The Solid/Surface/STL Model Manufacturing System

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End-User Software License Agreement
This MecSoIt Corporation's VisualMill End User SoItware License Agreement that accompanies the
VisualMill(TM) soItware product ('SoItware) and related documentation ("Documentation"). The term
"SoItware" shall also include any upgrades, modiIied versions or updates oI the SoItware licensed to you by
MecSoIt.
MecSoIt Corporation grants to you a nonexclusive license to use the SoItware and Documentation, provided that
you agree to the Iollowing:
1. USE OF THE SOFTWARE.
You may install and use one copy oI the SoItware on a single computer in a single location on a hard disk.
2. COPYRIGHT.
The SoItware is owned by MecSoIt Corporation and its suppliers. The SoItware`s structure, organization and code
are the valuable trade secrets oI MecSoIt Corporation and its suppliers. The SoItware is also protected by United
States Copyright Law and International Treaty provisions. You must treat the SoItware just as you would any
other copyrighted material, such as a book. You may not copy the SoItware or the Documentation, except as set
Iorth in the "Use oI the SoItware" section. Any copies that you are permitted to make pursuant to this Agreement
must contain the same copyright and other proprietary notices that appear on or in the SoItware. You agree not to
modiIy, adapt, translate, reverse engineer, de-compile, disassemble or otherwise attempt to discover the source
code oI the SoItware. Trademarks shall be used in accordance with accepted trademark practice, including
identiIication oI trademark owner`s name.
Trademarks can only be used to identiIy printed output produced by the SoItware. Such use oI any trademark does
not give you any rights oI ownership in that trademark. Except as stated above, this Agreement does not grant you
any intellectual property rights in the SoItware.
3. TRANSFER.
You may not rent, lease, sublicense or lend the SoItware or Documentation.
4. LIMITED WARRANTY.
MecSoIt Corporation warrants to you that the SoItware will perIorm substantially in accordance with the
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you must notiIy MecSoIt Corporation within such thirty (30) day period. II the SoItware does not perIorm
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HAS BEEN ADVISED OF THE POSSIBLITY OF SUCH DAMAGES OR FOR ANY CLAIM BY ANY
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Use, duplication, or disclosure by the government is subject to restrictions as set Iorth in subparagraph (c) (1) (ii)
oI The Rights in Technical Data and Computer SoItware clause at DFARS 252.227-7013 or subparagraphs (c) (1)
and (2) oI Commercial Computer SoItware Restricted Rights at 48 CFR 52.227-19, as applicable. ManuIacturer
is: MecSoIt Corporation, 17905, Sky Park Circle, Suite N, Irvine CA 92614-6386, USA.
Unpublished - rights reserved under the copyright laws oI the United States.
MecSoIt Corporation
17905, Sky Park Circle, Suite N
Irvine, CA 92614-6386
VisualMill is a registered trademark oI MecSoIt Corporation
1998-2003, MecSoIt Corporation


Trademark credits
Windows is a registered trademark oI MicrosoIt Corporation
Pentium is a registered trademark oI Intel Corporation
Parasolid is a registered trademark oI Unigraphics Solutions
SolidWorks is a registered trademark oI SolidWorks Corporation
Solid Edge is a registered trademark oI Unigraphics Solutions
Rhino is a registered trademark oI McNeel & Associates.
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Welcome to VisualMill ............................................................................................................................. 7
About This Guide................................................................................................................................... 7
VisualMill ConIigurations ..................................................................................................................... 7
Computer Requirements ........................................................................................................................ 8
Installing VisualMill .............................................................................................................................. 8
Installing the VisualMill Security Key.............................................................................................. 8
Troubleshooting the Security Key..................................................................................................... 9
VisualMill Installation Eolder ........................................................................................................... 9
Running VisualMill.............................................................................................................................. 10
Registering VisualMill .................................................................................................................... 10
VisualMill Display.......................................................................................................................... 11
VisualMill User Interface....................................................................................................................... 12
Typical Scenario................................................................................................................................... 14
Programming WorkIlow ...................................................................................................................... 14
Machining Methods ................................................................................................................................ 15
3 Axis Operations................................................................................................................................. 16
2 Axis Operations.............................................................................................................................. 27
Drilling (Hole Making) Operations...................................................................................................... 36
4th Axis Operations ............................................................................................................................. 38
5
WK
Axis Machining............................................................................................................................... 40
Tutorial 1: 3 Axis Milling....................................................................................................................... 41
The Standard Bar.................................................................................................................................. 41
Loading a Part Model........................................................................................................................... 41
View Bar .............................................................................................................................................. 43
Browser ................................................................................................................................................ 45
Geom Tab........................................................................................................................................ 45
Tools Tab......................................................................................................................................... 46
Mops Tab......................................................................................................................................... 46
Stock Tab......................................................................................................................................... 47
Creating the Stock................................................................................................................................ 47
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Creating Tools...................................................................................................................................... 50
Setting Eeeds and Speeds..................................................................................................................... 57
Customizing Eeeds and Speeds ....................................................................................................... 58
Status Bar ............................................................................................................................................. 61
Creating the Horizontal Roughing Toolpath........................................................................................ 62
Simulation ............................................................................................................................................ 67
Simulating the Horizontal Roughing Toolpath.................................................................................... 68
Creating the Pre-Einish Toolpath......................................................................................................... 70
Creating the Pencil Tracing Toolpath .................................................................................................. 73
Creating the Einish Toolpath................................................................................................................ 75
Post-Processing .................................................................................................................................... 79
Set Post Options .............................................................................................................................. 80
Post Processor Generator ................................................................................................................ 81
Post-Processor Problems ................................................................................................................. 83
Tutorial 2: 2 Axis Milling Operations................................................................................................ 85
Creating Tools and Stock..................................................................................................................... 86
Creating Regions.................................................................................................................................. 92
Points............................................................................................................................................... 93
Lines ................................................................................................................................................ 94
Arcs ................................................................................................................................................. 94
Curves.............................................................................................................................................. 95
Selecting Regions............................................................................................................................... 105
Multiple Regions ........................................................................................................................... 106
Creating Toolpaths............................................................................................................................. 107
Clearance Plane.................................................................................................................................. 114
Adjusting the Regions........................................................................................................................ 124
Replacing the Eirst Toolpath.............................................................................................................. 126
ModiIying Toolpath Parameters ........................................................................................................ 128
Toolpath Editing ................................................................................................................................ 131
Tutorial 3: Drilling Operations............................................................................................................ 142
Tutorial 4: 4
WK
Axis Machining Operations ........................................................................................ 156
Creating Eourth Axis Toolpaths......................................................................................................... 156
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Cutting Strategy ................................................................................................................................. 156
Measurement Bar ............................................................................................................................... 157
Setting the Machine Zero................................................................................................................... 158
Setting the Rotation Axis ................................................................................................................... 161
Creating the Parting Region............................................................................................................... 162
Creating 3 Axis Roughing Toolpaths................................................................................................. 167
Creating 4
WK
Axis Indexed Mode Einishing Operations ..................................................................... 173
Creating 4
WK
Axis Continuous Mode Einishing Operation ................................................................. 177
Tutorial 5: 5
WK
Axis Machining Operations ........................................................................................ 180
Setting the Construction Plane and MCS........................................................................................... 181
Machining the Top Eace..................................................................................................................... 185
Machining the Side Eace.................................................................................................................... 190
Machining the Eront Eace .................................................................................................................. 194
Tutorial 6: CAD.................................................................................................................................... 197
Setting up and Creating ReIerence Points.......................................................................................... 197
Creating the Inner Cutouts ................................................................................................................. 199
OIIseting and Extending Curves ........................................................................................................ 202
ChamIering and Mirroring................................................................................................................. 205
Creating SurIaces ............................................................................................................................... 212
Additional Topics.................................................................................................................................. 217
Knowledge Base................................................................................................................................. 217
Where to go for more help ................................................................................................................... 217

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Welcome to VisualMill
Welcome to VisualMill and thank you Ior choosing one oI most powerIul and easy to use
Solids/SurIace/STL manuIacturing packages on the market today.
VisualMill is a unique, Windows-based, CAM product that seamlessly integrates toolpath generation
and cutting simulation/veriIication, in one package that is both easy and Iun to use. VisualMill`s
machining technology capabilities enable you to produce toolpaths that you can send to the machine
with utmost conIidence. A simple and well-planned user interIace makes VisualMill suitable Ior use on
the shop Iloor, working in conjunction with your existing CAD/CAM/CNC system.
Solid models, surIace models and Iaceted models can be imported into VisualMill, and a wide selection
oI tools and toolpath strategies to can be deIined when generating toolpaths. These toolpaths can then be
simulated and veriIied, and Iinally post-processed to the controller oI your choice.
About This Guide
This guide is designed to introduce Iirst-time users to VisualMill 5.0. The Iirst part describes aspects oI
the user interIace, machining strategies, and milling types. This is Iollowed by several tutorials designed
to Iamiliarize you with the main Ieatures oI VisualMill.
In addition to the inIormation provided in this guide, see the context-sensitive online help Ior more
comprehensive explanations. You can also look at the models included in the Tutorials Iolder.
VisualMill ConIigurations
VisualMill 5.0 comes in two conIigurations - VisualMill Basic and VisualMill (standard conIiguration).
VisualMill Basic is a general-purpose machining program targeted at the typical machinist. It is ideal Ior
the rapid-prototyping, general machining, hobby and educational markets. The standard product is an
advanced version, suitable Ior mold, die and tool making, woodworking, and other complex
applications. This conIiguration is suitable Ior machinists with sophisticated manuIacturing
requirements.
Both conIigurations support 2 and 3 axis milling, as well as drilling. The standard version also
supports 4
WK
and 5
WK
axis milling. In addition, both versions can import Rhino, STL, IGES, DXE/DWG,
VRML, and Raw Triangle Iiles.
The Parasolid interIace add-on module includes the Parasolid kernel. This enables you to import
Parasolid geometry data Irom the native design Iiles oI any Parasolid-based CAD system, as well as
SolidWorks, Solid Edge and A3DS Iiles.
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Computer Requirements
Intel Pentium compatible computer
Windows NT, 95, 98, 2000, ME, or XP with at least 64 MB RAM.
OpenGL-compatible graphics card, displaying at least 64,000 colors
Approximately 50 MB oI hard disk space.
Installing VisualMill
To install VisualMill soItware, Iollow these instructions:

Windows NT
1. Insert the CD-ROM into the CDROM drive.
2. Go to the Program Manager and select Run Irom the File menu.
3. In the Command Line box, enter D:\Launch (where D is the letter oI your CD-ROM drive) and
Iollow instructions.

Windows 95, 98, 2000, ME, and XP
1. Insert the CD-ROM Disk into the CDROM drive.
2. The setup program will automatically launch once the computer detects the CD.
3. Eollow the setup instructions.
Installing the VisualMill Security Key
VisualMill 5.0 ships with a hardware security device called the security key (or 'dongle). This is either
a 25-pin connector that connects to the parallel port oI your computer, or a USB key that plugs into any
USB port on your computer. II you have any other device, such as a printer, connected through the
parallel port, disconnect it and connect the VisualMill security key. Then reattach the connector oI the
original device on top oI the security key; the device will continue to operate as beIore.
VisualMill will not operate correctly iI the security key is not connected to the computer!
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Troubleshooting the Security Key
II you have installed the dongle but VisualMill is not running properly, try restarting your computer. II
that still does not work do the Iollowing:
1. Eor Windows NT / 2000 / XP, double-click on the setupx86.exe icon
Iound in the Win_NT Iolder in the VisualMill installation Iolder (see the section below that
describes the installation Iolder). Eor Windows 95 / 98 / ME, double-click on the sentw9x.exe
icon in the Win_9x Iolder.
2. Select Functions / Remove Sentinel driver and click OK.
3. Double-click on the RainbowInstaller.exe icon in the VisualMill 5.0 Iolder, then click OK.
4. Restart your computer.
You can also download the Combo Installer Irom the Rainbow website
(http://www.rainbow.com/Support/SentinelESC.asp) and run the installation program. This will
automatically install the drivers necessary Ior the proper operation oI your security key.
II the above method does not work, download the Sentinel Medic Irom the Rainbow website
(http://www.rainbow.com/Support/SentinelESC.asp). Install it and and go to Start-~Programs-~Rainbow
Technologies-~Sentinal Medic-~Sentinel Medic. Click Find SuperPro and send the Iollowing
inIormation that appears on the screen to supportmecsoIt.com, so that we can locate and Iix your
speciIic problem:
1. System Driver InIo
2. Status
3. Description
4. Medic Says
VisualMill Installation Folder
VisualMill installation creates a main installation Iolder whose name and location you can speciIy
during the installation process (or accept the deIault location oI C:\Program Eiles\MecSoIt
Corporation\VisualMill 5.0). This Iolder contains the VisualMill executable and *.dll Iiles. There are
also several subIolders in the installation directory:
Data: Contains tool library Iiles - DefaultEnglishTools.csv and DefaultMetricTools.csv. These Iiles
can be used as they are, or you can use them as templates and customize them with your own data. You
will also Iind a speeds/Ieeds & material library Iile called FEEDSPEEDS. Eor more inIormation on
how to modiIy these tool library Iiles, please reIer to VisualMill`s online help.
Examples: Contains various example Iiles that you can experiment with. There are Iiles Irom other
CAD systems you can import, as well as VisualMill Iiles (*.vmp). The *.vmp Iiles contain saved
machining operations that you can study and modiIy.
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Help: Contains the online help Iiles used with VisualMill. You can open these Iiles directly Irom this
Iolder, or access them within VisualMill.
Posts: Contains the standard set oI post-processor (*.spm) Iiles. Additional post-processor Iiles can be
obtained Irom MecSoIt Corporation. II you receive additional *.spm Iiles, be sure to place them in this
Iolder, so that VisualMill will recognize them.
Schema: Contains all the necessary Iiles Ior loading Parasolid and Parasolid-based products, such as
SolidWorks and Solid-Edge Iiles.
Tutorials: Contains a tutorial and several part Iiles to help Iirst-time users get Iamiliar with VisualMill.
These are similar to the tutorials presented in this guide, in onscreen Iormat. To launch these tutorials,
open the VisualMill5.0Tutorials.chm Iile, and use the table oI contents or arrows to browse through the
steps.
WIN_9x and WIN_NT: Contains the necessary Iiles Ior the proper Iunctioning oI the hardware security
key (dongle).
MCU: Contains the necessary Iiles Ior the proper Iunctioning oI a third party G-code analyzer tool that
is bundled with VisualMill 5.0.
Running VisualMill
Click on the Windows Start button and select Programs. Point to the program group containing
VisualMill. The name oI this program group will be VisualMill 5.0, unless you speciIied otherwise
during setup. Once you locate the program group, select it and then select VisualMill 5.0.
Registering VisualMill
AIter installation, you can run the Iull VisualMill version 50 times or Ior 30 days without registering the
product. AIter this period, VisualMill will operate only in demo mode, without the ability to save part
Iiles or output toolpaths.
When VisualMill is invoked, you will see the Enter License Code window. The Tries Left Iield
indicates the number oI times you can run VisualMill beIore it starts operating in demo mode.
To obtain license codes you must register the product using the Web Iorm available at
www.mecsoIt.com/register.htm. II you have purchased the product directly Irom MecSoIt Corporation,
you will have to provide the purchase invoice number beIore you can be licensed. II you have
purchased the product through an authorized VisualMill reseller, please obtain the license codes Irom
your reseller. In addition to this inIormation make sure you also provide the Dongle ID that is shown on
the registration screen. You can also access this Iorm Irom within VisualMill by selecting Help /
Register VisualMill.
Registration can also be done through the MecSoIt website (www.mecsoIt.com). Go to the 'Support
page and click the 'Register VisualMill tab.
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VisualMill Display
II you are experiencing problems with the way VisualMill appears on the screen, try the Iollowing:
Eor Windows 98, ME, 2000 and XP:
1. Right-click anywhere on the desktop and select Properties Irom the menu.
2. Open the Settings tab and click Advanced.
3. Open the Troubleshoot or Performance tab and set Hardware acceleration to None.
II you are still having problems, reinstall the video drivers oI your video card. Or you can try another
video card to see iI the problem is speciIic to your card.
II VisualMill opens as a minimized window and closes when maximized (this happens on rare
occasions, typically on computers with deIective display cards), it is probably due to bad window
coordinates stored in your computer`s registry. Try the Iollowing to eliminate this problem:
1. Press Windows R button.
2. Type in regedit and click OK.
3. In HKEYCURRENTUSER / SoItware, delete the VisualMill5.0 entry.


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VisualMill User InterIace
VisualMill adheres to the Windows standard Ior user interIace design. All Iunctions can be accessed
Irom the menus, and common Iunctions are accessible via toolbar icons. Most user interIace settings are
modal - VisualMill 'remembers these settings and they remain active in subsequent operations unless
you change them.
The main VisualMill user interIace objects are described below:





Aote: You can control the displav bv selecting Jiew / 1oolbars.
Status Bar: Displays current
Iunction or prompt, active tools,
units, snaps, and cursor location
View Bar: Zoom, pan, rotate,
standard views, display/hide
Iunctions
Browser: Displays geometry,
machining operations, tools,
and stock removal simulation
Command Window: Enter values
manually, or displays calculated values
Standard Bar: Eile load/save, layer and
selection control, and more
Geometry Bar: Create and edit
points, curves, and surIaces
Measurement Bar:
Measures dimensions
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VisualMill WorkIlow
The manuIacturing process aims to successively reduce material Irom the stock model until it reaches
the Iinal shape oI the designed part. To accomplish this, the typical machining strategy is to Iirst use
large tools to perIorm bulk removal Irom the stock (roughing operations), then use progressively smaller
tools to remove smaller amounts oI material (pre-Iinish operations). When the part has a uniIorm
amount oI stock remaining, a small tool is used to remove this uniIorm stock layer (Iinish operations).
















This machining strategy is what you program using VisualMill. You can also simulate material removal
to visualize how the stock model will look at any time during the process. This provides valuable
Ieedback that can help you choose the most appropriate machining strategy.
Load Part & Stock
Create Roughing
Operations
Simulate Material
Removal
Output Toolpaths
to Machine
Create Pre-Finish
Operations
Create Finishing
Operations
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Typical Scenario
Rough machining can be done by Horizontal Roughing (3 axis) or Pocketing (2 axis) operations,
using a relatively large Ilat end mill or an end mill with a corner radius. These rough operations can be
Iollowed by subsequent roughing operations, either using the same tool or a smaller tool.
The part can then be pre-Iinished by using Parallel Finishing or Horizontal Finishing (3 axis) or
Profiling (2 axis). Pre-Iinishing and Iinishing operations typically use ball end mills, with or without a
side angle.
Eor complex 3D parts, additional Iinish operations may be necessary. Eor example, Parallel Finishing
operation can be deIined using a small ball tool with a Iine stepover value.
Once all oI the operations are completed, you can go back and review the operation sequence, re-order
and/or change operations iI desired, simulate the material removal, and post-process the toolpaths. The
Browser can be used to manage these operations.
Another powerIul Ieature included in VisualMill is that oI a Knowledge Database or K-Base. AIter
creating an operation sequence Ior one part, you then save the operations and apply the same set oI
parameters and operation sequence to another part. This Ieature allows even novice users oI VisualMill
to machine parts quickly and easily.
Programming WorkIlow
Once the part is loaded, the typical workIlow is reIlected in the layout oI the icons in the Mops tab oI
the Browser.

The steps are described below, and are demonstrated in the tutorials.
Setup Machine: Set the number oI axes and deIine rotation axes and tool change positions.
Set Machine CSYS: Set the origin oI the machine coordinate system, with respect to stock / part, or
at an exact location.
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Create/Select Tool: Opens a window in which you can deIine all the tools that will be needed in
the machining operations.
Set Feeds/Speeds: DeIines the Ieed and speed rates Ior cutting, rapid, approach, engage, retract,
and depart tool motions.
Clearance Control: Sets the level above the part Ior saIe rapid tool motion.
Select Regions: Provides several methods Ior selecting curves that will act as machining
boundaries.
Machining Methods: Choose the type oI toolpath you want to create. Machining methods are
described in the next section.
Toolpath Editor: Opens a window in which you can edit any line oI toolpath code, insert special
machine control commands, and make changes on groups oI tool motions. Not available in JisualMill
Basic.
Post Process: Sends the toolpath code to the machine.
Machining Methods
There are two major classes oI machining operations that can be created in VisualMill - milling and
drilling. Milling operations are used to mill out material to Iorm shapes. Drilling operations are used to
create holes. Both classes are essential in any manuIacturing industry.
Milling operations can be categorized as 3 axis, 2 axis, 4
WK
axis, and 5
WK
axis milling.
N 3 Axis: The tool can move simultaneously in all three directions.
N 2 Axis: The tool can move in X and Y directions, while the Z level is Iixed at set locations.
N 4
WK
Axis: Rotates the machine table in order to machine parts that cannot be machined with
simple 2 axis or 3 axis operations.
N 5
WK
Axis: The tool can rotate in all directions, so that areas oI any orientation can be milled.
These categories, and the available operations, within them are described in the sections to Iollow.
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3 Axis Operations
In this type oI machining, the tool can move simultaneously in all three axes. This is appropriate Ior
parts that have complex, curved, and non-vertical surIaces.

A typical machining scenario would be to Iirst use Horizontal Roughing, the pre-Iinishing using
Parallel Finishing and/or Horizontal Finishing. Once the part is at near net shape then Iine detailed
Iinishing could be perIormed by any oI the re-machining or the region-based projection methods.
The available 3 axis operations are shown and described below.

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Aote: Onlv Horizontal Roughing, Parallel Finishing and Horizontal Finishing are available in
JisualMill Basic.
Horizontal Roughing
This is VisualMill`s principal method oI roughing, also knows as waterline or constant Z cutting, in
which the material is roughed out in horizontal layers. This type oI machining is very eIIicient Ior
removing large volumes oI material, and is typically perIormed with a large tool. Roughing is
typically Iollowed by semi-Iinishing or Iinishing toolpaths.
Both part and stock geometry are used to determine the regions that can be saIely machined. Three
types oI cutting patterns are available: Linear (parallel, zigzag lines), Stock Offset (spiral pattern
within stock and part), and Part Offset (spiral pattern outside the stock and outside the part). Tool
motions are shown Ior single Z levels in the pictures below.

Horizontal Roughing - Linear
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Horizontal Roughing - Stock Offset (Pocketing)

Horizontal Roughing - Part Offset (Facing)
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Plunge Roughing
Not available in JisualMill Basic
Sometimes called drill roughing, the tool can cut in the Z direction only, not in X and Y. The tool
makes a series oI overlapping plunges to remove cylindrical plugs oI material.

Horizontal Re-roughing
Not available in JisualMill Basic
This is used to create toolpaths in areas that were not machined by previous operations. Unmachined
areas are determined by comparing the part to the stock remaining aIter the previous operation.
Machining is perIormed in constant Z levels, one oI which is shown below:

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Plunge Re-roughing
Not available in JisualMill Basic
Similar to Horizontal Re-Roughing, this method uses plunge motions to machine areas that were
not machined by previous operations.

Parallel Finishing
This is an eIIicient method oI Iinishing or pre-Iinishing, typically used when part surIaces are
relatively Ilat. A 2D linear zigzag pattern is generated on the XY plane above the part geometry. The
tool moves along this cut pattern, Iollowing the contours oI the part geometry below.

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Pocket Finishing
Not available in JisualMill Basic
This method is used Ior pre-Iinishing and Iinishing oI pockets with sculpted bottoms and/or sides.
The pockets are deIined by regions, and successive inner oIIsets oI these outer regions are generated.
The tool moves along these oIIset curves while Iollowing the contours oI the part below.

Horizontal Finishing
This method is used Ior pre-Iinishing or Iinishing in constant Z levels, typically used when the part
has large vertical surIaces and when Parallel Finishing will not yield satisIactory results.

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Pencil Tracing
Not available in JisualMill Basic
Used either Ior roughing, re-machining, or cleanup, the tool is driven along valleys and corners oI the
part. The system identiIies all double contact or bi-tangency conditions based on the tool radius. It
then creates cutting paths along these locations.
When used as a roughing operation, valleys and corners are relieves so that subsequent operations
will not encounter large amounts oI material in these regions, thereby reducing tool deIlection and
wear. When used as a cleanup operation, scallops that remain aIter Iinishing operations are removed.

Valley Re-machining
Not available in JisualMill Basic
This is used to machine corners and valleys that were inaccessible in previous Iinishing operations.

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Plateau Machining
Not available in JisualMill Basic
This method machines the tops oI Ilat areas areas that are within a speciIied angle Irom horizontal.
This is typically used to re-machine areas that remain unmachined aIter a Horizontal Roughing or
Horizontal Finishing toolpath.

Parallel Hill Machining
Not available in JisualMill Basic
This method machines steep areas. These are areas that are within a speciIied angle Irom vertical.
This method is typically used when a Parallel Finish toolpath leaves scallops on steep areas. The cut
angle is adjusted so that machining is always normal to the steep areas, thereby leaving minimal
scallops.

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Horizontal Hill Machining
Not available in JisualMill Basic
Similar to Horizontal Finishing, this method machines in constant Z levels. However, machining
can be restricted only to areas in the part that are steeper than a user-deIined steepness angle.

Radial Machining
Not available in JisualMill Basic
This method is used as a Iinishing operation Ior areas that have annular pockets. You must speciIy
one or more machining regions; the tool moves radially Irom the centroid oI these regions.

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25
Spiral Machining
Not available in JisualMill Basic
This method is used Ior Iinishing areas that have circular or near-circular characteristics, such as
pocket bottoms. You must speciIy one or more machining regions; the tool moves in a spiral pattern
based on the centroid oI these regions.

Curve Machining
Not available in JisualMill Basic
Suitable Ior machining isolated areas or shapes, this method machines along a curve. You must
speciIy one or more machining regions, direction and cut pattern. The tool simultaneously Iollows the
region and the contours oI the part below.

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Between 2 Curves Machining
Not available in JisualMill Basic
Sometimes called Ilowline machining, this method machines between two open or closed curves.
Using a pattern either parallel or normal to the curves, the toolpath makes a gradual transition Irom
one curve to the other. This creates a blended toolpath that can be used to eIIiciently Iinish complex
shapes.

Reverse Post Milling
Not available in JisualMill Basic
This Ieature loads toolpaths Irom APT CL Iiles and ISO standard G Code Iiles. You can use these
toolpath motions to project the tool onto part surIaces. You can also load an existing toolpath in order to
simulate it in VisualMill.
9HUVLRQ
27
2 Axis Operations
In 2 axis toolpath, the tool can move in X and Y directions, but Z movements are limited to set levels.
Because 2 toolpaths do not relate to either part or stock geometry, machining regions must be selected;
these deIine the boundaries oI tool motions.
This type oI machining is useIul Ior machining prismatic parts extrusions oI curves along the Z axis.
Because oI its straight sides, a prismatic part can be machined by locking the tool at the Iirst Z level,
perIorming XY motions, then repeating Ior subsequent Z levels.

Using this class oI machining, you can machine parts that are deIined only by 2D curves. 3D part
geometry can be present, though it is not necessary.

As with 3 axis operations, a typical machining operation would involve roughing then Iinishing. Unlike
the more complex 3 axis parts, detailed Iinishing is typically not necessary Ior prismatic parts. Roughing
is typically perIormed using a combination oI Facing and Pocketing operations, and Profiling is used
Ior Iinishing.
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The available 2 axis operations are shown and described below.

Aote: Advanced Pocketing and Advanced Profiling are not available in JisualMill Basic.
Facing
This method machines closed regions as iI they were completely enclosing material to be removed.
This means that the tool can approach the material Irom outside the outer regions, creating reverse
pockets.
This example uses multiple regions the rectangle is the outer region, and each letter is an inner
region. Some letters have nested regions; these are treated as islands (areas to avoid).

Aote: The outer region should encompass the stock. You can easilv create this tvpe of region bv
selecting Bounding Region from the Curves categorv of the Geometry bar.
Version 5.0
29
The toolpath looks like the Iollowing:

The stock simulation:

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Pocketing
This method machines closed regions as iI 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.
This example uses similar regions as the previous Facing example, but the outer region is within the
stock limits.

The toolpath looks like the Iollowing:

The stock simulation:

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31
Profiling
This method machines open and closed regions by tracing along one side oI their contours. You can
deIine oIIsets so that the tool makes multiple passes relative to the regions.
ProIiling can be used as a Iinishing operation aIter a Pocketing or Facing toolpath, or it can be used
alone.


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Advanced Pocketing
Not available in JisualMill Basic
This method encompasses the Iunctionality oI both pocketing and proIiling operations. You can
rough (pocket) and Iinish (proIile) in one operation. The stock leIt aIter roughing can be cleaned up
by Iinishing, without having to input how much to cut while Iinishing.

Advanced Profiling
Not available in JisualMill Basic
This method is used when multiple proIiling passes are needed at varying widths with diIIerent step
over distances. The width can be divided into roughing (larger step over) and Iinishing (smaller step
over) passes.
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Re-machining
This method uses a smaller tool to remove uncut material leIt aIter a previous operation (Iacing,
pocketing, or proIiling).

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Hole Pocketing
This method is used to cut large holes as a milling operation, rather than drilling. Engage can be
speciIied as a helix with height and angle or pitch. Output can be a helix cycle (Ior machines with this
capability) or a series oI linear moves. AIter the helix engage, the hole is cut to the outer diameter
using a spiral motion, Iollowed by a circular motion to clean up the hole.

Thread Milling
This method is used to cut threads using a thread mill. The pitch is deIined in the thread mill tool
deIinition. Thread milling options include internal or external threads, and right or leIt threads. The
threads can be cut in a single pass or over multiple passes with a step over distance.

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35
Engraving
Typically used Ior engraving text or logos on a Iinished mode, this method machines open or closed,
2D or 3D regions by tracing along the contours. This method is similar to Curve Machining, in
which the tool is projected onto the part surIaces below the regions being Iollowed. A conical tool is
used Ior engraving.


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Drilling (Hole Making) Operations
These operations are used to create holes in the part, including drill holes, counter sunk holes and
through holes. Tapped and bored holes can also be created.

The Iollowing drilling operations are available:

Drilling
The Iollowing drill cycles are available:
N Standard: Used Ior holes whose depth is less than three times the tool diameter.
N Deep: Used Ior holes whose depth is greater than three times the tool diameter, especially
when chips are diIIicult to remove. The tool retracts completely to clean out all chips.
N Counter Sink: Cuts an angular opening at the end oI the hole.
N Break Chip: Similar to Deep drilling, but the tool retracts by a set clearance distance.
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Tapping
A Tap cycle is used to drill threaded holes in the part, clockwise or counter-clockwise.
Boring
A Bore cycle is used to Iorm shapes inside a hole. The Iollowing boring cycles are available:
N Drag: The tool is Ied to the speciIied depth at the controlled Ieed rate. Then the spindle is
stopped and the tool retracts rapidly.
N No Drag: The tool is Ied to the speciIied depth at the controlled Ieed rate. It is then stopped to
orient the spindle, moved away Irom the side oI the hole and then retracted.
N Manual: The tool traverses to the programmed point and is Ied to the speciIied depth at the
controlled Ieed rate. Then the tool stops and is retracted manually.
Reverse Boring
This is simply a Bore cycle in the reverse direction. The spindle is oriented to the speciIied angle and
moves rapidly to the Ieed depth and moved to the part. The spindle is turned on and the cycle is
started.
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4th Axis Operations
Not available in JisualMill Basic
4th Axis operations are used to machine parts that cannot be machined with simple 2 axis or 3 axis
operations. During 2 and 3 axis milling, the tool remains vertical and the table is Iixed. This means
that areas oI the part that cannot be accessed Irom above cannot be cut.
There are generally two ways to use 4
WK
axis operations indexed or continuous mode. The Set Table
Rotation Params command enables you to set the rotation axis and origin Ior the table.
N Indexed mode: Use 3 axis operations to mill one halI oI the part, Ilip the table using a Rotate
Table command, and then mill the other halI. You are not restricted to 180-degree rotations.
N Continuous mode: The part is rotated continuously so that the tool is always normal to the
axis oI rotation. This is useIul Ior machining multi-sided parts.
The available 4
WK
axis operations are shown and described below.

Rotate Table
Rotates the table so that diIIerent sections oI the part can be machined.
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39
4
WK
Axis Parallel Finishing
In this method, the tool is always normal to the axis oI table rotation (continuous mode). The tool can
move in all directions while the table rotates continuously. The tool motions can be parallel to or
normal to the rotation axis.

4
WK
Axis Engraving
Similar to 3 axis engraving, this method machines text or logos by Iollowing the contours oI the
selected regions. Continuous mode is also used here.


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5
WK
Axis Machining
Not available in JisualMill Basic
In 5
WK
axis machining, the tool can rotate in all directions, so that areas oI any orientation can be milled.

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41
Tutorial 1: 3 Axis Milling
In this tutorial, you will create 3-axis milling toolpaths to manuIacture a designed part.
The stepped instructions are accompanied by explanatory and introductory text. Reading this text will
help you understand the tutorial methodology and provide inIormation about additional options
available. However, iI you preIer to work straight through the steps without any additional reading, look
Ior the Iollowing symbol:

Don`t Iorget to save your work periodically! You may want to save the Iile under a diIIerent name so
that the original Iile will be preserved.
The Standard Bar
BeIore beginning, the Iirst commands you should know are on the Iirst Iew on the Standard Bar. These
commands are used to load and save Iiles, and can also be accessed Irom the File menu.

New: Creates a new Iile.
Open: Loads part geometry into VisualMill. This geometry is typically imported Irom other CAD
Iormats, but can be created Irom within VisualMill as well.
Save: Saves the current Iile as a *.vmp Iile. We recommend saving your work periodically, to avoid
losing data.
Loading a Part Model
'Part reIers to the geometry that represents the Iinal manuIactured product. You can create parts within
VisualMill, but it is more typical to import geometry created in another CAD system.
You can import solid models oI standard Parasolid XT Iormat, or Stereo-Lithography (both ASCII and
binary) Iormat Iiles. SurIaces can be imported Irom IGES or Rhino 3DM. Eaceted (triangulated) models
can be imported Irom VRML, Raw Triangle, DXE / DWG Iacet data, or Rhino Mesh. Non-Iaceted
geometry, once imported, is immediately converted and stored as triangulated data.
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Imported geometry is stored internally as a VisualMill part Iile. This allows Ior much Iaster part loading
time.

To load a part:
1. Select File / Open, or click the Open Part File icon Irom the Standard bar.

2. Erom the Open dialog box, select the dumbells.vmp Iile Irom the Tutorials Iolder in the
VisualMill installation Iolder.
The imported part appears as shown below (in a diIIerent color, and without the coordinate
axes).


To change display settings:
1. The part is located on the DeIault layer. II you want to change the color oI the part, you must
change the color oI this layer. Click the Layers icon.

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43
2. IntheLayerManager,clicktheColorboxtoselectanewcolorIorthepart.

3. DisplayoIthecoordinateaxesiscontrolledintheCSYSManager.Clicktheiconshownbelow.

4. The two coordinate systems listed are MCS (machine coordinate system) and WCS (world
coordinatesystem).UnchecktheDisplayboxIorbothtoblankthem.

View Bar
TheView barisusedIorviewanddisplaymanipulation.BydeIault,itappearsverticallyalongtheleIt
sideoIthescreen,butyoucandockitanywhere.

EachoItheviewIunctionsisdescribedbelow:
Zoom In: Doublesthedisplayedsize.
Zoom Out: Halvesthedisplayedsize.
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Zoom Box: Zooms in on an area you speciIy by deIining a rubber-banded rectangle.
Center View: Centers the view about a selected point.
Fit View: Eits the entire part into display extents.
Repaint View: Repaints, or reIreshes, the view.
Dynamic Pan View: Pans the view by holding and dragging the mouse.
Dynamic Zoom View: Zooms the view by holding and dragging the mouse. Move the mouse up to
zoom in, move the mouse down to zoom out.
Dynamic Rotate View: Rotates the view by holding and dragging the mouse. The rotation Iollows
the mouse movements as iI there were an imaginary trackball at the center oI the view.
Dynamic Rotate View About Z: Rotates the view about the Z axis and the origin point, by holding
and dragging the mouse.
Top View: Displays the top view - the XY plane.
Right View: Displays the right view - the YZ plane.
Front View: Displays the leIt view - the XZ plane.
Iso View: Displays the model in isometric projection.
View to CPlane: Sets the view so that the construction plane is parallel to the screen.
Shade Part: Toggles the display oI part geometry between shaded and wireIrame modes.
Hide Stock: Toggles the display oI the stock geometry.
Display Grid: Toggles the display oI the construction grid.
Hide Toolpath: Toggles the display oI the toolpath associated with the current machining
operation.
Display Next Z: Displays the toolpath Ior each level. This button is only active Ior horizontal
milling operations.
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45
Browser
The Browser appears to the leIt oI the screen by deIault, and can be displayed or hidden by selecting
View / Toolbars / Browser. Like all toolbars, you can drag it to another location by clicking and
dragging it by one oI its corners. You can also resize it by dragging one oI its sides.
Standard Windows operations can be used here, when appropriate. You can drag and drop items to
change their order, and CtrlC (copy), CtrlX (cut), and CtrlV (paste) can be used. Dragging an item
outside the Browser will delete it. Items can be renamed here as well.
The Browser contains the Iollowing Iour tabs:
Geom Tab
The geometry manager displays the three types oI geometry that can be created and manipulated in
VisualMill: Surfaces/Meshes, Curves and Stock.

The Iirst icon represents the Part. Eor an imported part, the Iull path is indicated. II the part consists oI
surIaces, each surIace is represented as a Mesh. You can click on each mesh name to highlight its
corresponding surIace.
Curves in the model are regions used to deIine machining boundaries. You will work with regions in the
next tutorial.
Lastly, the Stock icon indicates the type oI stock. You can double-click to create a diIIerent type oI
stock, or right-click to or delete the stock or export it to an *.stl Iile. A red star next to this icon indicates
that the work-in-progress stock model corresponding to this operation needs to be created.
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Tools Tab
This tab lists all tools currently deIined in the Iile.

II you have created machining operations, the toolpath will appear in the Tools tab underneath the tool it
uses.
You can rename and delete tools, but you cannot delete a tool that is used in a toolpath. Double-click a
tool icon to edit its parameters.
Mops Tab
'Mops stands Ior Machining Operations. All toolpaths you create are listed here, in order oI creation.

Within each toolpath Iolder you can edit its various components, such as tool, regions, or cut parameters,
by double-clicking the relevant icon. Right-clicking on a toolpath name provides several options,
including simulation, generation, and post-processing.
II you make any changes to a toolpath`s parameters, the yellow Iolder icon Ior that toolpath will turn
red. This indicates that the toolpath needs to be regenerated.
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47
Stock Tab
This tab lists the type oI stock used Ior the part. The commands on this tab are used Ior toolpath
simulation.

Creating the Stock
'Stock represents the raw stock Irom which the part will be manuIactured. Stock geometry can either
be created within VisualMill or imported Irom an external Iile.
You can import Parasolid XT solid models and STL solid models (ASCII and binary) Ior stock
geometry. SurIaces can be imported Irom IGES or Rhino 3DM. Eaceted (triangulated) models can be
imported Irom VRML, Raw Triangle, DXE / DWG Iacet data, or Rhino Mesh.
Stock can also be created within VisualMill by entering coordinates or as the bounding box oI the part or
a toolpath. You can also deIine stock as a uniIorm oIIset oI the part geometry, to simulate casting or
Iorging raw stock model.
Aote: You must define a stock model before creating Horizontal Roughing and Plunge Roughing
operations. All other operations can be created without first creating a stock model.
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To create the stock:

1. Select Stock / Part Box Stock, or click Create/Load Stock Irom the Geom tab oI the Browser
and select Part Box Stock. (This tool is also available on the Stock tab oI the Browser.)

This option enables you to create a stock box that encloses all oI the part geometry (bounding
box).
2. In the Part Bounding Stock Box window, you can expand the bounding box by entering oIIset
values. Eor the purposes oI this exercise, do not enter any oIIsets. Click OK.

9HUVLRQ
49
3. The stock model is created. To display the stock, click the Stock tab oI the Browser. The stock is
displayed as a box over the part. Its color can be set in the Color Preferences.
1ip: Stock is used for simulation, and its displav involves data-intensive rendering. This can slow down
JisualMills performance. Therefore, we recommend turning off the stock displav when not needed.

4. II you don`t see the stock, make sure the Hide Stock toggle icon in the View bar is not pressed.


Note. A part box stock with :ero offsets is actuallv created automaticallv for vou when vou open the
Stock tab.
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Creating Tools
VisualMill supports numerous types oI milling and drilling tools. Eor each tool you can speciIy standard
APT parameters: diameter, corner radius, taper angle, Ilute length and tool length. Elute length is the
cutting length, and Tool Length is the total length oI the tool up to the tool holder. All deIined tools can
be viewed in the Tools tab oI the Browser. You can also save a set oI tools to an external Iolder that can
be loaded in other Iiles.

To create the roughing tool:

1. Select Tool / Create/Select Tool, or click the Create/Select Tool icon on the Tools tab oI the
Browser.

One tool has already been deIined Ior this model (CradMill1), and appears in the Corner
Radius Mill tab oI the Create/Select Tool window.

9HUVLRQ
51
2. In the Select/Create Tool window, click the Flat End Mill tab. Leave the deIault values as they
are and click Save as New Tool.

Aote: There are fewer tools available in JisualMill Basic.
The tool will be created and its name (FlatMill1, by deIault) will be displayed in the tool list.

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To create the pre-finishing tool:

1. In the Select/Create Tools window, click the Ball End Mill tab.
2. Again, accept the deIault tool parameters and click Save as New Tool.
You have created the BallMill1 tool that has a diameter oI 0.5 inches.

9HUVLRQ
53

To create the pencil trace tool:

Pencil tracing is usually perIormed with a bull nose tool with a smaller diameter than the pre-Iinish tool.
1. While still in the Ball End Mill tab, change the tool to 0.25 inches.
2. Change the tool name to BallMill2.
3. Click Save as New Tool.

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To create the finishing tool:

Einishing is typically perIormed using a ball mill with a diameter much smaller than that oI the pre-
Iinishing tool.
1. While still in the Ball End Mill tab, change the tool diameter to 0.125 inches.
2. Change the tool name to FineFinisher.
3. Click Save as New Tool.

4. Click OK to close the window.
9HUVLRQ
55
5. Now that all tools have been created, click the Tools tab in the Browser. All the tools are listed.

Aote: You can double-click on anv tool to open its definition window. This is an easv wav to make
changes, if needed.

To create the tool library:

You can save the tools in the list to a library, which can be accessed by Iuture Iiles.
1. Eirst, you can delete the corner radius tool that was supplied with the Iile. Right-click on it and
select Cut. You can also select it and press the Delete key.

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Now the lists contains only the Iour tools you have deIined.

2. A group oI tools can be saved to a library Iile Ior Iuture use. Select Tool / Save Tool Library or
click the icon in the Tools tab oI the Browser.

3. In the deIault Iolder (should be Tutorials, which contains the part Iile), assign the name
Dumbells_Tools. The deIault extension is *.csv (comma-separated values), which means the Iile
can be opened and edited as a spreadsheet or in a text editor. Click Save.
4. Right-click on the Tools header in the Browser and select Delete All.

5. To replace the tools, select Tool / Load Tool Library. Select the *.csv Iile you just saved, and
the tools reappear in the Iile.

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57
Setting Feeds and Speeds
You can set toolpath Ieeds and speeds and customize these settings Ior later use.

You can assign values Ior the Iollowing:
Y Spindle Speed: The rotational speed oI the spindle, in RPM.
Y Plunge Feed: The vertical approach Ieed rate beIore the tool starts to engage in material.
Y Approach Feed: The pre-engage Ieed rate that prepares the tool just beIore it starts engaging
into material, as it starts cutting. These tool motions are dependent on the machining method.
Y Engage Feed: The Ieed rate as the tool starts engaging into material. By deIault this value is
75 oI the Cut Feed.
Y Cut Feed: The Ieed rate used when the tool is cutting.
Y Retract Feed: The Ieed rate as the tool stops cutting. By deIault, this is equal to Engage Feed.
Y Departure Feed: The post-engage Ieed rate that prepares the tool just as it stops cutting.
Y Transfer Feedrate: SpeciIies the Ieedrate oI transIer motions (air motions). You can either use
the Rapid setting oI the tool, or set a custom Ieed rate.
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Customizing Feeds and Speeds
You can customize the Ieeds and speeds based on the stock material, tool material, and operation type.
Then your settings can be saved to a Iile Ior Iuture use.
A deIault Ieed / speed table is in the FEEDSPEEDS Iile (no extension), located in the Data Iolder. You
can edit this Iile and then store your values in an ASCII external Iile. The Iormat Ior this Iile is shown
below:
TYPE
{
STOCK_MATERIAL TOOL_MATERIAL SURFACE_SPEED UNITS FEED/TOOTH UNITS MACHINABILITY UNITS
STOCK_MATERIAL TOOL_MATERIAL SURFACE_SPEED UNITS FEED/TOOTH UNITS MACHINABILITY UNITS
......
}

Example:
FaceMilling
{
aluminum-cast carbide 900 fpm 0.0200 in 4.0 ci/min/hp
aluminum-cast hss 650 fpm 0.0160 in 4.0 ci/min/hp
aluminum-plate carbide 900 fpm 0.0200 in 4.0 ci/min/hp
aluminum-plate hss 650 fpm 0.0160 in 4.0 ci/min/hp
}

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59
You can load values Irom this table by selecting Feeds/Speeds / Load Feeds/Speeds.

Type, Stock Material, and Tool Material are parameters in the external Iile. The Surface Speed and
Feed/Tooth values are calculated based on these Iields. Tool Diameter and # of Flutes are taken Irom
the currently active tool (iI any) and are used to calculate Spindle Speed and Cut Feed. By changing
parameters oI the active tool, you can use this window as a Ieed/speed calculator.
II you want to modiIy the current Cut, Engage, Retract, and Transfer Feeds based on these calculated
values, click Copy Computed Values to copy the values to the relevant Iields in the Set Feeds / Speeds
window.
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To set feeds and speeds:

1. Select Feeds/Speeds / Set Feeds/Speeds or click the icon on the Mops tab oI the Browser.

2. Leave the spindle speed as is and change the Cut Feed to 30 in/min. Set the Engage Feed and
Retract Feed to 20 in/min. Click OK.

These Ieeds and speeds will be used during the post-processing oI the toolpath.
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61
Status Bar
The Status Bar, located at the bottom oI the screen, is used to display inIormation about the current
activities.

The leIt-most Iield displays the current command and any prompts or help inIormation associated with
this command. II you place the cursor over an icon, its description will appear here.
The next Iield indicates the active tool, iI any. The name oI the tool, Iollowed by the diameter and corner
radius, is displayed.
The next Iield indicates the progression oI toolpath simulation ('Goto), displaying the number oI the
motion being simulated. When the simulation is complete, the last motion number will be displayed.
The icon Iields are snaps that can be toggled on and oII:
Grid Snap (snaps to grid points)
Ortho Snap (constrains lines to be horizontal or vertical)
Origin Point Snap (snaps to the origin)
End Point Snap
Mid Point Snap
Center Point Snap
Intersection Point Snap
Quad Point Snap (snaps to 0, 90, 180, and 270-degree points oI circles and arcs)
The second to last Iield displays the work units inches or mm.
The last Iield shows the current location oI the cursor as X, Y, Z coordinates. These values update as the
cursor moves.
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Creating the Horizontal Roughing Toolpath
In this type oI toolpath, VisualMill uses stock geometry and part geometry to determine the saIe
machining region at each user-speciIied Z level. The saIe machining region is the region in which the
tool can saIely traverse removing stock. Once this machining region is determined, a tool traversal
pattern such as a zigzag or oIIset machining cut pattern can then be applied to remove stock.
Aote: For 3 axis milling, vou can also create and activate regions that act as machining boundaries. An
example would be if vou wanted to machine onlv one surface, vou could define a region around that
surface so that no other areas will be milled.
Regions are curves that already exist in the model, or curves you create within VisualMill. In the Geom
tab oI the Browser, you will see that one region already exists in this Iile. Regions will not be used in
Tutorial 1, since they are not required Ior 3 axis milling. However, they are required Ior 2 axis milling,
so you will learn about them in Tutorial 2.

To create the horizontal roughing toolpath:

1. All you need Ior toolpath creation is Iound on the Mops tab oI the Browser. Eirst you must
activate the tool to be used. Select Tool / Create/Select Tool or click the icon on the Browser.

2. Select the Flat End Mill tab, pick FlatMill1 and click OK. FlatMill1 is now the active tool, and
is listed in the Status Bar.

9HUVLRQ
63
3. Select 3-Axis Milling / Horizontal Roughing, or click the Machining icon on the Browser, and
then select 3 Axis Machining / Horizontal Roughing.

The Horizontal Roughing window opens, in which you can set parameters Ior the toolpath.
4. Click the Cut Parameters tab. At the top oI the window are Global Parameters: Intol, Outol,
and Stock.

N Stock: The thickness oI the layer that will remain on top oI the part aIter the toolpath is
complete. Roughing operations generally leave a thin layer oI stock, but Ior Iinishing
operations this value is zero.
Intol and Outol are allowable deviations (tolerances) Irom the actual part geometry plus the
Stock layer (iI any).
N Intol: Inward tolerance - the maximum thickness oI material that can be removed Irom the
Stock layer.
N Outol: Outward tolerance - the maximum thickness oI material that can remain above the
Stock layer.
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5. Leave the Global Parameters as they are, but change the Cut Direction to Mixed. This enables
the tool to cut either up or down, so that the tool does not have to retract each time the direction
changes. Minimizing the number oI tool retractions creates a cleaner toolpath.

6. Click the Cut Levels tab and set the Bottom cut level to 0.0.

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7. Leave the remaining parameters in the other tabs as they are, and click Generate, located at the
bottom oI the window.
The window will disappear and an hourglass cursor will appear on the screen. When the
calculation is complete, the roughing toolpath will appear.

Aote: You can control the toolpath colors bv selecting Preferences / Color Preferences.
II the toolpath is not displayed, make sure Hide Toolpath is not selected.

In this toolpath there are so many cut levels that the display is too dense Ior you to decipher
much detail. It is helpIul to view the toolpath one level at a time.
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8. Click Display Next Z on the View bar. All Z levels are listed, and you can click the desired level
to see its tool movements.

9. Close the Z Level Display window.
10. Look in the Mops tab oI the Browser, where you can see the toolpath you just created.

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Simulation
The VCR commands are used Ior toolpath simulation. These commands can be Iound on the Stock tab
oI the Browser.

The VisualMill simulator enables you to view your toolpath in action, reIlecting what the actual model
would look like aIter machining. Simulation can also be used to catch errors.
The cut stock can also be visually compared with the part model to indicate any areas oI uncut or
overcut material.
Eor simulation to work, you must have stock geometry deIined, and the stock must be displayed.
Create/Load Stock: As you`ve already seen, this tool is used to create various types oI stock
material. Generally a stock is created automatically, depending on the type oI toolpath you create, but
you can always change the stock.
Simulate: The simulation will be run Ior the entire toolpath, and the end result oI the material
removal will be displayed.
Pauses: Stops the simulation.
Step: The simulation will be perIormed Ior a speciIied number oI toolpath motions. To set the step
value, open the Simulation Preferences (the last icon on the toolbar), and adjust the Maximum
Display Interval.
Step Z Levels: Shows the resultant stock aIter each Z level. This is applicable only Ior machining
methods that use multiple Z levels Ior machining, such as Horizontal Roughing and Pocketing.
Simulate to End: Jumps to the end oI the simulation.
Rewind: Jumps to the start oI the simulation.
Compare Part/Stock: PerIorms a visual comparison oI the stock model against the part model.
You can color-code areas based on the amount oI material remaining or overcut.
Simulation Settings: Opens the Simulation Preferences, in which you can set various properties
oI the simulation and display.
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Simulating the Horizontal Roughing Toolpath
Now that the Iirst toolpath has been created, you can simulate it.
There are two simulation models in VisualMill Voxel and Polygonal. The Voxel model is very Iast. It
uses a grid to represent the stock, so it can only be used
Ior 2 and 3 axis simulations (in which the bottom oI the part is squared oII). The Polygonal simulation
is a true simulation (uses the true stock shape), and may thereIore be slower than the Voxel model.

To simulate the toolpath:

1. Be sure you are using the Voxel Model. VeriIy this in Simulation Preferences.

2. To see how the stock looks aIter this toolpath, switch to the Stock tab. The part stock box is
displayed. The toolpath name is displayed with a red X, indicating that the simulation has not
been run.

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3. Highlight the toolpath and click Simulate.

Once the simulation is complete, the cut stock model will be displayed. This cut model can be
used as input stock geometry Ior simulating the toolpath oI subsequent machining operations.

Aote: You can also trv clicking Step simulation to view a set number of tool motions at one time, or Step
Z Levels to see levels removed one at a time.
1ips: You can change the color of the stock and cut stock bv selecting Preferences / Color Preferences
and clicking the color box for Cut Stock Color.
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The toolpath now has a 'simulation complete icon next to its name in the Stock tab.

Creating the Pre-Finish Toolpath
Once the roughing toolpath is generated, a pre-Iinish toolpath can be created to remove the steps leIt by
the roughing process, and to bring the stock closer to the part. There are several methods oI generating
pre-Iinishing toolpaths; in this exercise will use the Parallel Finishing method.

To create the pre-finish toolpath:

1. Return to the Mops tab.
2. Open the Select/Create Tools window, click the Ball End Mill tab, and select BallMill1. Click
OK to make this the active tool. (You could also double-click the tool name.)

3. Select 3 Axis Milling / Parallel Finishing.

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We will use all deIault settings except Ior the stock value. Pre-Iinishing is typically done so that
there is a uniIorm thickness oI stock leIt on the part, to be removed by the Iinal Iinish path.
4. In the Cut Parameters tab, enter 0.025 in the Stock Iield.

5. Click Generate to calculate the toolpath. This toolpath uses a linear zigzag pattern.

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To simulate the pre-finish toolpath:

1. Switch to the Stock tab. This toolpath needs to be simulated.

2. Click Simulate. The results show how the stock will look aIter the pre-Iinishing toolpath is run.


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Creating the Pencil Tracing Toolpath
Not available in JisualMill Basic. Basic users proceed to 'Creating the Finish Toolpath.`
In Pencil Tracing, VisualMill automatically determines all areas oI the part where a tool would have
more than one contact position. These areas are typically in valleys and corners. The tool is then moved
along these areas to remove material.
This is a very eIIicient method to stress-relieve corners and valleys beIore running a pre-Iinish toolpath.
It can also be used as a cleanup operation to remove scallops leIt in these areas aIter Iinishing
operations. Pencil tracing is typically perIormed with a ball end mill.

To create the pencil tracing toolpath:

1. Make BallMill2 the active tool.
2. Select 3 Axis Milling / Pencil Tracing.
3. In the Pencil Trace Cut Parameters tab, set Stock to 0.01. Leave all other parameters at their
deIault settings.

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4. Click Generate.

1ip: Pencil tracing is tvpicallv performed with ball end mills. If there are anv fillets in the model, make
sure that the pencil tool radius is slightlv larger than the maximum fillet radius. This ensures that the
tool will be driven along all of the fillet surfaces.
5. Switch to the Stock tab and simulate this toolpath. The pencil trace toolpath removes the scallops
along the valleys oI the part.

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Creating the Finish Toolpath
In Iinish machining, all oI the remaining stock is removed to create the Iinal net shape. This example
will use the Parallel Finishing method again.
Einish machining is almost always perIormed with a ball end mill. Here we will use the Iinal Iinish
tolerance as well as use a very Iine stepover value.

To create the finish toolpath:

1. Activate the FineFinisher ball end tool.
2. Select 3 Axis Machining / Parallel Finishing.
3. The parameters are already set to Iinish tolerances, but we will change a Iew items:
Change the Stock value Irom 0.025 (used in the previous toolpath) to 0.0. This leaves no layer oI
stock over the resulting part.
Change the Angle of Cuts to 90 degrees, relative to the previous pre-Iinish cuts. This will create
a better Iinish on the part.
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Change the Stepover Control value Irom 25 to 10 oI the tool diameter. This reduces the
distance between passes, making Ior a better Iinish.

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4. Click Generate.

5. Simulate.

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6. To veriIy that the resultant stock represents the Iinal part, click Compare Part/Stock.


7. You can set colors to represent the levels oI tolerance oI remaining material. When you click
Apply, the entire milled area should be colored in the zero range (0.033 to 0.33).

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8. Click the Tool tab in the Browser to see each tool, linked to the toolpath that uses it.

Post-Processing
Once the toolpath has been generated, it can be post-processed to a speciIic machine controller.
VisualMill Standard comes with a set oI post-processors to choose Irom. Each post-processor is
represented by an *.spm Iile, all oI which are located in the Posts Iolder under the VisualMill
installation Iolder.
You can post-process an individual toolpath, or all toolpaths at once. Eor an individual toolpath, right-
click on its name in the Mops tab oI the Browser and select Post. You can also click the Post Process
icon on the Mops tab oI the Browser.

The entire list oI toolpaths can be post-processed by right-clicking the root Iolder in the Mops tab and
selecting Post All.
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Set Post Options
Some post-processor options can be set by selecting Post Process / Set Post Options.

By deIault, VisualMill perIorms interactive post-processing. In other words, VisualMill launches the
post-processor and waits Ior the post-processor to complete. You can check Post Process in Batch
Mode to tell VisualMill not to wait Ior the completion oI the post-processor. You can also output the list
Iiles and display the selection dialog Ior each post processing operation.
During interactive post-processing, VisualMill launches a text editor to display the output Iile. By
deIault, Notepad is used, but you can speciIy a diIIerent program.
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Post Processor Generator
You can select Post Process / Post Processor Generator to edit post processor parameters, and set up
your own post-processors. Click a post processor to change or copy, and click Edit.

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The editable parameters can be Iound on the various tabs.

To create a new post-processor, deIine the parameters and click Save As. A new *.spm Iile will be
created in the Post Iolder.
You can also output the toolpath in an APT standard Cutter Location (CL) Iile. APT is a widely
accepted Numerical Control Machine standard. This CL Iile can then be used to create a machine
speciIic post-processed output through any oI the many commercially available APT post-processors.

To create the post-processed output:

In this exercise we will post-process all oI the toolpaths at once.
1. In the Mops tab, right-click on the root Iolder (Machining Operations) to open the popup
menu. Select Post All.

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2. Browse to the desired output directory and assign a Iile name Ior the output. The deIault
extension is *.nc. Then double-click on the post-processor you want to use (such as Fanuc 1).

3. When complete, the post output Iile will open in the deIault text editor (Notepad by deIault).
This Iile contains all the G-code Ior your toolpaths.
Aote: You can post individual toolpaths bv right-clicking on their name in the Mops tab and selecting
Post. The Post-Process icon on the Mops tab can also be used. To post multiple toolpaths, select each
toolpath while keeping Ctrl pressed, right-click, and select Post All.
Post-Processor Problems
II only two built in posts (APT CLS and Roland CAMM GL) are displayed in the selection dialog, then
your Post Iolder is not set correctly. Try the Iollowing:
1. Select Post Process / Set Post Options.
2. Click the Browse icon to change the Iolder where post-processor Iiles are located.
3. Select the Posts Iolder located in the VisualMill installation Iolder.
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II nothing happens when the toolpath is posted, try the Iollowing:
1. Select Post Process / Set Post Options.
2. Make sure Show Selection dialog when Post Processing is checked.
3. Make sure Post Process in Batch Mode is not selected.
4. Make sure Output Listing Files is not selected.
5. Post the machining operations, making sure you are browsing to the Post Iolder in the VisualMill
installation Iolder. Eor the output Iile at the bottom, make sure there is a valid Iile name (valid
path).
End of Tutorial 1!
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Tutorial 2: 2 Axis Milling Operations
This exercise uses the Iile spanner.vmp, located in the Tutorials Iolder. Use File / Open to load the
part. (There is also an Open Part File icon on the Geom tab oI the Browser.)

Aote: Tuturial 6 is a CAD exercise in which vou create this part from scratch within JisualMill.
This part is suitable Ior 2 axis milling because it is prismatic it is a straight extrusion oI curves in the
XY plane. The solid geometry is not actually necessary Ior programming this part, but it is helpIul when
visualizing the process.
The curves on and around the part are called regions. These are used Ior deIining milling limits, as you
will see later in this exercise. The regions are currently located on the same layer as the part, so they
have the same color as the part.
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Creating Tools and Stock
BeIore any operations can be perIormed, you must deIine the milling tools and the stock geometry.

To create the 2 axis milling tools:

1. Create and save the Iollowing three tools:
Elat end mill named Rougher with a diameter oI 0.5 inches
Elat end mill named Finisher with a diameter oI 0.25 inches
Ball end mill named Ball Rougher with a diameter oI 0.5 inches
2. Open the Tools tab oI the Browser to see the tools listed.

3. Right-click on the Tools header and select Information.

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This displays a table listing the properties oI all the tools you`ve deIined.

To create the stock:

1. Create a Box Stock.

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2. The dimensions oI the bounding box are automatically calculated. Change the height to 1.25
Irom 1.0, so that there will be 0.25 inches oI stock material above the part. Do not click OK yet.

3. The stock box is automatically located at the corner oI the bounding box, as you can see Irom the
calculated (Xc, Yc, Zc) coordinates above. This is the correct location, but Ior the sake oI the
tutorial, change the coordinates to (0,0,0).

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4. Click OK, and you now have a box that is the right size, but located in the wrong place. Open the
Stock tab to see the stock box. By deIault, the part is not displayed, so you cannot compare the
stock and part locations.

5. Open the Layer Manager and make the Default layer visible.

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You can now see that the stock and part do not coincide.

6. To locate the stock correctly, click Locate Part Within Stock on the Geom tab.

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7. Check Move Stock (so that the stock will move to meet the part) and Bottom so that the bottom
Iace oI the stock will align with the bottom Iace oI the part. Check Center to center the stock
about the part.

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8. Click OK to locate the stock correctly. II you display the part and rotate to see the bottom, you
can see how the stock is located.

Creating Regions
Regions are curves that already exist in your model, or curves you create within VisualMill, using the
Curve tools. Regions serve diIIerent purposes in 2 and 3 axis milling.
In 3 axis milling, regions are used, when necessary, to deIine the machining boundary. The center oI the
tool remains inside the region while Iollowing the contours oI the part. Eor example, iI you deIine a
region surrounding one surIace, only that surIace will be milled.
In 2 axis milling, however, regions determine the entire area to be milled. Part and stock geometry are
not considered, and the tool always moves at a Iixed Z level. ThereIore, regions act as the drive curves,
and their geometry is projected onto the stock.
Regions must be selected (activated) in order to be used in an operation. Creating a region does not
make it active; you must use one oI the Select Regions tools beIore creating the toolpath.
Aote: If a region is not defined for finishing operations, the part silhouette is automaticallv identified
and used as a containment region for the tool. For roughing operations, the stock geometrv determines
the constraints on the tool location.
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The Geometry Bar contains all the tools you need to create regions, in addition to other types oI
geometry. It is located to the right oI the graphics area. II you do not see this toolbar, select View /
Toolbars / Geometry Bar.

Each tool in the Iirst Iour categories (Points, Lines, Arcs, and Curves) is described below. (Toolbars
are shown rotated 90 degrees.)
Points

Point: Creates a point by selecting it on screen or entering its coordinates. Points are used as
reIerences Ior other region tools.
Mid Point: To create a point at the midpoint oI a line, click this icon and select the endpoints oI the
line.
Center Point: To create a point at the center oI a circle, click this icon and then select three points
oI the circle.
Point Grid: SpeciIy the number oI spaces between points in U and V, then select the opposite
corners oI the grid.
Bolt Circle: Creates a circular array oI points.
Points on Curve: Creates a speciIied number oI points evenly spaced along a selected line or curve.
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Lines

Line Segment: Creates a line by selecting two points.
Polygon/Polyline: Select the vertices oI the polygon. II you want to close the region, move the
cursor close to the start point oI the region and select it. Right-click to Iinish.
Rectangle: Creates a rectangle by selecting its opposite corners.
Rounded Rectangle: Creates a Iilleted rectangle; Iirst select the opposite point then set the
rounding radius.
Line at Angle: Creates a line at a set angle Irom a speciIied baseline.
Line from Mid Point: Creates a line that extends the same distance on either side oI a selected
point.
Tangent Line: Creates a line tangent to a curve or collinear to an existing line.
Normal Line: Creates a line perpendicular to a curve or line.
Line Tangent to 2 Curves: Creates a line tangent to two curves or a curve and a line.
Line Normal to 2 Curves: Creates a line normal to two curves or a curve and a line.
Line Tangent and Normal: Creates a line tangent to one object, and normal to another.
Arcs

Circle Center, Radius: Creates a circle by selecting its center and a point on the circumIerence.
Circle Start, Diameter: Creates a circle by selecting two opposite points (diameter endpoints).
3 Point Circle: Creates a circle by selecting three points on its circumIerence.
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Circle Tangent to 3: Creates a circle tangent to three objects.
Arc by Center, Start and Angle: Creates an arc by selecting the arc center, start point, and end
point.
Arc: Start, End and Point: Creates an arc by selecting its endpoints, then setting its radius.
3 Point Arc: Creates an arc by selecting the start point, a point on its circumIerence, and the
endpoint.
Curves

Text: Creates a text string.
Spiral: Creates a Ilat coil.
Helix: Creates a 3D coil.
Single Flat Area Region: Creates a region bounding a single Ilat area.
All Flat Area Region: Creates bounding regions around each Ilat area.
Extract Edge Curves: Creates a region along a chain oI edges. This is useIul Ior creating a region
along the outer boundaries oI a surIace. Select one edge, and all edges in the chain are automatically
selected.
Bounding Region: Creates a rectangular region along the XY plane oI the part`s bounding box.
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To create the regions:

Because 2 axis milling does not relate to part or stock geometry, milling regions must be created to
deIine the machining boundaries.
There are Iour regions already deIined Ior the part. You can also see the regions in the Geom tab oI the
Browser (not available in JisualMill Basic). These regions are provided so that you can see the regions
that need to be deIined Ior the part. We will recreate them manually.
These regions are on the same layer as the part, and thereIore are the same color as the part and hard to
see. The Iirst step is to create a new layer Ior regions with a diIIerent color.
1. Open the Layer Manager, and click New Layer.

2. Rename the new layer 'Regions and assign both layers contrasting colors. Make the Regions
layer active, so that new geometry you create will be placed on that layer.

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3. Now the regions will be selected and placed on their correct layer. Click the drop-down arrow
next to the Select icon, and select Single. This is the deIault selection mode, in which you select
each object individually.

4. To select multiple objects, press the Ctrl key. Select all Iour curves.

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II you click on a point that belongs to more the one object, the Selections window will appear.
Scroll in this list to select the correct object, in this case the Curve (not Surface).

The Geom tab oI the Browser (not available in JisualMill Basic) displays all the curves as
selected. You can also click the items directly on this tab, using ShiIt or Ctrl, to select the
regions.

5. Now to place the curves on the correct layer. Select Edit / Properties, or click the Properties
icon.

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6. Select Regions Irom the Layer drop-down menu.

The curves now have the color you speciIied Ior the Regions layer.

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7. Select the Curves header in the Browser, right-click, and select Delete All Regions. (You could
also delete each curve individually by right-clicking and selecting Delete, or by dragging a curve
outside the Browser area.)

JisualMill Basic users Select the curves individually as beIore, and press the Delete key.
Aote: If vou need to redraw the displav, select Jiew / Repaint.
8. II the Geometry Bar is not displayed, select View / Toolbars / Geometry Bar. This toolbar
appears vertically to the right oI the screen.
9. In the Curves tab, click Single Flat Area Region.

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10. This creates a bounding curve around a Ilat surIace. Click the top Iace oI the part and a region is
created around it.

11. In the same tab (Curves), select Extract Edge Curves.

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12. With this option, you can select one edge and the entire chain oI edges is selected. Use this to
create regions around the chain oI edges shown below.

Aote: If vou click a curve that results in the wrong chain being created, use Undo and trv again,
selecting a different curve.
13. The next region is along the circular hole. In the Arcs tab, click 3 Point Circle.

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14. Select any three points along the top circle to create this region.

15. The Iinal region is a rectangle surrounding the part. In the Curves tab, select Bounding Region.

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16. Because the region should extend slightly past the part extents, enter X and Y oIIsets oI 0.35
inches.

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17. Click OK to create the rectangular region.

Selecting Regions
Once regions are created in the model, you must select (activate) the regions you want to use in the
subsequent toolpath.
Region selection tools can be accessed Irom the Select Regions icon. These tools are also available in
the Mops tab.

When selected, a region turns black. Note that any selected regions remain active until deselected, so
when you want to activate diIIerent regions be sure to deselect any you do not want.
The Iollowing region tools are available:
Single: You can select existing regions by picking them manually. Multiple regions can be
selected by pressing Ctrl.
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Rectangle: Selects all regions within a deIined rectangle.
Polygon: Selects all regions within a deIined polygon.
All: Selects all regions deIined in the model.
None: Deselects any selected regions.
Multiple Regions
Multiple and nested regions can be selected, but not regions that intersect. When selecting more than one
region, keep the Ctrl key pressed.
Nested regions are handled according to the Iollowing rule: The tool will remain inside an outer region
and outside an inner region. A region within an inner region is considered to be an outer region. In the
Iollowing picture, the shaded areas are where the tool motions occur:

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Creating Toolpaths
Eour toolpaths will be created Facing to remove the top layer oI stock, Pocketing Ior the outer and
inner areas, and Profiling to Iinish the holes.

To create the facing toolpath:

1. The Iirst step is to activate the region you want to mill. Click Select in the Standard Bar.

Note. Single Select is alreadv active, so vou dont actuallv need to invoke this tool.
2. Pick the outermost rectangular region. It turns black when selected.

Aote: In the Regions section of the Geom Browser tab, vou can see what regions are selected. You can
also use the Browser to select and deselect regions.
3. Activate the Rougher tool.
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4. To get a better orientation oI how the part is located, open the CSYS Manager. Display the WCS
(world coordinate system), and assign it a diIIerent color iI the current color is hard to see.

You can now see that the top oI the part is at the Z0 level.

5. Select 2 Axis Milling / Pocketing.

Aote: Because this is supposed to be a facing toolpath, vou mav be wondering whv Facing wasnt
selected. We will demonstrate how to make changes later in the exercise.

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6. In the Roughing tab, check the Offset Cuts pattern, and select the Mixed cut direction.

7. In the Cut Levels tab, set the Total Cut Depth 0.25 (the depth oI the stock above the part).
Click Top and set it to 0.25 (remember, the top oI the part is Z0, so the top oI the stock is
Z0.25.
Set Rough Depth to 0.25 so that no Iinishing will be perIormed.
Set Rough Depth/Cut to 0.25 so that only one machining level will be used.

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8. Accept the other deIault parameters and click Generate. The pocketing toolpath is generated
within the deIined region.

9. In the Stock tab, simulate the pocketing toolpath.

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This mills to the level oI the part, removing the 0.25 inches above the part that was added to the
stock box. (You need to display the DeIault layer to see the part.)

To create the outside pocketing toolpath:

This Pocketing toolpath is similar to the one you just created, and uses the same tool.
1. Hide the stock and make sure the regions are displayed.
2. On the Mops tab oI the Browser, click Select Regions, and select Single (as beIore).

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3. Select the two outermost regions. To select multiple regions, keep the Ctrl key pressed. The tool
will move in the area between these two regions.

4. The Rougher tool should still be active. Select 2 Axis Milling / Pocketing.
The Cut Parameters tab should have the same parameters as beIore (Stock Offset and Mixed).
5. Click the Cut Levels tab, and enter the parameters as shown below. This will create a toolpath
Irom the top oI the part to the bottom, using Iour layers oI rough motions (0.25 x 4 1 Total
Cut Depth).

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6. Click Generate. The outer volume surrounding the part is removed.

7. Simulate the toolpath.

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Clearance Plane
The clearance plane is a horizontal plane (set Z level) Irom which the approach motions start and retract
motions end. AIter retracting, the tool moves rapidly along this plane to the position oI the next engage.
This plane is typically a certain saIe distance above the part geometry.
Clearance levels are set by clicking the Clearance Control button on the Mops tab.

By deIault (Automatic option), the clearance level is calculated by adding a saIety distance to the
highest point Iound on both part and stock geometry. This saIety distance is set to be the current tool
radius. You can set the clearance level to be a set distance Irom either the part or stock, or enter the
absolute Z level.

To create the inside pocketing toolpath:

This pocketing toolpath is almost identical to the outside pocketing, but uses a diIIerent tool and
diIIerent regions.
1. Activate the Ball Rougher tool.
2. Eor the regions, we want to select the two inner (hole) regions. Eirst, to deselect the current two
regions, click Select Regions on the Mops tab, and click Select None.

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3. You could use the Single method to select the inner regions (pressing Ctrl to select multiple
regions), but let`s use a diIIerent method. Use Select Inside Rectangle.

4. Select two points so that the rectangle completely encloses the desired regions. Objects must be
Iully enclosed by the rectangle in order to be selected.

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5. Create a Pocketing toolpath, changing only the Start Point parameter to Outside.

The inner pockets are milled.

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6. Turn oII the DeIault and Regions layers, so that only the toolpath is visible. You can see the
various diIIerent types oI motions. These are color-coded according to the table in Preferences /
Color Preferences check these colors iI there are motions you cannot see.

Engage motions extend vertically Irom the clearance plane down into the material.
Cut motions represent actual cutting oI material.
Retract motions extend vertically Irom the material up to the clearance plane.
Rapid motions are along the clearance plane. They are Iast because there is no danger oI
collision with material; the clearance plane is set a saIe distance above the stock.
Departure motions come beIore Retract motions, allowing the tool to exit the cut material
saIely.
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7. To change the clearance plane, double-click the Clearance Plane item in the Browser Ior this
toolpath.


8. Switch Irom the deIault Automatic to Part Max Z + Dist, and add 1.0 inch.

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9. Click OK. In the Browser, note that the Iolder icon Ior this toolpath is red instead oI yellow. This
indicates that a parameter has changed, and the toolpath needs to be regenerated.

10. Right-click on the toolpath name and select Generate.

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11. Display the part again. You can see the modiIied toolpath now uses a higher clearance plane.

12. Simulate this procedure to view the remaining stock. There is a very thin layer leIt at the bottom
oI the holes, because the tool is a ball tool.

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To create the inside profiling toolpath:

The Iinal toolpath will proIile the inner regions, to bring the stock closer to the desired part. These
regions should still be selected Irom their use in the previous toolpath.
1. Activate the Einisher tool.
2. Select 2 Axis Milling / Profiling.
3. In the Cut Levels tab, the parameters as shown. The Finish Depth/Cut value oI 1/8 means that
there will be 8 Iinishing levels.

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4. Click Generate. The proIiling toolpath mills around the inner holes.

Aote: If the toolpath appears on the wrong side of one of the regions, vou need to reverse the region
direction. Make sure the region in question (and onlv that region) is selected (black), and select Curve /
Reverse. Then regenerate the Profiling toolpath.
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5. Select Preferences / Color Preferences and change the Cut Stock color. This enables you to
see the results oI the toolpath you`re about to simulate.

6. Simulate the toolpath. You can see the proIiling results in the new color, bringing the cut stock
closer to the machining regions.

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Adjusting the Regions
You probably have noticed that the second Pocketing toolpath leIt an undesired piece oI stock
remaining at the end oI the part.

This is because the outer region is too close to the part. It was created with a 0.35 oIIset Irom the part,
but that does not leave enough space Ior the tool to mill suIIiciently around this curve.

To increase the region:

1. Select the outer region, making sure all the other regions are not selected.

2. Select Edit / Scale. This will scale all objects currently selected.
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3. In the Command Window, enter an X scale Iactor oI 1.05 and press Enter. (II you don`t see this
area, select View / Toolbars / Command Window.

4. Enter the same scale value Ior Y. Enter 0 Ior the Z Iactor.

5. Now that this region is slightly larger, the tool should have more room to move. Right-click on
the second Pocketing toolpath and select Generate.

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6. Simulate to see that the piece oI stock is now removed.

Replacing the First Toolpath
JisualMill Basic users proceed to 'Modifving Toolpath Parameters.`
As mentioned above, the Iirst toolpath was created as Pocketing, although it was supposed to be
Facing. (The results are the same, but this step illustrates how to delete and replace toolpaths.)

To replace the toolpath:

1. In the Mops tab oI the Browser, select the Iirst Pocketing toolpath and press the Delete key.
Then highlight the Machining Operations header so that the next toolpath will be created under
it (i.e. Iirst in the list).

2. Activate the Rougher tool.
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3. Select only the outer region, and make sure no other regions are selected.

4. Select 2 Axis Milling / Facing and enter the same parameters Ior Cut Levels as you did Ior the
original Pocketing toolpath.

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5. Generate the toolpath. It is placed Iirst on the list.

ModiIying Toolpath Parameters
Once a toolpath is created, you can go back and change any oI its parameters. This example will include
two simple changes to the inner pocketing toolpath.

To modify the toolpath parameters:

1. In the third (and last) Pocketing toolpath, double-click Regions.

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2. Choose Single Select.

3. Deselect the circular region. Now only one region (the long one) should be selected.

Note that the Regions icon Ior this toolpath has a red asterisk, indicating that the regions have
changed. The Iolder icon is also red.

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4. Now double-click Parameters Ior this toolpath.

5. Change the pattern to Linear Cuts. This changes the pattern Irom a spiral pattern to a series oI
parallel cuts.

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6. Click Generate. The modiIied toolpath is now only in one region, and has a linear pattern.

Toolpath Editing
Not available in JisualMill Basic. Basic users proceed to Tutorial 3.
Once a machining operation is created, the toolpath can be graphically edited and post-processor
commands can be added. The Toolpath Editor provides many useIul tools, a Iew oI which will be
demonstrated here.
The editing will be done on the same toolpath you just modiIied the pocketing on the inner region.
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To edit the toolpath:

1. Eirst, hide everything but the toolpath.

2. Double-click on the Toolpath icon in the Browser Ior this toolpath. This opens the Toolpath
Editor.

(Another way to open the Toolpath Editor is to click the icon on the Mops tab.)

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The Toolpath Editor opens to the right oI the screen. You can move it by dragging one oI its
corners. Each line is a line oI the G-code that will be sent to the machine. At the bottom is the
operation name, number oI GOTO`s (tool motions), and estimated machining time.

3. Place the cursor in one oI the numbered lines, and use the arrows to move up or down. Eor the
lines that represent tool motion, the tool will appear to indicate how it moves on that particular
line.

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4. We will now change some oI the movements. Click Rectangle Select Motions.

5. Click two points to deIine a rectangle that encloses some oI the tool motions.

6. All oI the motions, and portions oI motions, within the rectangle are selected. Click Cut Selected
Motions.

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The motions inside the rectangle are deleted, and engage / retract motions are added to
accommodate the new toolpath.

7. To restore the toolpath, click Toolpath Edit Undo. (You can also regenerate the toolpath using
the Browser.)

8. Draw another rectangle to select tool motions in the center oI the toolpath.

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9. Click Isolate Selected Motions

All motions other than those selected are deleted.

10. Restore the toolpath, and use another rectangle to select motions near the top.

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11. Click Move Selected Motions in Z.

12. Move all selected motions up by a DeltaZ oI 1.0.

The selected motions move up by 1 inch.

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13. Restore again, and click Transform Toolpath. This tool enables you to move, rotate, or scale
the toolpath, and optionally make copies oI it.

14. Click the Rotate tab, and rotate the toolpath 90 degrees about the Z axis. Click OK.


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The toolpath rotates 90 degrees.

The Iinal editing we will demonstrate is instancing. This means creating multiple copies oI a
toolpath, either in an XY array or in Z levels.
15. Restore the toolpath and click Instance in XY.

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16. Eor the array, speciIy an X and Y spacing and numbers in X and Y as shown below. (This uses
the Spaced method; in the Fitted method you Iit a number oI copies evenly in a speciIied total
distance.)

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17. Click OK, and there are now six toolpaths. You will probably have to zoom out to see them all,
or use Fit View.

End of Tutorial 2!
(Obviously you wouldn`t leave your toolpaths in this condition, but we`ll assume it`s OK Ior the
purposes oI the tutorial.)


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Tutorial 3: Drilling Operations
This exercise will help you understand and use the drilling module in VisualMill. The Iollowing types oI
drilling operations are available:
Drill: Standard, Deep, Break chip, Counter Sink
Tap: Clockwise, Counter Clockwise
Bore: Drag, No Drag, Manual
Reverse Bore

To set up the file:

1. Load the part Iile, RouterBitHolder.vmp.

2. Create another layer in which you can place the circular regions that are included with this Iile.
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3. To select only the regions, you can use the Selection Mask to determine which types oI objects
can be selected. Click Selection Masks.

4. Click the Seletable Types tab, and deselect Mesh. This will prevent surIaces Irom being
selected.

5. Click the Select Regions tool, and select Rectangle.

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6. In Top view, select two points that deIine a rectangle that encloses all circles.

7. Open the Properties, and move these circles to the Regions layer.

8. At this point, you should reset the selection option to Single. Otherwise every click you make
will be part oI a selection rectangle.
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9. Because you can select drill holes by size, click Measure Arc Radius, located on the
Measurement Bar, to determine the size oI the holes.

10. Click one oI the larger holes.

The diameter (0.5 inch) is listed in the Command Window.

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To drill the larger holes:

1. Click the Tools tab in the Browser. There are several tools that have already been created in this
Iile. The Iirst two (drill tools) have already been used in toolpaths.

2. Double-click on DrillTool1 to open the window in which it was created. This is one way to
veriIy and edit a tool`s parameters.

3. Double-click on the tool name, or click OK, to activate DrillTool1.
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4. Look in the Mops tab now to see the two drilling toolpaths that have already been created.
StandardDrill1 creates the larger holes.

StandardDrill2 creates the smaller holes.

5. Delete both oI these toolpaths; they will be recreated.
6. All oI the large holes are to be selected Iirst. Select Hole Machining / Select Holes.

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7. Because you measured the large holes, you can speciIy the radius oI holes to select. The diameter
is 0.5, so enter 0.25 into the Minimum Radius and Maximum Radius Iields. Click OK.

The Iour rows oI large holes are selected.

Aote: You could also have selected these holes in the Geom tab of the Browser, bv using Shift to select
multiple curves.
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8. Select Drilling / Drilling, or Hole Machining / Drilling on the Mops tab.

9. The Drilling window appears, in which you can set Cut, Engage / Retract, and Hole Sort
parameters. This window can be used to perIorm Standard, Deep, Break Chip or Counter
Sink drilling. Eor now, leave the parameters at their deIault values. The drilling depth should be
0.5.

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10. Click Generate.

11. II the drill is to enter the stock Irom a higher level, the clearance plane needs to be changed.
Double-click the Clearance Plane item in the Mops tab under this toolpath, and set an Absolute
Z Value oI 1.0. (You can see that the WCS lies at the top oI the part, so the clearance plane will
be 1 above the part.)

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12. Click Generate. The approach motions now start 1 above the part.

To drill the smaller holes:

1. Activate the smaller tool - DrillTool2. This tool has a diameter oI 0.25 inches.
2. Deselect the selected circles.
3. Open the Select Holes window again. The settings still reIlect those Ior the larger holes. The
smaller holes do not have to be measured; you can determine their dimensions by selecting one
on screen. Click the Select (arrow) button next to Minimum Radius.

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4. The Select Holes window is minimized, and you can click one oI the smaller holes.

The calculated radius (0.125) is displayed in the Minimum Radius Iield.

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5. Repeat the process to set the Maximum Radius. Click OK.

Now the three rows oI small holes are selected.

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6. Generate another Drilling toolpath, with the same parameters as beIore, on these holes. The
clearance plane is the same as the previous toolpath.

7. Click the Parameters item Ior this second drilling toolpath, and open the Sort Holes tab. These
Iields enable you to determine the order in which the holes are drilled. Click Sort Points and set
a Zigzag cut pattern.

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8. Generate again, and the holes are now drilling in a diIIerent order.

9. Simulate both toolpaths.


You can proceed to use the same part to generate Tap, Bore and Reverse Bore toolpaths.
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Tutorial 4: 4
WK
Axis Machining Operations
Not available in JisualMill Basic
Creating Fourth Axis Toolpaths
This exercise uses Iourth axis machining operations to machine a two-sided part. Eourth axis machining
is considerably more complex than 2 and 3 axis machining, and requires thorough understanding oI
the machining process. You should be very Iamiliar with aspects oI 3 axis milling beIore working this
exercise.
Load the part Iile Flashlight.vmp. Change the colors and add a layer Ior regions, iI you want.

Cutting Strategy
This part cannot be completely machined using only one set oI 3 axis operations. We will divide the part
geometry into two sections, by creating a parting plane through the middle oI the part. Then we will cut
the top halI Iirst, Ilip the part over and cut the bottom halI.
We Iirst need to determine how the part will be held in the machine. In this exercise we will hold the
part so that the axis oI the part geometry is aligned with the X axis oI the machine coordinate system.

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We next need to determine which areas oI the part will not be machined. Some areas oI the part must
remain un-machined to prevent the part Irom 'Ialling out oI the stock material. In addition, iI there is
not suIIicient material joining the part to the raw stock material, the part may move during machining.
In this exercise we will initially keep the ends oI the part in the stock geometry. These ends will have to
be cut away aIterward to obtain the Iinal Iinished model.

Measurement Bar
One oI the steps in the next part oI this tutorial is to measure the part. Measuring tools can be Iound on
the Measure menu and on the Measurement bar (View / Toolbars / Measurement).

When a measurement is calculated, it is displayed in the bar at the top oI the screen.

Vertex Coordinates: Displays XYZ coordinates oI a selected point.
Measure Distance: Measures the distance between two points. The point coordinates and the
distance between them will be displayed.
Measure 3 Vertex Radius: Measures the radius oI an arc spanning 3 points. The point coordinates
and their arc radius will be displayed, and the arc will appear temporarily.
Measure Arc Radius: Measures the radius oI an arc or circle.
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Part Bounding Box: Calculates the dimensions oI the bounding box around the part.
Part Center: Calculates the coordinates oI the center oI the part.

Setting the Machine Zero
Eor parts be machined using the rotary axis, it is recommended that the machine zero be located on the
axis oI rotation oI the part geometry.

To set the machine zero:

10. Eirst, click Part Center in the Measurement Bar to veriIy that the part is centered at the WCS
origin.

You can see that the part is centered in all directions.

11. The next step is to locate the MCYC (machining coordinate system). In this case, you can see
that the MCS and WCS are already coincident, but it`s good to see how this is done. Click Set
Machining CSYS in the Mops tab.

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12. Select Set to Part Box, Highest Z, and Center. This places the MCS above the center oI the
part, not where it belongs. Do not click OK yet.

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13. Now select Set to Stock Box, Mid Z, and Center. The MSC is back with the WCS. Click OK.

In the Mops tab, the MCS operation is now listed.

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Setting the Rotation Axis
VisualMill assumes that the part is located on a rotating table, and that the table can rotate about either
the X (A) axis or the Y (B) axis. You need to speciIy the rotation axis and the rotation center point. It is
recommended to align the machine`s rotation axis with the natural rotation axis oI the part.

To set the rotation axis and center:

1. Click Setup Machine in the Mops tab. You can also click the Machine Setup header in the list.

2. Select the 4 Axis, and speciIy the X Axis as the rotary axis. This is the axis along the length oI
the Ilashlight the axis about which the tool should rotate.


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Creating the Parting Region
We will Iirst use 3 axis operations to rough this part, in which the tool can only move in the Z direction.
Eor parts like this, objects should be divided into top and bottom sections. Then the top halI can be
milled, Iollowed by the bottom halI. A region should be deIined so that tool motions will not extend past
the two ends oI the Ilashlight.

To create the parting region:

There are several ways to create this region. This method will use the grid, though other options will be
mentioned as well.
1. Click Display Grid. It passes through the X-Y plane oI the WCS. The grid represents the current
construction plane (CPlane).

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2. Switch to Top view. You can see the red and green grid lines, representing the axis lines oI the
CPlane. The Y axis does not quite coincide with the WCS Y axis.

3. To move the grid so that it is centered on the part, click CPlane and select CPlane Origin.


4. Eor the origin point, type in 0,0,0 which appears in the Command Window.

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The grid is now centered along the part; the grid axes coincide with the WCS (and MCS).

5. The grid spacing needs to be changed so that there will be vertical (Y Axis) grid lines Ilush with
the ends oI the part. Eirst the part needs to be measured. Click Part Bounding Box in the
Measurement Bar.

According to the results in the Command Window, the length oI the Ilashlight is 5.625.

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6. Select Preferences / Grid Preferences.

7. Change the spacing to 0.3125 this gives an even spacing over 5.625 inches. Change the grid
extents as well so that the grid doesn`t extend so Iar past the part.

The revised grid should look like this, with vertical lines Ilush with the ends oI the Ilashlight.

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8. To create the region, click Lines tab oI the Geometry Bar, and click Rectangle.

9. On the lower right toolbar, make sure Grid Snap is turned on. II it is grayed out, click it to
activate it.

10. Click the two points shown to deIine opposite ends oI the rectangle.

11. Hide the grid so that the region will be visible.

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12. Rotate the model to an isometric view; you can see that the region passes through the XY plane
oI the WCS.

There are other ways you could have created this region. Eor instance, you could use the Curves / Part
Box Bounding Region tool, speciIying a non-zero Y oIIset. Or you could create a bounding region with
zero oIIsets, and scale it in the Y direction.
Creating 3 Axis Roughing Toolpaths
The toolpaths can now be created. The strategy is to Iirst rough the top halI oI the part, then rotate the
table180 degrees to expose the bottom halI. The bottom halI will be roughed, and then Iinish operations
will be perIormed.

To create the roughing toolpath for the top half:

1. Open the Tools tab. This Iile already contains two tools a / ball mill and a Ilat mill.
Activate ElatMill1.

2. II necessary, reset the Clearance Plane to Automatic.
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3. Select 3-Axis Milling / Horizontal Roughing. In the Cut Parameters tab, select Part Offset
and Conventional.

4. Eor Cut Levels, set Bottom to zero so that the machining stops at the parting region.

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5. Click Generate to rough the top part.

6. Simulate the machining so Iar.

Now the part needs to be Ilipped, to expose the bottom halI. This will be done by rotating the
table 180 degrees. In VisualMill, this is done as a machining operation.
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To rotate the table:

7. Select 4
WK
Axis Milling / Rotate Table, or use the 4
WK
Axis icon on the Mops tab.

8. Enter a rotation angle oI 180 degrees.

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9. Click Generate. A Rotate Table machining operation appears in the Mops tab. The MCS has
Ilipped the Z axis now points downward.

Aote: The displav of the part does not change as a result of the table rotation. In realitv, however, the
machine would have turned the table.

To create the roughing toolpath for the bottom half:

Because the roughing Ior the bottom halI will have the same parameters as the roughing Ior the top halI,
we can copy and paste the toolpath.
1. AIter the Rotate Table operation, create another Horizontal Roughing toolpath with the same
parameters as the previous one. The toolpath is created on the underside oI the Ilashlight.


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Since VisualMill does not actually alter the part geometry in the display aIter the Rotate Table
operation, this is how you know the correct side is being machined.
2. Simulate this second toolpath. Assuming you are still running the Voxel simulation model, you
will receive a message that rotated toolpaths cannot be handled. Click Yes to switch to the
Polygonal simulation model, which means you will have to simulate all toolpaths Irom the
beginning.

Aote: As described earlier, the standard JisualMill product has two material removal simulation modes
(or models). The Joxel model can onlv be used for 2/ and 3 axis toolpaths. The main advantage of this
model is verv rapid processing times. The Polygonal model is necessarv for simulating all 4
WK
axis
toolpaths. This model is more comprehensive and results in better displav qualitv, at the expense of
speed.
The Stock tab shows that both toolpaths need to be simulated.

3. Simulate both roughing toolpaths.

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4. Click Simulation Settings to see that the model has been changed to Polygonal.


Creating 4
WK
Axis Indexed Mode Finishing Operations
Once the rough machining is perIormed, you have the option oI Iinishing the part in either indexed
(locked table) or continuous (tool motions normal to table rotation) 4
WK
axis mode.
Eor roughing, the recommended method is always indexed mode. When the table is in a locked position,
as it is during indexed mode machining, it is at a much more rigid state. This allows Ior heItier cuts and
thereIore higher rates oI material removal.
Indexed mode Iinishing can be used iI all Ieatures oI the part can be accessed completely during this
type oI machining. II any Ieatures are completely or partially inaccessible to the tool during indexed
mode machining, the machining will be incomplete and you should use continuous machining. We will
examine both methods, starting with indexed mode.
Remember that the rotation table is already at an indexed position oI 180 degrees. So we will Iirst Iinish
the bottom halI, and then the top halI.
Einish machining can be perIormed by Parallel Finishing machining.

To create the finish toolpaths for both halves:

1. Deselect all regions. (The Parallel Finishing method will automatically detect parting planes, as
well as the extents oI part geometry.)

2. Activate the ball mill tool.
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3. Select 3 Axis Machining / Parallel Finishing. The parameters are already set to Iinish
tolerances. Set Stock thickness to 0, and speciIy Stepover 10 oI the tool diameter.

4. Click Generate. The toolpath is created on the bottom halI.

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5. To Ilip the table back, create another Rotate Table operation, using a rotation angle oI 0
degrees. The MCS is now identical again to the WCS.

6. Create anothere Parallel Finish operation aIter the Rotate Table operation, and Generate it.
This time the top halI is machined.

7. Simulate these Iinish toolpaths.


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Note the ridge oI un-removed material at the parting plane. This is present because a ball end
mill tool was used.


To remove this ridge, the tool has to go below the parting plane by the length oI the tool radius. You
could also avoid this problem by using a Ilat end mill, but this might not be appropriate Ior Iinishing.
You could also use more than two table rotations, or use continuous mode Iinishing to remove the ridge.

As mentioned beIore, indexed mode Iinishing can be used eIIectively only iI all Ieatures can be accessed
completely, which is not exactly the case in this example.
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Creating 4
WK
Axis Continuous Mode Finishing Operation
In continuous machining, tool motions are always normal to the axis oI table rotation; the table rotates
constantly rather than Ilipped once or twice. This type oI machining is especially suitable Ior machining
jewelry such as rings and bracelets. Roughing operations should still use indexed mode.

To create the continuous finishing operation:

1. The last two Iinishing operations should be deleted, leaving the Rotate Table that was between
them. You can use Ctrl to select them both, then press the Delete key.

2. Select the last Rotate Table operation, so that the new Iinish toolpath will be created aIter it.

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3. Select 4
WK
Axis / 4
WK
Axis Parallel Finishing. In the Cut Parameters tab, make sure the
remaining Stock thickness 0. Other parameters are calculated automatically.

4. In the Step Control tab, enter 10 oI the tool diameter.

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5. Click Generate. Because this is such a Iine toolpath, it may take a Iew minutes to complete.

6. Simulate this toolpath. The result is very close to the part, and no ridges are leIt behind.

Aote: This method does not relv on regions for containing the tool. Regions are inherentlv 3 axis in
nature and are meaningless in 4
WK
axis machining. However, containment of the tool can still be
accomplished bv limiting the angle of rotation or the length of travel. These values are set in the Cut
Pattern section of the Cut Parameters tab of the dialog.
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Tutorial 5: 5
WK
Axis Machining Operations
Not available in JisualMill Basic
EiIth axis machining enables you to change tool direction relative to any set oI axes.
Load the part Iile 5Axis.vmp. There are already two layers in the Iile (one Ior regions), and the WCS
and initial MCS are at the lower back leIt corner.




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Setting the Construction Plane and MCS
Milling has to be done in three sets oI axes one Ior the sloped top Iace, and one Ior each oI the two
side Iaces. By changing the CPlane (construction plane), you can easily change the MCS (Machining
Coordinate System).

To set the MCS to the top face:

7. Eirst, display the grid. The grid is used to visualize the current CPlane, and to create geometry (iI
you want to use grid snaps). Initially, the CPlane is along the Iront Iace oI the part.

8. We will make a new coordinate system based on this plane, which we can use later to change the
MCS. Erom the CPlane drop-down menu, select CSYS from CPlane.

9. Assign a name Ior this coordinate system, such as 'Eront Eace.

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The new CSYS is placed on the Iront Iace (the X-Y plane coincides with the Iace). II you open
the CSYS Manager, you can see three coordinate systems, ErontEace, MCS, and WCS.

10. Now to change the CPlane to coincide with the top Iace. Select CPlane by 3 Points.

11. The Iirst point sets the origin, the second sets the direction oI the X axis, and the third sets the Y
axis. Select the points in the order shown below. The Endpoint snap must be active (it should be
by deIault).

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The grid appears along the new CPlane. You can adjust the spacing and extents by selecting
Preferences / Grid Preferences.

12. In the Mops tab, select Set MCS.

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13. Check With Construction Grid to set the machining axes relative to the top Iace.

The MCS has moved to the top Iace, with the X-Y plane coincident with this Iace.

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Machining the Top Face
Now that the MCS is oriented correctly, the top Iace can be machined. Eirst the pocket will be roughed
out, then a Iacing operation will be applied to the top Iace, then the hole will be pocketed.

To machine the top face:

1. Activate the ElatMill1 tool (0.5 diameter).
2. Create a 3-axis Horizontal Roughing toolpath. In the Cut Levels tab set the Bottom level to 0.5
this is the depth oI the pocket. Accept all other deIault parameters.

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3. Generate.

4. The next toolpath is 2.5 axis, so regions must be deIined. Use Single select to select the outer
boundary oI the top Iace.

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5. Create a 2.5 axis Eacing toolpath, setting the Total Cut Depth to 0.

6. Generate.

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7. Eor the pocketing toolpath, select both the inner rectangular region and the circular region.

8. Activate the ElatMill2 tool (0.25 diameter) and create a 2.5 axis Pocketing toolpath, setting the
Total Cut Depth to 1 (the depth oI the pocket).

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9. Generate.

10. Simulate the three toolpaths created so Iar.

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Machining the Side Face
In this section, the MCS will be changed to the side Iace, and two more toolpaths will be added.

To machine the side face:

1. Use CPlane 3 Points again to change the construction plane to the side Iace.

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2. Set the MCS to the new CPlane


3. Select the outer region oI this Iace.

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4. Using ElatMill1, create a Eacing toolpath with the same parameters as beIore.

5. Select the inner region.

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6. Using ElatMill2, create a Pocketing toolpath, with the same parameters as beIore.

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Machining the Front Face
In this section, the MCS will be changed once again, and the same 2.5 axis toolpaths will be applied.

To machine the front face:

1. Because there is already a CSYS Ior this Iace (the one you created called ErontEace), there is no
need to move the CPlane. Select Set MCS, check With Coordinate System, and select
ErontEace.

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The MCS is now coincident with ErontEace.

2. Create the Eacing toolpath as beIore, using the outer region oI this Iace.

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3. Create the Pocketing toolpath as beIore, using the inner region.

4. Simulate all the toolpaths. The tool switches orientation Irom Iace to Iace, in order to machine
each Iace at the correct angle.


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Tutorial 6: CAD
As you have seen, you can import a ready-made part into VisualMill. II you want to create your own
part Irom scratch Irom within VisualMill, the Geometry Bar contains all the CAD tools you need.
In this exercise, you will create a part identical to the spanner used in Tutorial 2.

Setting up and Creating ReIerence Points
The spanner will be created based on the location oI several reIerence points. The grid will be used to
create these points.

To set the grid and create reference points:

1. Start a new Iile, switch to Top view, and display the grid. The deIault grid spacing, assuming you
are working in inches, is 1.

2. Select Preferences / Grid Preferences and change the spacing to 0.5.

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3. To create geometry with respect to the grid, you must be able to snap to grid points. In the lower
right part oI the screen, make sure Grid Snap is activated.

4. As you`ve already seen in previous exercises, all geometry tools are in the Geometry Bar,
located by deIault on the right side oI the screen. In the Points category, click Point.


5. Place the Iirst point at the origin.

6. Place the second point 2.5 to the right oI the origin. This is Iive grid lines away, or you can look
at the cursor location indicator at the lower right corner.

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7. Place two more points at 5 and 7 to the right oI the origin.

8. Hide the grid and all coordinate systems, and you should be leIt with Iour points.

Creating the Inner Cutouts
The two inner cutouts will be created using circles and lines.

To create the inner cutouts:

1. Switch to the Arcs category and select Circle Center and Radius.

2. Eor the center point, pick the last point.

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3. Enter 0.75 Ior the radius and press Enter.

The circle is created at the last point.

4. Use the same tool to create two 0.5 radius circles at the middle two points.

5. Erom the Lines category, select Line Segment.

6. Because these lines will be based on quadrant points oI the smaller circles, make sure the
Quadrant Point Snap is active.

7. Create one line between the top quadrant points oI the smaller circles.

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8. Repeat Ior the lower quadrant points.

9. To complete the leIt cutout, the circles must be trimmed. Open the Edit Curves category and
select Trim Curve.

10. Click the portion oI the circle you want to delete.

11. Repeat Ior the circle portion on the other side.

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OIIseting and Extending Curves
In this section the right section oI the spanner will be completed.

To finish this section of the spanner:

1. While still in Edit Curves, select Offset Curve.

2. Click one oI the horizontal lines.

3. A preview line should appear, indicating the assumed oIIset direction. Enter 0.75 (or 0.75) in
order to oIIset the line outward. II you create the oIIset line in the wrong direction, press Undo
and try the opposite direction.

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4. Use this method to oIIset both horizontal lines.

5. Create a circle using the same center point as the existing circle, using a radius oI 1.25.

6. To modiIy the oIIset lines so that they meet the large circle, click Extend Curve.

7. Click one oI the oIIset lines.

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The line extends to the point where it meets the circle.

8. Repeat Ior the other oIIset line.

9. Now use Trim Curve to trim the large circle where it meets the two extended oIIset lines.

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ChamIering and Mirroring
In this section the leIt section oI the spanner will be completed.

To finish this section of the spanner:

1. The next object is the arc at the end oI the spanner. In the Arcs category, select Arc: Center,
Start, Angle.

2. Eor the center point, select the Iirst oI the construction point (the origin).

3. Eor the start point, enter the point directly above the center: (0, 1.25, 0).

4. Next you can enter the end point or speciIy the angle. Type 180 Ior the angle.

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The arc is created in the proper direction.

5. The next object is a rectangle, but this requires a reIerence point be created Iirst. Erom the Points
category select Point.

6. Enter the Iollowing coordinates, placing the point directly above the arc center.


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7. Now select Rectangle Irom the Lines category.

8. Eor the corner points, select the reIerence point and the endpoint oI the oIIset line.

9. This rectangle is one object one multi-segmented curve. Its only endpoint is at Point 1. In order
to be able to edit or modiIy this rectangle, it must be broken into individual lines. Erom Edit
Curves, select Explode.


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10. Click the rectangle, and now each oI its lines has endpoints. Each line is now a separate object.

11. While still in Edit Curves, select Fillet Curves.

12. II the deIault Iillet radius is 0.5, you can press Enter to accept it. II the radius is another value,
type 0.5.

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13. Select the two lines shown, to create a 0.5 Iillet at the indicated corner.


14. Erom Arcs, select Arc: Center, Start, Angle.

15. Eor the center and start points, select Points 1 and 2, respectively.

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16. Enter an angle oI 90 to create an arc in the top right corner oI the rectangle.


17. Use Trim Curve to obtain the shape shown below.

18. You should be in Single select mode. Select the Iour curves shown below, pressing Ctrl to select
multiple objects.

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19. Select Edit / Mirror. (You can also right-click and select Mirror Irom the local menu). Eor the
Mirror Plane, select XZ Plane. Eor Point (P), leave it as Origin, since the origin lies on the
centerline oI this part. Einally, check Create Copy, and press OK.

20. The curves are mirrored to the other side oI the spanner.

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Creating SurIaces
In this Iinal section, the curves will be used to create the surIaces oI the part.

To create the spanner surfaces:

1. You can create surIaces Irom separate, connected curves, but it is easiest to merge the curves
Iirst so that you only have to pick one object. In the Edit Curves category, select 1oin Two or
More Curves.

2. Use Ctrl to select the Iour curves oI the cutout shown below. Right-click to Iinish the selection,
and the curves are joined into one curve (polyline).

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3. Another way to merge curves is to chain them. Select Chain Curves.

4. Select any oI the outer curves, and the entire chain is identiIied and joined into one polyline.

5. Now the curves can be easily made into surIaces. Erom the Surfaces category, select Extrude
Surface from Curves.

6. Select the outer chain and right-click. Eor the extrusion distance, accept the deIault oI 1.0.

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Orbit to an isometric view to see the surIace you created.

7. Extrude the two inner curves the same way. You can select both curves and extrude at the same
time. II the surIace is extruded the wrong way, undo the action and redo using a negative
extrusion distance.

8. Eor the bottom surIace, select Plane from Curves. This creates a planar surIace, with or without
islands.

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9. In Top view, select the three curves and right-click. This creates the bottom surIace oI the
spanner, with islands at the cutout curves.

10. The top surIace will be a copy oI the bottom surIace. Select the bottom surIace, right-click, and
select Move.

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11. Move Irom (0,0,0) to (0,0,1). Eor Number of Copies, enter 1.

12. Press OK to copy the surIace. The spanner is created, and is ready Ior 2.5 axis milling, as you did
in Tutorial 2.


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Additional Topics
Knowledge Base
Not available in JisualMill Basic
This powerIul Ieature makes "push button" programming a reality. You can save an entire machining
strategy speciIic to a certain class oI parts in a Knowledge Database or K-Base.
One application oI a K-base is Ior a Iamily oI parts, Ior which the same set oI tools and toolpaths would
be used. Another situation is in shop Iloor programming; experienced programmers can determine the
sequence oI operations to be used to machine a certain class oI parts and create a K-base Iile. Once these
K-base Iiles are thoroughly debugged, operators on the shop Iloor can then load and generate toolpaths
almost automatically. This speeds output and increases productivity oI the entire manuIacturing team,
resulting in dramatic cost savings Ior the manuIacturer.
A machining strategy can include both the sequence oI machining operations and speciIic parameters oI
each operation. To create a Knowledge Base, simply start creating machining operations. Re-order
toolpaths iI necessary, and select K-Base / Save K-Base. Parameters are saved to a *.vkb Iile. K-base
Iiles do not have associated toolpaths.
To load a K-Base, select K-Base / Load K-Base. Once loaded, select each oI the machining operations
in the Browser and create toolpaths based on the parameters saved in the K-base Iile.

Where to go Ior more help
In addition to the Ieatures described in this guide, VisualMill has many more Ieatures designed to make
it easier Ior you to create toolpaths and G-code. VisualMill`s complete on-line help provides reIerence
inIormation Ior each oI VisualMill`s Ieatures and Iunctions.
II you need additional help, or iI you have any questions regarding VisualMill, Iirst try the EAQ section
on our web site, www.mecsoIt.com. Most oI the common issues that users Iace are cataloged here. II
you still have additional questions, visit our Users Eorum at our web site to learn Irom other VisualMill
users. You can also contact us via e-mail at supportmecsoIt.com.