre-finishing, typically used when part surfaces are relatively flat. A 2D linear zigzag pattern is generated on the XY plane above the part geometry. The tool moves along this cut pattern, following the contours of the part geometry below.

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

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

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







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



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

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





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

In preparation for the Horizontal Finishing operation, we will now create regions by extracting curves from the 3D model.

1. Turn off the Stock Model and Toolpath Visibility from the RhinoCAM-MOps browser.

2. Switch to the Top View by double clicking on the Top under the Viewport.

3. Create a rectangle by selecting the Curve ->Rectangle Corner to Corner.

4. Turn on the grid snap from the status bar and pick the first corner and second corner by snapping to 2 points on the grid as shown below.

Note: To set Grid spacing select Tools->Options. Click on Grid, Use Minor Grid Lines every 0.25 inches, Major lines every 4 minor grid lines, Grid Snap spacing 0.25 inches.



5. The created rectangle is displayed on top of the 3d model. We are now ready to create the horizontal finishing operation.

1. Switch to the Create Operations tab. 2. Select 3 axis Milling and Horizontal Finishing.





4. Select the rectangle as machining region and right click to complete the selection.



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





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



10. Switch to the Cut Levels tab.

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

12. Leave the entry/exit parameters at default. 13. Click Generate. The Horizontal Finishing operation is now created and is

listed under the MOps browser.



14. Switch to the Simulate tab, select Horizontal Finishing, and click Simulate to

run the simulation. 15. The simulated part is shown below.



Post Processing


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


End of Tutorial 7!



Tutorial 8: Profiling with Bridges (Tabs)



Introduction This tutorial will illustrate machining of multiple parts on a single sheet of stock using 2-1/2 milling operations. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the part

• We will machine the part using a 2-½ axis profiling operation. • We will define bridges so that the parts do not fall off the sheet once its cut to

its full depth. • The part will be machined out of a 36 x 24 x ½ inch poplar wood sheet using

a 0.25 inch Flat End Mill. • The wooden sheet will be held to the machine table or the spoil sheet on the

table using fixtures/clamps. Main Programming Steps

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

• Create part geometry • Create the Stock geometry • Set the Machine zero point or Locate geometry with respect to the machine



Preparing the part for Machining Creating the Part Model “Part” refers to the geometry that represents the final manufactured product.

To create a part:

1. Select File / New from the Menu, or click the New icon from the Standard bar. This creates a new session of Rhino.



2. Switch to the Top View by double-clicking on the Top under the Viewport.

3. The part will be modeled in Inches. To check the model units select Tools->Options and click Units.

4. We will now set the Grid Preferences. Use the following grid settings. Select Tools->Options from the menu bar and click on Grid. Use the following settings.

5. Create a rectangle by selecting the Curve ->Rectangle Corner to Corner. 6. Under the Command bar, specify the first corner as 0,0. 7. Specify the second corner as 36,24.



8. A rectangle of 36” X 24” is now created and displayed on the screen. This represents the extents of our stock model in XY plane.

Create Rounded Rectangle

We will now create the part geometry to be cut out inside the sheet.

1. Create a rectangle by selecting the Curve ->Rectangle Corner to Corner. 2. Under the command bar, specify the following parameters.

a. Using the mouse pointer select Rounded as shown below.

b. Specify First corner as 0.5,0.5.

c. Specify second corner as @3,4 (or you could specify in absolute dimensions as 3.5,4.5).



d. Set the radius to 0.25.

3. This creates a rounded rectangle of size 3 x 4 and a radius of 0.25.

Create Rectangular Array

We will now create multiple copies of the rounded rectangle to fit it to a sheet of 36 x 24.

1. From the Transform Menu, select Array->Rectangular 2. Select Objects to array: Pick the rounded rectangle. Right click or hit the

enter key to complete the selection.

3. Specify Number in X direction = 9



4. Specify Number in Y direction = 5

5. Specify Number in Z direction = 1

6. Set the Unit Cell or X Spacing = 3.75

7. Set the Unit Cell or Y Spacing = 4.75

8. Set the Unit Cell or Z Spacing = 1. Press Enter to accept the array.



4. We now have 5 rows and 9 columns of the rounded rectangle. A total of 45 parts on a sheet of 36 x 24

9. From the File Menu, select Save and save the file under the Tutorials folder.

5. The part geometry is now created. We are now ready to generate a toolpath to machine the part. We will now switch to the RhinoCAM-MOps browser.

Note: You can skip the above steps for creating the part geometry by loading Profile_Tabs.3dm file into Rhino. This is available under the Tutorials folder in RhinoCAM 2.0



Setup Tab

















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





Locate Machine Zero












2. Set Object to Move as Move Part, Z alignment as Top, and XY alignment as Center.



The part geometry is aligned to the center of stock in XY and top in Z. Click Save to save the work and specify a file name. The file is now saved with extension 3dm.

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
















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


2 ½ Axis Profiling

2. Select 2.5 Axis Mill and choose Profiling.

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



Select Machining Features/Regions 3. Go to the Machining Features/ Regions tab, click Remove All, and click

Select Curves as Regions.

4. Now, select the all the rounded rectangles. From the Top View drag a window from upper left corner to the bottom right corner that encloses all the rounder rectangles. Right mouse click or select enter from the keypad to complete the selection.



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



Selecting the Tool


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














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



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

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



Entry/Exit

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



Advanced Cut Parameters

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

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

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



Sorting

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

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















Post Processing




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


End of Tutorial 8!



Tutorial 9: Hole Making



Introduction This tutorial will illustrate machining holes using Drilling operations. Even though we have created a 3-D representation of the part, it will be seen later on that we can machine this using just 2-D curves. The reason we are able to do this is because of the prismatic nature of this model. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the part

• We will machine part by using a Hole machining operation called Drilling. • The part will be machined out of a 7.25 x 8.5 x 0.75 inch poplar wood sheet

using a 0.5” and 0.25” Standard Drill bit. • The wooden sheet will be held to the machine table or the spoil sheet on the

table using clamps. Main Programming Steps In creating programs for each setup, the following steps will be followed:





To load a part:




2. From the Open dialog box, select the Bitholder.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)




Setup Tab







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


C:\Program Files \Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Posts








2. This brings up the Box Stock parameters. Set the Length (L) = 7.00, Width W = 8.50, and Height (H) = 0.75. Leave the other parameters as default and Click OK.





Locate Machine Zero



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









2. Set to Object to Move as Move Part, Z alignment as Top, and XY alignment as Center



The part geometry is aligned to the center of stock in XY and top in Z. Click Save to save the work and specify a file name. The file is now saved with extension 3dm.

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

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

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









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




Create/Extract Regions

In order to machine the holes, we need to extract the curves from the 3d model to select them as machining regions.

1. Select the Layer Manager from the Standard bar

2. The layer manager is now open. Set the Layer 01 as the active layer.




6. Select the top face (surface) on the part.



7. The curves are now created and displayed in red on the part geometry.




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


Hole Machining

2. Select Hole Machining and choose Drilling.

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



Select Hole Features 3. Go to the Hole Features tab and click Select Drill Points/Circles.

4. Switch to the Top view and select the larger radius circles by using the rectangular selection as indicated below.



5. Right mouse click or select enter from the keypad to complete the selection. 6. The selected regions are now displayed under Hole Features.



Selecting the Tool

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

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














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

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



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

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

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
















Creating the Drill operation for the 0.25” Holes 1. Switch to the Create operations tab 2. Select the Standard Drill Operation created from the previous step, right

mouse click, and select Copy. 3. Right click and select Paste. 4. This would create a copy of the Drilling Operation and lists below the first

pocketing operation as show below.

5. Double click on the Standard Drill-1 to edit the Hole Features. 6. Click Remove All from the Hole Features Dialog to remove all the regions

from the list. 7. Now use Select Drill Points/Circles and select the smaller radius circles

using the rectangular select as shown below.



8. Right mouse click or select enter from the keypad to complete the selection. 9. The selected regions are now displayed under Hole Features. 10. Switch to the Tools tab under the Drilling Operations dialog and select Drill-

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

12. Switch to Simulate tab and select Drill Operation-1 and click to simulate toolpath.



Post Processing


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


End of Tutorial 9!



Tutorial 10: Re-Machining a 3D Mold



Introduction This tutorial will illustrate machining this Mold using advanced 3 axis-milling operations. This tutorial will introduce the usage of advanced 3-axis operations such as pencil tracing & valley remachining. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. However, if you prefer to work straight through the steps without any additional reading, look for the following symbol: Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the mold

• We will machine the mold completely using 3 axis-machining operations. • The part itself will be machined out of a 5.5 x 5 inch x 1.25-inch wood block. • The stock may be held to the machine table or the spoil sheet on the table

using double-sided tape or by clamps. • The part will be machined using 0.5” flat end mill, 0.25” & 0.125” ball end

mills. Main Programming Steps In creating programs for each setup, the following steps will be followed:




Preparing the part for Machining “Part” refers to the geometry that represents the final manufactured product. You can create parts within RhinoCAM, but it is more typical to import geometry created in another CAD system.




2. From the Open dialog box, select the 3Axis_Example2.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)

Create Machining Operations Note: The part is pre-programmed with 2 machining operations. Horizontal Roughing and Parallel Finishing. We will now use remachining to finish the mold using 2 different machining operations – Pencil Tracing and Valley Re-Machining. Switch to the Create Operations tab in RhinoCAM-Mops browser.

3 axis Pencil Tracing

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



2. Select 3 Axis Milling and choose Pencil Tracing.

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

the steps for creating the toolpath. 4. Switch to the Tools tab inside the Pencil Tracing operation and select BallMill-

0.125.



5. Click on the Feeds and Speeds tab and select Load From Tool. RhinoCAM will

now get the feeds and speeds information that was set when the tool was defined.



6. Switch to the Clearance Tab and set the Clearance Plane Definition to

Automatic and Cut Transfer Method to Clearance Plane.




1. Click on the Cut Parameters tab. 2. Set the Intol and Outol = 0.001, Stock to leave =0.0, Cut Direction to

Climb, Select Do multiple cuts and set Number of Cuts = 2 and Step over control = 20 (% Tool Diameter).



Advanced Cut parameters

3. Switch to the advanced cut parameters Tab. 4. Use the Following Settings.

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



Entry/Exit

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



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

10. 7. Click Generate. The 3-axis Pencil Tracing toolpath is now generated, and the




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

simulation.



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

1. From the Create Operations tab, select 3 axis Milling and Valley Re-Machining. 2. This brings up the Valley Re-Machining Operations dialog. We will go over the

steps for creating the pocketing operation. 3. Switch to the Tools tab inside the Parallel Finishing operation and select

BallMill-0.125. 4. Click on the Feeds and Speeds tab and select Load From Tool. RhinoCAM will

now get the feeds and speeds information that was set when the tool was defined.


6. Click on the Cut control tab. Specify Cut Control

1. Click on the cut control tab. 2. Set the Tolerance to 0.001, Stock to leave =0, Under Reference Tool

Parameters set Tool Diameter (D) = 0.25 (This is the diameter of the tool that was used for parallel finishing).



Specify Cutting Parameters

1. Click on the Cutting Parameters tab. 2. Use Split Cuts under slope Control. Specify the Cuts Split Angle (A) = 10 3. Select Output Flat and Steep Cuts.



4. Select Flat Cut Parameters. 5. Select Cut Pattern as Along, Cut Direction as Along, Cut Direction as Mixed

and specify Step Over control = 20 (% tool diameter).

6. Select Steep Cut Parameters. 7. Select Cut Pattern as Across, Cut Direction as Along, Cut Direction as Mixed

and specify Step Over control = 20 (% tool diameter).



8. Click Generate. The Valley Remachining toolpath is now generated, and the

Operation is listed in the RhinoCAM-MOps browser.

Partial view of the Valley Re-machining toolpath 9. Switch to Simulate tab, select Valley Remachining, and click Simulate to run

the simulation.

Post Processing




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


End of Tutorial 10!



Tutorial 11: Machining a Ring



Introduction This tutorial will illustrate machining this Ring using 4 axis-milling operations. This tutorial will introduce the usage of several 4-axis operations such as 4 axis roughing and finishing. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the ring

• We will machine the ring completely using 4 axis-machining operations. • The part itself will be machined out of a cylindrical blank. • The stock will be held to the machine table using a rotary chuck. • The part will be machined using 0.125” and 0.0625” ball end mills.



coordinates. • Set the rotary axis and rotary center. • Create / Select the tool used for machining • Set the feeds and speeds • Set the clearance plane for the non-cutting transfer moves of the cutter • Select the machining operations and set the parameters • Generate the toolpath • Simulate the toolpath.



To load a part:


2. From the Open dialog box, select the RingExample_1.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)




Setup Tab





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









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



2. This brings up the Cylinder Stock parameters. Set the Axis (rotary) = X, Radius = 0.56” and Length (L) = 0.866142. Leave the other parameters as default and click OK.

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



Perspective (Isometric) View Front View

4. You must switch the simulation model to Polygonal model to run 4 axis simulations. Select Preferences->Simulation Preferences from the Setup Tab and switch the simulation model to Polygonal if set to Voxel.






Locate Machine Zero



3. Under Set WCS Origin, choose Set to Stock Box, the Zero Face to Highest Z, and Zero Position to East. This sets the machine home to the top of the stock material and the right most edge of the part geometry.



Perspective View Front View






In this step, we will position the part to the center of the stock in XY & Z.

2. Use the following settings, Object to Move: Move Part, Z alignment: Center and XY Alignment: Center.







Specify Rotary Center In this step we will determine the rotary center for the part geometry. The rotary center must pass thro’ the entire part geometry. RhinoCAM will not compute a toolpath if the part/feature is below the rotary center as this is considered as an undercuts in the part.

1. Select Machine Setup from the setup tab. In the above example, the stock diameter is 1.12”.

2. Set the rotary center in X and Y = 0 and Z = -0.56 which is the center of the stock geometry.

The rotary center is represented by an arrow and displayed on the part geometry when the Machine Setup Dialog is invoked.





Create Tools To machine the above part, we will now create a 0.125” Ball End Mill and a 0.0625” Ball End Mill.

1. Go to the RhinoCAM-Tools browser that is located below the RhinoCAM-MOps browser and select Create/Edit Tools. Select the Tool Type to Ball End Mill.

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









6. Create a 2nd Ball End Mill with the following parameters.


b. Switch to Feeds & Speeds tab set Spindle Speed = 5000 rpm, plunge, approach & engage feed = 20 ipm, cut feed = 30 ipm, retract and departure feeds = 20 ipm. Set the Transfer Feedrate to Use Rapid.





Create Machining Operations We will machine the ring using 2 different machining operations – 4 axis Roughing and Finishing. The first step in machining the ring will be a roughing operation. In this cut method, the tool cuts the stock in successive levels. The spacing between these levels are specified by the user. This type of machining is very efficient for removing large volumes of material and is typically performed with a large tool. Roughing is typically followed by semi-finishing or finishing toolpaths.


4 axis Roughing

1. Select 4 Axis Milling and choose Roughing.



If the rotary center is not set to the same location as the Machine Zero, a warning message dialog would be displayed at all times when a 4 axis machining operation is selected. Users can override this message by clicking OK in the dialog.

Note: You can check Do no show this dialog again to stop the warning message appearing again when you create/edit a 4 axis machining operation.

2. This brings up the 4 Axis Roughing Operation Dialog. We will now go over the steps for creating the toolpath.

3. Switch to the Tools tab inside the 4th axis Roughing operation and select BallMill-0.125.












6. Click on the Cut Parameters tab. 7. Set the Intol and Outol = 0.001, Stock to leave =0.005, Cut Pattern to Across

Axis, Zig Zag and Low to High, Cut Containment Low Value = -0.866142, High Value = 0 (as the machine zero is set to the right edge of the stock/ part), Step over distance = 25 (% Tool Diameter).

8. Switch to the Step Down Control Tab.



Step Down Control 9. Use the Following Settings.

a. Cut Levels, Check Top (T) and specify Top (T) = 0.56 (radius of stock material)

b. Step Down Control (dR) = 75 (% Tool Diameter).

10. Click Generate. The 4th axis Roughing toolpath is now generated, and the Operation is listed under the RhinoCAM-MOps browser.



11. Switch to Simulate tab, select 4 Axis Roughing, and click Simulate to run the simulation.



4 axis Finishing We will now use 4th Axis Finishing operation to finish the part using a 0.0625” Ball End Mill.

In this method, the tool is always normal to the axis of table rotation (continuous mode). The tool motions can be parallel to or normal to the rotation axis. From the Create Operations tab, select 4 axis Milling and 4 Axis Finishing.

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

1. Switch to the Tools tab inside the 4 Axis Finishing operation dialog and select BallMill-0.0625.









5. Set the Tolerance to 0.001, Stock to leave =0, Cut Pattern = Along Axis, Zig Zag, Low to High, Set Cut Containment Low Value = -0.7, High Value = -0.1, Step over distance = 10 (% Tool Diameter).

6. Click Generate. The Finishing toolpath is now generated, and the Operation is listed under the 4th Axis Roughing Operation in the RhinoCAM-MOps browser.



7. Switch to Simulate tab, select 4 Axis Finishing, and click Simulate to run the simulation.



Post Processing


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


End of Tutorial 11!



Tutorial 12: Engraving on a Cylinder



Introduction This tutorial will illustrate engraving text on a cylinder using a 4 Axis Engraving operation. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to engrave text on a cylinder

• We will machine the ring completely using 4 axis-machining operations. • The part itself will be machined out of a cylindrical blank. • The stock will be held to the machine table using a rotary chuck. • The part will be machined using 15deg V-Bit.






To load a part:


2. From the Open dialog box, select the 4Axis_Engrave.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)




Setup Tab





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










2. This brings up the Cylinder Stock parameters. Set the Axis (rotary) = X, Radius = 1” and Length (L) = 8”. Leave the other parameters as default and click OK.










Locate Machine Zero



3. Under Set WCS Origin, choose Set to Stock Box, the Zero Face to Mid Z, and Zero Position to West. This sets the machine home to the center of the stock material and the left most edge of the part geometry.








In this step, we will position the part to the center of the stock in XY and Z.






2. Set the rotary center in X, Y and Z = 0 which is the center of the stock geometry. In this tutorial both the Machine Zero and the Rotary center are at the same location. The rotary center is represented by an arrow and displayed on the part geometry when the Machine Setup Dialog is invoked.



Create Tools To machine the above part, we will now create a 15 deg V-Bit.

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

2. Set the tool name as VeeMill1, Taper Angle = 7.5, Flute Length = 0.5, Tool Length = 1. Under the Properties tab set Tool Number = 1.












Create Machining Operations We will engrave the text on the cylinder using 4 Axis Engraving. This method machines text or logos by following the contours of the selected regions by projecting the text onto the cylinder.




4 Axis Engraving

1. Select 4 Axis Milling and choose Engraving.





2. This brings up the 4 Axis Engraving Operation Dialog. We will now go over the steps for creating the toolpath.



4. Now, select the text by using the left mouse click, starting from left to right. Make sure to get the inner curves on the letters ‘R’,’A’, and ’0’. Each curve is separate (by curves, not by letters) and must be selected separately.





7. Switch to the Tools tab inside the 4th Axis Engraving operation and select VeeMill1.












10. Click on the Cut Parameters tab. 11. Set the Tolerance = 0.001, Check Project Curve(s) to Model, Check Finishing

Passes and set # of finishing passes = 2, and R Depth (Rf) = 0.05 (this is the depth/pass. Total depth = 0.1”).

12. Click Generate. The 4 axis Engraving toolpath is now generated, and the Operation is listed under the RhinOCAM-MOps browser.



13. Switch to Simulate tab, select 4 Axis Engraving, and click Simulate to run the simulation.



Post Processing


2. Specify the File Name as 4AxisEngrave.nc and click save.

The post by default is set to Haas as specified under the Post processor setup. You can change the post processor by selecting a different one from the drop down menu



in the list. The posted g code by default will be saved to the folder where the part file is located.

End of Tutorial 12!



Tutorial 13: Machining a Ring



Introduction This tutorial will illustrate machining this Ring using 4 axis-milling operations. This tutorial will introduce the usage of several 4-axis operations such as 4 axis roughing and finishing. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to Machine the ring

• We will machine the ring completely using 4 axis-machining operations. • The part itself will be machined out of a cylindrical blank. • The stock will be held to the machine table using a rotary chuck. • The part will be machined using 0.0625” and 0.03125’ ball end mills.






To load a part:


2. From the Open dialog box, select the RingExample_2.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)




Setup Tab





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












2. This brings up the Cylinder Stock parameters. Set the Axis (rotary) = X, Radius = 0.48” and Length (L) = 0.4. Leave the other parameters as default and click OK.











Locate Machine Zero



3. Under Set WCS Origin, choose Set to Stock Box, the Zero Face to Highest Z, and Zero Position to East. This sets the machine home to the top of the stock material and the right most edge of the part geometry.









In this step, we will position the part to the center of the stock in XY & Z.

2. Use the following settings, Object to Move: Move Part, Z alignment: Center and XY Alignment: Mid-East.








1. Select Machine Setup from the setup tab. In the above example, the stock diameter is 0.96”.

2. Set the rotary center in X and Y = 0 and Z = -0.48 which is the center of the stock geometry.




Create Tools To machine the above part, we will now create 0.0625” and 0.03125” Ball End Mills.

1. Go to the RhinoCAM-Tools browser that is located below the RhinoCAM-MOps browser and select Create/Edit Tools. Select the Tool Type to Ball End Mill.

2. Set the tool name as BallMill-0.0625, Tool Diameter = 0.0625 Flute Length = 1” and Tool Length = 1.5”. Under the Properties tab, set Tool Number = 1.











6. Create a 2nd Ball End Mill with the following parameters.







Create Machining Operations We will machine the ring using 2 different machining operations – 4 axis Roughing and Finishing. The first step in machining the ring will be a roughing operation. In this cut method, the tool cuts the stock in successive levels. The spacing between these levels are specified by the user. This type of machining is very efficient for removing large volumes of material and is typically performed with a large tool. Roughing is typically followed by semi-finishing or finishing toolpaths.




4th axis Roughing

1. Select 4 Axis Milling and choose Roughing.



2. This brings up the 4 Axis Roughing Operation Dialog. We will now go over the steps for creating the toolpath.

3. Switch to the Tools tab inside the 4 Axis Roughing operation and select BallMill-0.0625.












6. Click on the Cut Parameters tab. 7. Set the Intol and Outol = 0.001, Stock to leave =0.005, Cut Pattern to Along

Axis, Zig Zag and Low to High, Cut Containment Low Value = -0.4, High Value = 0.03, Step over distance = 25 (% Tool Diameter).

8. Switch to the Step Down Control Tab.



Step Down Control 9. Use the Following Settings.

c. Cut Levels, Check Top (T) and specify Top (T) = 0.48 (radius of stock material), Bottom (B) = 0.4, Step Down Control (dR) = 75 (% Tool Diameter).







4th Axis Roughing operation #2 We will now create a second 4 Axis Rough operation to machine the pocket areas around the ring by limiting the toolpath using start, end angle cut containments. Copying a MOp

1. Switch to the Create Operations tab in the Mops Browser. 2. Select the 4 Axis Roughing operation, right click copy. 3. Now right click and select paste.

4. A copy of the rough operation is created below the 4th Axis Roughing

operation. The operation name is labeled 4th Axis Roughing-1 and is as shown below.





Specify Cut Parameters 5. Double click on 4th Axis Roughing-1 to edit the operation.

6. Switch to the Cut parameters tab and use the following parameters. a. Leave the global parameters and cut pattern unchanged b. Under Cut Containment change the Start Angle (S) = -90, End

Angle (E) = 90.

7. Switch to the Step Down Control tab



Specify Step Down Control 8. Use the Following Settings.

a. Cut Levels, Check Top (T) and specify Top (T) = 0.4 (as we had limited the toolpath to a radius = 0.4 on the 1st Rough operation), Step Down Control (dR) = 75 (% Tool Diameter).







4th axis Finishing We will now use 4th Axis Finishing operation to finish the part using a 0.03125” Ball End Mill.

In this method, the tool is always normal to the axis of table rotation (continuous mode). The tool motions can be parallel to or normal to the rotation axis. From the Create Operations tab, select 4 axis Milling and 4 Axis Finishing.

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

1. Switch to the Tools tab inside the 4 Axis Finishing operation dialog and select BallMill-0.03125.









5. Set the Tolerance to 0.001, Stock to leave =0, Cut Pattern = Along Axis, Zig Zag, Low to High, Set Cut Containment Low Value = -0.4, High Value = 0.01, Step over distance = 10 (% Tool Diameter).

6. Click Generate. The Finishing toolpath is now generated, and the Operation is listed under the 4 Axis Roughing Operation in the RhinoCAM-MOps browser.



7. Switch to Simulate tab, select 4 Axis Finishing, and click Simulate to run the simulation.



Post Processing


2. Specify the File Name as Ring2.nc and click save.


End of Tutorial 13!



Tutorial 14: Pocketing and Drilling on a Ring



Introduction This tutorial is intended to describe the 4 axis pocketing and hole making operations. Pocketing machines closed regions as if they were pockets - completely enclosed by inner and outer regions. The tool cannot go beyond the outer region, and cannot go within inner regions. This is unlike Facing, in which the outermost region is considered to enclose material to be removed. Hole making operations are used to create holes in a part; the hole types varying from simple drill holes, counter sunk holes, through holes to tapped and bored holes. Here you will learn to drill simple holes. The stepped instructions are accompanied by explanatory and introductory text. Reading this text will help you understand the tutorial methodology and provide information about additional options available. Don’t forget to save your work periodically! You may want to save the file under a different name so that the original file will be preserved. Strategy to machine the part

• We will machine the ring completely using 4 axis-machining operations. • The part itself will be machined out of a cylindrical blank. • The stock will be held to the machine table using a rotary chuck. • The part will be machined using a 0.0625” Flat End Mill and 0.125” Standard

Drill Main Programming Steps In creating programs for each setup, the following steps will be followed:





To load a part:




2. From the Open dialog box, select the 4AxisPocketing_1.3dm file from the Tutorials folder in the RhinoCAM 2.0 installation folder. (C:\Program Files\Rhinoceros 4.0\Plug-ins\RhinoCAM 2.0\Tutorials)


Setup Tab





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












2. This brings up the Cylinder Stock parameters. Set the Axis (rotary) = X, Radius = 2” and Length (L) = 1”. Leave the other parameters as default and click OK.










Locate Machine Zero



3. Under Set WCS Origin, choose Set to Stock Box, the Zero Face to Highest Z, and Zero Position to East. This sets the machine home to the center of the stock material and the right most edge of the part geometry.








In this step, we will position the part to the center of the stock in XY and Z.






2. Set the rotary center in X, Y and Z = -2 (which is the center of the stock geometry Diameter of stock = 4”).




Create Tools To machine the above part, we will now create a 0.125” Drill (Standard Drill) and a 0.0625” Flat End Mill.

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

2. Set the tool name as Drill-0.125, Tool Diameter = 0.125, Tip Angle = 120. Under the Properties tab set Tool Number = 1.











6. Create a 2nd tool, a Flat End Mill with the following parameters.

a. Tool Name: FlatMill-0.0625, Tool Diameter = 0.0625, Flute Length = 1,Tool Length = 1.5, Tool Number = 2.






Create Machining Operations First we will drill the holes on the cylinder using 4 Axis Drilling. As in any other 4 axis operations, the tool is positioned normal (perpendicular) to the rotary axis. Once the holes (regions) are selected, the dialog boxes are similar to the 3 axis hole making operations. Sorting of holes is also possible to optimize the tool motion.


4 Axis Drilling

1. Select Hole and choose 4 Axis Drilling.





2. This brings up the 4 Axis Drilling Operation Dialog. We will now go over the steps for creating the toolpath.

Select Hole Features

3. Go to the Machining Features/ Regions tab and click Hole Features.



4. Now, select the 12 circles around the part (represented in green color). You can also use the Edit tool from the menu bar and use Edit->Select Objects->By Layer and choose Layer 04.




The selected regions are now displayed under Hole Features.



6. Switch to the Tools tab inside the 4 Axis Drilling operation and select Drill-0.125.




8. Switch to Clearance tab and set the Clearance Plane Definition to Stock Max R + Dist = 0.25. Set the cut transfer method to Clearance Plane.






9. Click on the Cut Parameters tab. 10. Set the Drill Type = Standard Drill, Drill Depth = 0.1, Check Add Tool tip

to Drill Depth and Approach Distance = 0.1

11. Switch to Sorting tab in the 4 Axis Drilling dialog.



Sorting

12. Use Minimum Distance Sort and specify the Start Point as Lower Left 13. Click Generate. The 4 Axis Drilling toolpath is now generated, and the




14. Switch to Simulate tab, select 4 Axis Drilling, and click Simulate to run the simulation.



4 axis Pocketing

1. Select 4 Axis from the Create operations tab and choose 4 Axis Pocketing



2. This brings up the 4 Axis Pocketing Operation Dialog. We will now go over the steps for creating the toolpath.




Regions.

4. Select all the curves on Layer 02 using Edit from the menu, Edit->Select Objects->By Layer and choose Layer 02.





7. Switch to the Tools tab inside the 4 axis pocketing operation and select FlatMill-0.0625.




9. Switch to the Clearance Tab and set the Clearance Plane Definition to Stock Max Z + Dist = 0.25 and Cut Transfer Method to Clearance Plane.





11. Set Tolerance = 0.001, Stock = 0, Cut Pattern = Offset Cuts, Cut Direction = Mixed, Start Point = Inside, Step Distance = 25% (Tool Diameter), Check Corner Cleanup.

12. Switch to Cut Levels Tab.

13. Use the following Settings

a. Location of Cut Geometry – At Top.



b. Total Cut Depth = 0.1, Rough Depth = 0.1

c. Rough Depth/Cut = 0.025.

d. Cut Level Ordering = Depth First.

14. Click Generate. The 4 Axis Pocketing toolpath is now generated, and the Operation is listed under the RhinoCAM-MOps browser.



15. Switch to Simulate tab, select 4 Axis Engraving, and click Simulate to run the simulation.



Post Processing


2. Specify the File Name as 4AxisPocketing.nc and click save.


End of Tutorial 14!

Documents

Rhino Cam Gettingstarted Guide