Delcam FeatureCAM 15.0 Reference Help 2-2

FeatureCAM 15.
Reference Help
By Delcam plc
Release Issue 1.0
Disclaimer
Delcam plc has no control over the use made of the software described in
this manual and cannot accept responsibility for any loss or damage
howsoever caused as a result of using the software. Users are advised that
all the results from the software should be checked by a competent
person, in accordance with good quality control procedures.
Information contained in this manual is subject to change without notice
and does not represent a commitment by Delcam plc. The software
described in this manual is furnished under licence agreement and may be
used or copied in accordance with the terms of such licence. No part of
this manual may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying and recording,
for any purpose without the express permission of Delcam plc.
Copyright 1995-2008 Delcam plc. All rights reserved
Acknowledgements
This documentation references a number of registered trademarks and
these are the property of their respective owners. For example, Microsoft
and Windows are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries.
Restricted Rights Legend
The Program and Program Materials are provided with Restricted
RIGHTS. Use, duplication, or disclosure by the United States
Government is subject to restrictions as set forth in subparagraph
(c)(1)(ii) of the Rights in Technical Data and Computer Software Clause
at DFARS 252.227-7013, Manufacturer is the Licensor: Delcam plc.
Permission to Copy for Licensed Users
Delcam plc grants permission for licensed users to print copies of this
manual or portions of this manual for personal use only. Schools that are
licensed to use FeatureCAM may make copies of this manual or portions
of this manual for students currently registered for classes where
FeatureCAM is used.
FeatureCAM Version: 15.0 Date: 23/12/2008 12:13
Contents
Import/Export
15
Importing files..............................................................................................15
Importing *.dwg, *.dxf files ................................................................17
Importing dimensions from *.dxf and *.dwg files ..............................18
Simplifying 3D AutoCAD data for 2D import....................................18
Importing ACIS files ...........................................................................19
Importing Parasolid files......................................................................19
Importing Autodesk Inventor files ......................................................20
Importing Solidworks files ..................................................................20
Importing Solidworks assemblies........................................................20
SolidWorks and Autodesk Inventor automatic hole recognition example
..............................................................................................................21
Inventor hole recognition.....................................................................23
SolidWorks hole recognition ...............................................................24
SolidEdge hole recognition..................................................................25
Importing Unigraphics files.................................................................25
Importing CATIA V4 files ..................................................................26
Importing CATIA V5 files ..................................................................27
Importing Pro/E files ...........................................................................27
Importing STEP files ...........................................................................27
Importing SolidEdge files....................................................................28
Importing STL .....................................................................................28
Importing DMT ...................................................................................28
Digitized data import/export options...................................................28
Format of digitized files.......................................................................29
Importing IGES files............................................................................29
Working with imported geometry .......................................................31
General Import/Export Options ...........................................................32
Import/Export Options.........................................................................34
SolidWorks Export settings .................................................................34
AutoCAD Export settings....................................................................36
Exporting files..............................................................................................37
Exporting DXF and DWG files ...........................................................37
Exporting IGES Files...........................................................................38
Save STL dialog ..................................................................................38
FeatureCAM 15.0 Reference Help
Contents i
Import/Export Options.........................................................................39
Generating/simulating toolpaths
40
Simulating parts ...........................................................................................40

Interaction between viewing and simulation ...............................................41
How to generate toolpaths ...........................................................................41
Using simulation video-style controls .........................................................42
Pausing a toolpath simulation ......................................................................43
Region of interest.........................................................................................43
Preview simulation button ...........................................................................44
Part Compare ...............................................................................................45
Part compare example..................................................................................46
Simulation options .......................................................................................47
General simulation options ..................................................................47
2D/3D simulation options....................................................................49
Centerline simulation options ..............................................................52
Rapidcut conversion tolerance.............................................................54
Part compare rest material ...................................................................54
Target part tessellation tolerance .........................................................55
Wire simulation options.......................................................................56
Simulating 3D toolpaths ..............................................................................56
Mixing 3D simulation and rapidcut.............................................................57
Detecting gouges..........................................................................................58
Fixture and clamp collision detection..........................................................59
Simulating multiple setups...........................................................................59
Manufacturing errors ...................................................................................60
Tool load ......................................................................................................61
Power graph sample/min .............................................................................62
Part documentation
63
Manufacturing reports..................................................................................63
Reports .................................................................................................63
Operation List ......................................................................................64
Manufacturing tool detail sheet ...........................................................65
Changing the fonts for the reports in the Manufacturing Feedback
window.................................................................................................65
Op List tab....................................................................................................65
Simulation control using the Op List tab.....................................................66
Breakpoints in Op List tab ...........................................................................66
Display a single Z level ...............................................................................66
Viewing centerlines for an operation...........................................................67
Viewing intermediate shaded simulations ...................................................68
ii Contents
Turn operation order ....................................................................................69

Feature and operation editing using the Op List tab....................................69
Overriding the tool, feed or speed for multiple operations at once .............70
Printing.........................................................................................................70
File Print Preview command ...............................................................71
File Print Setup command ...................................................................71
Tooling
72
Overview of tooling .....................................................................................73

Previewing the automatically-selected tool .................................................73
Tool numbering............................................................................................74
Tooling database ..........................................................................................75
Initializing FeatureCAM databases .............................................................75
Shared Network Database............................................................................75
Tool Manager...............................................................................................76
Adding tools to an existing tool crib............................................................77
Adding a new tool grade for turning operations..........................................78
How to delete a tool crib..............................................................................78
How to import tooling..................................................................................78
How to export tooling ..................................................................................79
How to explicitly set a tool for a milling operation.....................................80
How to explicitly set a tool for a turning operation.....................................80
How to put two tools in the same tool slot ..................................................80
How to use an insert drill to drill and bore in the same program ................80
Form tools ....................................................................................................81
Creating a form tool .....................................................................................81
Displaying a profile of an existing tool .......................................................82
Using a form tool or insert drill for drilling operations...............................82
Using an insert drill for both drilling and boring.........................................83
Iscar Cut-grip tooling...................................................................................83
Milling tools.................................................................................................83
Tooling groups.....................................................................................83
Common milling tool parameters ........................................................84
Boring bars for milling ........................................................................85
Chamfer mills ......................................................................................85
Counter bores.......................................................................................86
Countersink..........................................................................................86
Endmill tools........................................................................................87
Face mills.............................................................................................88
Reams...................................................................................................88
Rounding mills.....................................................................................88
Side mills .............................................................................................89
Contents iii
Spot drills.............................................................................................89
Center drills..........................................................................................90
Taps......................................................................................................90
Thread mills .........................................................................................91
Twist drills ...........................................................................................91
Using a form tool or insert drill for drilling operations.......................92
Selecting tools by diameter..................................................................92
Turning tools................................................................................................92
Turning tool overrides tab ...................................................................92
Insert tab ..............................................................................................93
Holder drawing tab ..............................................................................99
Orientation tab .................................................................................. 107
Program point tab ............................................................................. 107
Tool Mapping............................................................................................ 108
Instructions for changing Tool number or Cutter comp ........................... 109
Spindles and tool holders.......................................................................... 109
Overview of spindles and toolholders .............................................. 110
Spindles and tool holders dialog....................................................... 110
Displaying spindles or tool holders during simulation..................... 111
Setting the length of tool extending past the holder ......................... 111
Detecting gouging with tool holders and spindles ........................... 111
Spindle properties dialog .................................................................. 111
Toolholder properties dialog............................................................. 111
Creating or modifying spindles ........................................................ 112
Creating or modifying toolholders ................................................... 113
Tool holder selection ........................................................................ 113
Tool life management overview ............................................................... 114
Restrictions for tool life management....................................................... 114
Tool Life dialog ........................................................................................ 115
Removing tool life restrictions on a tool .................................................. 116
Turret location........................................................................................... 116
Feeds and speeds
117
Overview of feeds and speeds .................................................................. 117

Feeds and speeds tables ............................................................................ 118
Viewing feed/speed tables ........................................................................ 118
Modifying existing feed/speed tables ....................................................... 119
Wire EDM cut data ................................................................................... 119
Adding a new material .............................................................................. 119
Adding a new tool grade for turning operations....................................... 120
Deleting a feed/speed table ....................................................................... 121
How to import feed/speed or cutting data tables ...................................... 121
iv Contents
Creating a text file for wire material databases ........................................ 122

How to export feed/speed tables............................................................... 123
How feedrates are scaled .......................................................................... 124
Setting a feed or speed value for a milled operation ................................ 124
Default feed/speed values for turning....................................................... 124
Show/hide material ................................................................................... 125
Initializing FeatureCAM databases .......................................................... 125
Adding default tools and feed/speed tables to the database ..................... 125
Macro programming options .................................................................... 126
Recreating tooling and feed/speed databases if they become corrupt...... 129
Shared Network Database......................................................................... 129
Feed optimization...................................................................................... 130
Feed optimization parameters................................................................... 131
Feedrate optimization example................................................................. 133
Target horsepower .................................................................................... 134
Creating NC code
135
Posting your program................................................................................ 135

Post options............................................................................................... 135
Post options for milling .................................................................... 135
Post options for turning .................................................................... 136
Post options FeatureWIRE ............................................................... 138
Saving an NC part program to disk .......................................................... 138
Save Options ............................................................................................. 140
Milling macros .......................................................................................... 140
Incremental programming and local coordinate systems ......................... 141
Turning canned cycles .............................................................................. 142
4th Axis (2.5D & 3D)
143
Indexing .................................................................................................... 143

Overview of indexing ............................................................................... 144
How to create an indexed program ........................................................... 144
4th-axis rotation ........................................................................................ 145
4th-axis indexing with a single setup - positioning features .................... 146
4th-axis indexing with multiple setups ..................................................... 147
4th-axis indexing - specifying the tool change position ........................... 148
4th axis indexing - How the clearance plane is calculated ....................... 149
Restrictions of indexing ............................................................................ 149
The Stock axis........................................................................................... 150
Viewing the stock axis.............................................................................. 150
Wrapping (3D) .......................................................................................... 150
4th-axis wrapping ............................................................................. 150
Contents v
Overview of 4th-axis wrapping ........................................................ 151

Wrap tolerance.................................................................................. 151
Basic 4th-axis wrapping requirements ............................................. 153
How to create a NC program using 4th-axis wrapping .................... 153
Creating a 4th-axis wrapped feature from a 3D model .................... 154
Curve unwrap.................................................................................... 155
Cylindrical cams ............................................................................... 155
How to create a cylindrical CAM..................................................... 156
Cut sides perpendicular to index axis ............................................... 157
Restrictions for cut sides perpendicular............................................ 158
Restrictions of 4th-axis wrapping..................................................... 159
4-axis simultaneous................................................................................... 160
Multiple fixture documents (2.5D & 3D)
161
Example of multiple fixture part............................................................... 162

Multiple fixture part.................................................................................. 162
Editing a multiple fixture design .............................................................. 163
Configuration ............................................................................................ 163
Layout ....................................................................................................... 163
Individual blocks....................................................................................... 164
Single block .............................................................................................. 164
Nested ....................................................................................................... 164
Stock.......................................................................................................... 165
Completing the multiple fixture part ........................................................ 166
Parts list..................................................................................................... 166
Saving and opening multiple fixture parts................................................ 166
3D surface modeling (3D)
167
Surface wizard .......................................................................................... 167

Surface definition...................................................................................... 168
Surface design hints .................................................................................. 168
Surface editing .......................................................................................... 169
Surface editing hints ................................................................................. 169
Surfaces from curves ................................................................................ 170
Extrude surface ................................................................................. 170
Revolution......................................................................................... 172
Sweep................................................................................................ 175
Ruled ................................................................................................. 179
Coons ................................................................................................ 182
Mesh.................................................................................................. 183
Loft.................................................................................................... 186
Cap .................................................................................................... 189
vi Contents
Surface primitives ..................................................................................... 192

Sphere ............................................................................................... 192
Cylinder ............................................................................................ 195
Flat surface........................................................................................ 196
Surfaces from one surface......................................................................... 197
Surface region ................................................................................... 197
Reverse surface ................................................................................. 199
Surface offset .................................................................................... 200
Extend ............................................................................................... 201
Trim surface...................................................................................... 203
Untrim surface .................................................................................. 207
Split surface ...................................................................................... 209
Surface from multiple surfaces ................................................................. 210
Fillet .................................................................................................. 210
Merging surfaces .............................................................................. 215
Surface/surface trimming.................................................................. 216
Surface from feature ......................................................................... 221
Modify surface.................................................................................. 222
Corner blend ..................................................................................... 225
3D solid modeling (Solid Modeling)
230
Overview of solids in FeatureCAM.......................................................... 230

Comparison of surface and solid modeling .............................................. 232
Part View for solids .................................................................................. 232
Unattached design features ....................................................................... 233
Selecting and deleting solids..................................................................... 234
Verifying that a solid is valid.................................................................... 234
Transforming a solid ................................................................................. 235
Solid wizard and Solid toolbar ................................................................. 235
Defining the base solid in the solid wizard............................................... 237
Extrude solid design feature ..................................................................... 237
Using open curves for solid extrudes ............................................... 238
Revolved solid design feature................................................................... 238
Examples of solids of revolution ...................................................... 239
Using open curves for solids of revolution............................................... 240
Swept solid design feature ........................................................................ 241
Troubleshooting swept solids ........................................................... 242
Lofted solid design feature ....................................................................... 242
Closed lofted solids........................................................................... 243
Overview of stitching................................................................................ 244
Stitching surfaces into solids ............................................................ 244
Troubleshooting stitching ................................................................. 245
Contents vii
Overview of solid from 2.5D feature........................................................ 245

Creating a solid modeling operation from a 2.5D feature ................ 245
Solid from stock or cube........................................................................... 246
Creating a solid from the stock dimensions ..................................... 246
Creating a cube solid design feature................................................. 246
Extrude surface solid design feature......................................................... 246
Revolved solid from surface design feature ............................................. 247
Overview of solid fillets ........................................................................... 248
Creating a constant radius solid fillet ............................................... 249
Controlling the shape of solid fillet joints ........................................ 250
Overview of cut solid with parting surface............................................... 250
Cutting a solid with parting surfaces ................................................ 251
Overview of combine solids ..................................................................... 252
Solid operations ................................................................................ 252
How to combine solids ..................................................................... 253
Overview of shell solid design feature ..................................................... 254
Creating a Shell Solid Design Feature.............................................. 254
Troubleshooting shell solid design features ..................................... 255
Silhouette curves....................................................................................... 255
Overview of Silhouette Curves......................................................... 255
Creating silhouette curves or splitting faces of a solid at silhouette curves
........................................................................................................... 256
Include hidden silhouettes ................................................................ 257
Select core/cavity ...................................................................................... 257
Overview of select core/cavity ......................................................... 258
Selecting core or cavity faces from a solid....................................... 259
Creating a solid form core or cavity faces of a solid........................ 260
Split face ................................................................................................... 261
Deleting faces............................................................................................ 262
Explode solid ............................................................................................ 263
Parting surface .......................................................................................... 263
Changing the direction of a segment of a parting surface ........................ 264
Draft a Face............................................................................................... 264
3D surface manufacturing (3D)
267
Overview of 3D surface manufacturing ................................................... 267

Overview of surface manufacturing ......................................................... 268
How to create a surface milling feature.................................................... 269
How to add an operation to an existing surface milling feature............... 269
Types of surface milling operations ......................................................... 270
Tool selection for 3D milling features...................................................... 273
Properties dialog for 3D milling ............................................................... 273
viii Contents
Tree view for surface milling features.............................................. 275

Dimensions tab (3D)......................................................................... 276
Part surfaces...................................................................................... 276
Check surfaces .................................................................................. 277
Process tab ........................................................................................ 277
Machining Side tab (3D) .................................................................. 279
Misc tab............................................................................................. 281
Strategy tab ....................................................................................... 283
Edges tab (3D) .................................................................................. 286
Stock tab ........................................................................................... 288
5-Axis tab.......................................................................................... 289
Slopes tab (3D) ................................................................................. 304
Surface control tab (3D) ................................................................... 307
F/S tab ............................................................................................... 309
Leads tab (3D) .................................................................................. 310
Z level slice classification................................................................. 318
3D milling strategies ................................................................................. 318
Types of surface milling operations ................................................. 318
Cutting strategy for new features...................................................... 321
Parallel milling.................................................................................. 323
2D Spiral milling .............................................................................. 328
3D spiral............................................................................................ 335
Radial toolpaths ................................................................................ 339
Z-level roughing ............................................................................... 339
Z-level finishing................................................................................ 350
Isoline milling ................................................................................... 358
Flowline ............................................................................................ 361
Between Two Curves........................................................................ 364
Pencil milling.................................................................................... 365
Horizontal + vertical strategy ........................................................... 367
Plunge roughing................................................................................ 368
Four Axis Rotary .............................................................................. 369
Overview of Corner Remachining.................................................... 373
Overview of remachining ................................................................. 375
Swarf milling .................................................................................... 380
5-Axis Trim....................................................................................... 387
3D machining attributes............................................................................ 388
3D Milling tab and Manufacturing attributes................................... 388
Switch settings .................................................................................. 388
Attributes .......................................................................................... 399
Default 3D attributes......................................................................... 424
Troubleshooting 3D toolpaths .................................................................. 426
Contents ix
Extending FeatureCAM
427
FeatureCAM add-ins................................................................................. 427

Installing new add-ins ............................................................................... 427
Loading the example add-ins that were installed with FeatureCAM ....... 428
Running the API examples provided with FeatureCAM ......................... 429
Creating toolbar buttons for macros ......................................................... 430
Assigning a macro to a toolbar button...................................................... 431
Feature Recognition (RECOG or 3D)
432
Overview of feature recognition ............................................................... 433

Types of features that can be recognized.................................................. 434
Feature recognition examples ................................................................... 435
Hole recognition........................................................................................ 436
Slot recognition......................................................................................... 438
Boss recognition........................................................................................ 439
Pocket recognition .................................................................................... 441
Side recognition ........................................................................................ 441
Face feature recognition............................................................................ 442
Methods of feature recognition................................................................. 442
Styles of automatic feature recognition .................................................... 443
Invoking the automatic feature recognition wizard .................................. 445
Automatic feature recognition error ......................................................... 445
Invoking the automatic option of new feature wizard.............................. 445
Automatic boss recognition on solid models............................................ 445
Interactively extracting chamfers from a solid or surface model ............. 446
Automatic pocket recognition on solid models ........................................ 446
Automatic side recognition on solid models ............................................ 448
How to recognize features from surfaces ................................................. 449
Feature recognition surface requirements................................................. 451
How to recognize all holes in a setup ....................................................... 451
How to recognize features from surfaces using curve chaining............... 452
How to recognize pockets and bosses from top or bottom surfaces......... 453
How to recognize pockets automatically from solids............................... 453
New feature - pocket recognition options................................................. 454
How to recognize drafted features ............................................................ 454
How to recognize face features from flat surfaces ................................... 456
Rerecognition wizard ................................................................................ 456
Unchanged features .......................................................................... 457
New features ..................................................................................... 457
Modified features.............................................................................. 457
Deleted features ................................................................................ 457
x Contents
Tombstone machining (TOMB)
458
Overview of tombstone machining........................................................... 459

Specifying tombstone dimensions ............................................................ 459
Creating global fixture coordinate systems from setups on placed parts . 460
Creating global fixture coordinate systems on the tombstone.................. 461
Creating a tombstone machined part ........................................................ 462
Adding a part to the tombstone................................................................. 462
Specifying ordering of tombstone operations........................................... 462
Saving and opening tombstone parts ........................................................ 463
Tombstone delete button........................................................................... 463
Tombstone edit button .............................................................................. 463
Tombstone reload button .......................................................................... 464
Overview of 5-axis positioning (5-axis Pos) 465

5-axis positioning example ....................................................................... 466
5-axis machine types................................................................................. 466
Use alternative 5 axis position .................................................................. 471
5-axis positioning using a single coordinate system ................................ 473
5-axis positioning using fixture offsets..................................................... 475
Rotation of primary axis ........................................................................... 476
Turn/milling (TURN/MILL)
477
Turnmilling ............................................................................................... 478

Beginning a turnmill part.......................................................................... 478
Turn/mill feature type dialog .................................................................... 479
Features appropriate for turn/mill ............................................................. 479
Feature location......................................................................................... 480
Tool selection for turn/mill features ......................................................... 480
Feed rates for turn/mill features................................................................ 481
Polar interpolation in turnmill................................................................... 481
Generate single program for all setups ..................................................... 481
Introduction to FeatureWIRE for FeatureMILL

users
482
Simulated slug removal ............................................................................ 483
FeatureWIRE feature types....................................................................... 483
Multiple curves in a single 2-axis wire EDM feature....................... 484
Die..................................................................................................... 484
Punch ................................................................................................ 485
Side ................................................................................................... 485
Contents xi
Side feature restrictions .................................................................... 486

Wire EDM Taper .............................................................................. 486
Types of wire EDM tapers................................................................ 486
Default conical corner....................................................................... 487
ISO cylindrical corner....................................................................... 487
Variable taper table........................................................................... 488
4-axis Die feature (Wire) .................................................................. 488
4-axis Punch feature (Wire).............................................................. 489
4-axis Side feature (Wire)................................................................. 489
Wire EDM feature recognition ......................................................... 489
New feature - surface boundaries ..................................................... 491
Alignment of 4-axis curves............................................................... 492
Overview of EDM operations................................................................... 493
Operations (FeatureWIRE)............................................................... 494
Retract operation............................................................................... 494
Stop operation ................................................................................... 495
Overview of Pocketing Cycle........................................................... 497
Overview of Zig-Zag Cycle.............................................................. 498
Start point for Zig-Zag Cycle ........................................................... 498
Cutoff operation................................................................................ 499
Contour operation ............................................................................. 499
Attributes................................................................................................... 501
Strategy tab ....................................................................................... 501
Start tab ............................................................................................. 511
Misc tab............................................................................................. 514
Cuting data tab .......................................................................................... 517
New cutting condition............................................................................... 517
Feed, water and cutter compensation registers ......................................... 518
Network security version (Net)
520
Overview of multi-axis multi-turret turning (MTT)

521
Setting up a part for multi-spindle turning ............................................... 522
Setting up a part for multi-turret turning .................................................. 523
Turrets tab ................................................................................................. 523
Time view ......................................................................................... 524
Operation view.................................................................................. 524
Automatic synchronized turning............................................................... 528
Viewing a turret's NC code....................................................................... 529
xii Contents
Machine simulation (MSIM)
530
Machine design overview ......................................................................... 530

Lathe design overview .............................................................................. 532
Machine design concepts .......................................................................... 534
Full Machine Simulation overview .......................................................... 536
Specifying file for machine simulation..................................................... 537
Setup simulation information.................................................................... 537
Using Full Machine Simulation................................................................ 537
Machine design tutorial ............................................................................ 539
Specify movement .................................................................................... 547
Parent/child relationship ........................................................................... 548
Top-most table .......................................................................................... 549
Subspindle................................................................................................. 550
Add tool location....................................................................................... 551
Local coordinate system ........................................................................... 555
Tool block for turret.................................................................................. 556
G53 Z0 before indexing............................................................................ 558
G28 before tool change............................................................................. 559
Delete tool location ................................................................................... 559
Positioning turning tool holders in a tool block ....................................... 559
How does FeatureCAM make its decisions? 561

How holes are manufactured .................................................................... 561
How bosses are manufactured .................................................................. 562
How is a chamfer machined?.................................................................... 562
How faces are manufactured..................................................................... 563
How is a face groove machined? .............................................................. 563
How is a simple face groove machined? .................................................. 564
How is an ID or OD groove machined? ................................................... 564
How pockets are manufactured ................................................................ 564
How rectangular pockets are manufactured ............................................. 565
How is a round machined?........................................................................ 566
How sides are manufactured..................................................................... 566
How slots are manufactured ..................................................................... 567
How Step Bores are manufactured ........................................................... 567
Manufacturing draft angles or bottom radius regions .............................. 568
Manufacturing milled features with tapered walls ................................... 568
How a turn feature is manufactured.......................................................... 568
How a bore feature is manufactured ......................................................... 569
How a turned groove feature is manufactured.......................................... 569
How a thread feature is manufactured ...................................................... 569
How a cutoff feature is manufactured ...................................................... 570
Contents xiii
How a turned face feature is manufactured .............................................. 570

3D manufacturing ..................................................................................... 570
How do I get the file to the machine?
572
Configuring HyperTerminal ..................................................................... 572

EZ-UTILS ................................................................................................. 573
Cables........................................................................................................ 573
Serial port pinouts ..................................................................................... 574
Support information
575
Technical support...................................................................................... 575

What does this warning mean? ................................................................. 575
General information on manufacturing errors .................................. 575
Manufacturing errors ........................................................................ 576
Error hints dialog box ....................................................................... 576
Warning codes .................................................................................. 577
Error codes........................................................................................ 581
Index
xiv Contents
585
Import/Export
Importing files
To import CAD files:
1. Open a new or existing part file. You must have a part open to
import geometry.
2. Select File > Import from the menu.
The Import function is not available unless you already have a part file
open. A standard Browse dialog for Windows appears. You can also set a
few parameters in the Import Options dialog such as replacing existing
profiles with newly imported profiles with the same name. You can also
set how fine to smooth the curves and to keep a *.iges log file.
You can set the file type and folders you want to import from or simply
browse until you locate the file you want to import.
After importing the file, the Import Results window opens.
FeatureCAM can import these formats. If the description listed has (3D)
following it, you need FeatureMILL3D or the Solid Import Module to
import it.
Type
Description
Latest
Version
*.dwg
(see page
17)
AutoCAD files (3D for embedded

solids)
2008
*.dxf (see
page 17)
AutoCAD files (3D for embedded

solids)
2008
Import/Export 15
*.iges
(see page
29)
Industry standard neutral CAD

files (3D for surface or solids)
*.geo
Bridgeport EZ-CAM 2D geometry
*.xmt and
*.xmb
(see page
19)
Parasolid-based solid models (3D)
19.1
*.sat and
*.sab (see
page 19)
ACIS-based solid models (3D)
18
*.sldprt
(see page
20)
SolidWorks files (3D)
2008
*.sldasm
(see page
20)
SolidWorks assembly files (3D)
2008
*.mod
and
*.model
(see page
26)
CATIA V4 files (This module is

priced separately.)
4.2.x
*.ipt and
*.iam (see
page 20)
Autodesk Inventor files (3D)
2008
*.prt,
*.prt<nu
mber>,
*.asm and
*.asm<nu
mber>
(see page
27)
Native Pro/ENGINEER files (This Wildfire 4

module priced separately.)
*.catpart
(see page
27)
CATIA V5 files (This module

priced separately.)
R18
*.par (see
page 28)
Native SolidEdge files (3D)
V19
16 Import/Export
5.3
*.prt (see
page 25)
Unigraphics native files (priced

separately)
NX5
*.stp or
*.step
(see page
27)
STEP files (priced separately)
AP
203/AP21
4
Importing *.dwg, *.dxf files

FeatureMILL supports the import of the *.dwg and *.dxf entities below.
Up to the AutoCAD 2007 version is supported for importing *.dwg and
*.dxf files. *.dxf files have both ASCII and binary forms, *.dwg files
have only binary form, all of these formats are supported.
FeatureMILL supports the import of the following *.dwg and *.dxf
entities. If the entity has a (3D) listed after it, then FeatureMILL3D or the
Solid Import Module is required.
.dxf entity
FeatureMILL object
LINE
line from 2 points
POLYLINE
lines from 2points
POLYLINE
with smooth
vertices
curve (see Digitized data import/export options

(see page 28))
POLYGON
MESH
surface (see Digitized data import/export options

(see page 28))
LINE3D
line from 2 points
POINT
point
SPLINE (DXF
only)
curve
UCS
UCS
SEQEND
line from 2 points
LAYER
layer
VERTEX
line from 2 points
COLOR
object colors are maintained upon import
Import/Export 17
CIRCLE
circle center radius

arc center begin end
curve
ARC

curve, if asymmetrically scaled
INSERT DXF
BLOCK
trimmed surfaces (3D)
BODY
SHEET
3DSOLID
DIMENSION
dimension object (see Importing dimensions from

*.dxf and *.dwg files (see page 18))
See Simplyfying 3D AutoCAD data for 2D import (see page 18) for
further details.
Importing dimensions from *.dxf and *.dwg files

AutoCAD files can contain two different spaces, model space and paper
space. Model space is where you draw up geometry, 3D solids, and so on.
Paper space is the formatted space where multiple views are formatted.
Most AutoCAD files have only model space. FeatureCAM can import
dimensions in both model space and paper space.
AutoCAD dimensions are imported as FeatureCAM dimensions. That
means that you can modify the color of the dimension, easily delete the
entire dimension or use the Show or Hide pull-out menus to toggle the
display of dimensions.
Simplifying 3D AutoCAD data for 2D import

Many AutoCAD models are comprised of higher level objects such as
3DSOLIDs or BODYs. If you have licensed FeatureMILL3D or the Solid
Import Module, you can import these entities directly into FeatureCAM.
If not, you must simplify this data before importing.
To import the geometry that is used to create the 3DSOLIDs, select your
model and then use the EXPLODE command, or the Explode pull-out
from the Modify toolbar, to repeatedly reduce your model into these
more primitive elements.
18 Import/Export
When exploding solids you often get duplicate lines and circles. Any
edge that was shared between two different faces will be duplicated. This
repeated geometry causes trouble if you try to chain the geometry by
double-clicking. To work around this, you can:
Chain manually, by picking each piece individually
Use AutoCAD to explode specific faces of the model (not the
entire model), and then do chaining normally with double-click or
piece-to- piece
Remove duplicate pieces in EZFM and then do chaining normally
To see if you have imported geometry:
1. Select a line or circle.
2. Look at the object's name listed in the status bar. Imported lines
have names that begin with _ln and imported circles have names
that begin with _circ.
3. Select the object again.
4. See if the same name is listed in the status bar.
5. If a duplicate name appears and selected geometry is the same,
delete the second occurrence of the geometry.
If your AutoCAD model contains layers, those layers will be retained
upon import.
Importing ACIS files

This function requires FeatureMILL3D or the Solid Import Module.
CAD systems that use the ACIS kernel can create files of type *.sat.
These files contain the solid models created by systems including
Mechanical Desktop, CadKey and others. These solids can also be
imported in *.dwg and *.dwf files. FeatureCAM can import ACIS files
of version 14.0 or earlier.
FeatureCAM cannot import wireframe models, only solids. The
normals of solids are reverse for ACIS models since the ACIS
convention is opposite of the FeatureCAM convention.
Importing Parasolid files

This function requires FeatureMILL3D or the Solid Import Module.
Import/Export 19
CAD systems that use the Parasolid kernel can create files of type *.xmt.
These files contain the solid models created by systems including
SolidWorks, SolidEdge and Unigraphics. FeatureCAM can import
ASSEMBLIES and PARTS that are made up of BODIES.
FeatureCAM can import files of version 18.0 or earlier of the Parasolid
library. Later versions may be supported since then, so please visit
FeatureCAM.com for further information.
SolidWorks is a registered tradename of Solidworks Inc.
Parasolid, SolidEdge and Unigraphics are registered tradenames of
Siemens AG.
Importing Autodesk Inventor files

Autodesk inventor *.ipt files can be directly imported into FeatureCAM.
Only the final 3D solid model is imported, 2D geometry, assemblies, and
sketches are not imported. Solids contained in Autodesk Inventor
assembly files can also be imported directly from *.iam files. Files up to
and including Inventor version 2008 can be imported.
Importing Solidworks files

The files have a *.sldprt extension. Only the final solid model is
imported. No geometry or curves are imported and the construction
history is also not imported. This means that you only get a single solid
and not the individual design features from SolidWorks.
SolidWorks configurations are also supported. If there are multiple
configurations, you are prompted for which one you want to import.
At the time of writing, SolidWorks2006 (or earlier version) files can be
read directly into FeatureCAM. Later versions may be supported since
then. Please visit FeatureCAM.com for further information.
See also Color in Solidworks and .x_t files,Importing Solidworks
assemblies (see page 20) and Importing_other_CAD_files (see page 15).
Importing Solidworks assemblies

The solids contained in Solidworks assemblies (files with a *.sldasm
extension) can be imported if you have the *.sldasm file and all of the
referenced *.sldprt files.
20 Import/Export
Files written with SolidWorks 2002 or earlier requires that you

have a copy of SolidWorks on the same computer on which
FeatureCAM is installed. Solidworks is run automatically by
FeatureCAM to extract the solids and send them to FeatureCAM.
Files written with Solidworks 2003 or a later version do not require
you to have a resident copy of SolidWorks.
Each solid of the assembly is loaded into a single FeatureCAM document.
See also Importing Solidworks files (see page 20), Color in Solidworks
and .x_t files, and Importing other CAD files (see page 15).
SolidWorks and Autodesk Inventor automatic hole

recognition example
The solid part is initially imported as follows:
Import/Export 21
After recognizing and suppressing the holes the model appears as shown
below. Note that the holes are filled in. The circles that are visible are
actually the top of the hole features that were recognized.
By looking at the Part view, you can see that eight holes were created
automatically.
22 Import/Export
Inventor hole recognition

This is the final page of the import wizard if you have imported an
Autodesk Inventor part file (see page 20). If you have Inventor on your
computer, you have the option of using Inventor to recognize and
suppress the holes in the solid model as shown in this example (see page
21). Using Inventor to recognize holes is the only way to recognize nongeometric information, like threads for tapped holes. The suppression is
used to remove the holes from the solid model so that FeatureCAM does
not try to recognize them again if you run FeatureCAM's automatic
feature recognition (AFR) (see page 432).
There are two important points regarding this page:
Only holes that were created using Inventor hole features will be
recognized automatically. Holes that were created as extrusions
have to be recognized using FeatureCAM's automatic feature
recognition.
You must have Inventor on the same machine where you are
running FeatureCAM for this method to work.
To complete this page:
1. To use Inventor to recognize the hole, select Use Inventor to
extract information about hole types and dimensions.
2. If you also want the holes suppressed, or removed from the solid
model after they are recognized, select Suppress recognized
holes in imported model.
3. If you do not want to perform hole recognition using Inventor,
select Use FeatureCAM to recognize holes later.
4. Click Finish.
It may take some time to start up Inventor and recognize the holes,
so please be patient.
Import/Export 23
SolidWorks hole recognition

This is the final page of the import wizard if you have imported a
SolidWorks part file (see page 20). If you have SolidWorks on your
computer, you have the option of using SolidWorks to recognize and
21). Using SolidWorks to recognize holes is the only way to recognize
non-geometric information, like threads for tapped holes. The suppression
is used to remove the holes from the solid model so that FeatureCAM
does not try to recognize them again if you run FeatureCAM's automatic
feature recognition (AFR) (see page 432).
There are four important points regarding this page:
Only holes that were created using SolidWorks hole wizard will be
recognition.
FeatureCAM supports recognizing tapped, counter drill and
counter bore holes created in SolidWorks. We don't support
reaming or boring since those are dependent on tolerance.
You must have SolidWorks on the same machine where you are
FeatureCAM will recognize Solidworks patterns only if those
patterns can be mapped to a FeatureCAM pattern.
1. To use SolidWorks to recognize the hole, select Use SolidWorks
to extract information about hole types and dimensions.
3. If you do not want to perform hole recognition using SolidWorks,
4. Click Finish.
It may take some time to start up SolidWorks and recognize the
holes, so please be patient.
24 Import/Export
SolidEdge hole recognition

This is the final page of the import wizard if you have imported a
SolidEdge part file (see page 28). If you have SolidEdge on your
computer, you have the option of using SolidEdge to recognize and
21). Using SolidEdge to recognize holes is the only way to recognize
nongeometric information, like threads for tapped holes. The
suppression is used to remove the holes from the solid model so that
FeatureCAM does not try to recognize them again if you run
FeatureCAM's automatic feature recognition (AFR) (see page 432).
There are three important points regarding this page:
Only holes that were created using SolidEdge hole wizard will be
recognition.
You must have SolidEdge on the same computer where you are
FeatureCAM will recognize SolidEdge patterns only if those
patterns can be mapped to a FeatureCAM pattern.
1. To use SolidWorks to recognize the hole, select Use SolidEDGE
to extract information about hole types and dimensions.
3. If you do not want to perform hole recognition using SolidEdge,
4. Click Finish.
It may take some time to start up SolidEdge and recognize the holes,
so please be patient.
Importing Unigraphics files

Native Unigraphics (or UG) *.prt files can be imported directly into
FeatureCAM. Only solid models are imported. Importing native
Unigraphics files requires licensing the Unigraphics import module.
Import/Export 25
At the time of writing FeatureCAM supports versions 11-18, NX, NX2

and NX3. Later versions may be supported since then, so please visit
FeatureCAM.com for more information.
Importing CATIA V4 files

CATIA version 4 (specifically versions 4.1.x or 4.2.x) files can be
imported directly into FeatureCAM. Note that importing CATIA files
requires the purchase of a separate optional module. These files must
have a *.mod or *.model extension. In general, only 3D surface and
solid models can be imported, but composite curves can also be imported.
A log of the import is recorded in windows\temp\catia.txt.
CATIA Object Type
FeatureCAM Object Type
Point
Not translated
Line
Curve
Circle
Curve
Ellipse, Hyperbola, Parabola
Curve
Curve
Curve
Composite curve
Curve
NURBS curve
Curve
Polynomial surface, B-spline

polynomial surface
Surface
NURBS surface
Surface
Skin
Surfaces or solid depending on

option settings (see page 32).
Exact solid

Polyhedral solid

26 Import/Export
Importing CATIA V5 files

CATIA V5 files can be imported directly. This requires the purchase of
an optional import module. These files must have an extension of
*.catpart. A log of the import is recorded in windows\temp\catia.txt.
Only solid models are read from a CATIA V5 file. Any curves or
surfaces read must be part of a solid. Colors are preserved upon import.
The CATIA V5 import module will not import CATIA V4 files.
CATIA V4 import must be licensed separately.
Not all CATIA solids can be imported into FeatureCAM as solids.
This is because the solid modeling technology used by FeatureCAM
requires that a solid be truly watertight, and CATIA uses a different
solid modeling technology that allows for solid models that aren't
truly watertight. So the bottom line is that FeatureCAM won't be
able to import every CATIA solid as a solid, but it should be able to
bring them in as surfaces at the very least. If you import-assurfaces, then you should be able to stitch the surfaces into a solid
with some amount of retrimming/remodelling effort depending upon
the quality of the original CATIA model.
Importing Pro/E files

These files must have an extension of *.prt, *.prt.<number> (for
example foo.prt.8), *.asm or *.asm.<number> (for example
bar.asm.23). Only solid models are imported from Pro/E. The solid
models are imported as Surfaces or solid depending on option settings
(see page 32). Only solids are read from a Pro/E file. Any curves or
surfaces read must be part of a solid. Importing native Pro/E files requires
licensing the separate Pro/E import module.
You can import Pro/E v16-v20, 2000i, 2000i2, 2001, Wildfire1-4 files
directly into FeatureCAM. Later versions may be supported since then, so
please visit FeatureCAM.com for further information.
Importing STEP files

FeatureCAM can import solid models via STEP AP203 or AP214. The
solid models are imported as Surfaces or Solids depending on option
settings (see page 32).
AP203 and AP214 contain the same geometry specifications. AP214
allows support for attributes which are not present in AP203 (color, line
thickness, line type, and so on).
Import/Export 27
Importing SolidEdge files

FeatureCAM can import the solid models directly from a native
SolidEdge (*.par) file. The solid models are imported as Surfaces or
Solids depending on option settings (see page 32).
Up to V18 is supported. Later versions may be supported since then.
Please visit FeatureCAM.com for more information.
Importing STL
STL (Standard Tessellation Language) is a file format native to
stereolithography CAD software. A standard format STL file can be
imported directly into FeatureCAM with no special license or optional
reader (STL import is part of the 2D milling product). These files must
have a *.stl extension. The result is an STL 'blob' which is all the
triangles as a single pickable unit, that is, not separate solids, or separate
faces. The blob can then be machined using 3D techniques for rapid
prototyping (surface manufacturing - in the 3D product), or can be used
as a stock model (in all products).
FeatureCAM supports both binary and ASCII STL.
Importing DMT
DMT (Delcam's Machining Triangles) is a file format generated by
Delcam (http://www.delcam.com)'s CAD software including
PowerMILL, PowerSHAPE, and CopyCAD. The file has the extension of
*.dmt and can be imported directly into FeatureCAM. The DMT file
represents 3D models as triangles, similar to an STL (see page 28) file.
Any function or operation that can be applied to an STL file can also be
applied to a DMT file.
Digitized data import/export options

Digitized data is imported into FeatureMILL through DXF POLYLINE
entities. The Digitized data import/export options affect how this data is
imported. These settings only affect the import of the data. If you want to
change one of these options, you must remove the old data and import the
*.dxf file again.
Non-smooth Polyline Import
If a non-smooth polyline is imported it is imported as a curve if As
curve is selected. If As connected lines is selected, the polyline is
imported as a series of line segments.
28 Import/Export
Smooth Polyline Import

If the POLYLINE has smooth vertices, it is imported as a curve. The
DXF Smooth Polyline Import Method has two settings:
Interpolation - the curve will pass through the data. If the data is
very dense, interpolation will sometimes cause the curve to wiggle
in between the points. The spline interpolation technique is used to
create the curve.
Approximation - the curve will come very close to the data
points and is unlikely to wiggle for densely-spaced data.
Polygonal Mesh Import
If the POLYLINE is a polygonal mesh it is imported as a surface. The
DXF Polygonal Mesh Import Method has two settings:
Interpolation - the surface will pass through all of the data points.
If the data is very dense, some wiggles may appear in the surface.
A cubic hermite technique is used to create the surface.
Approximation - the surface will come close to the data points.
The points are used as control points to the surface and the surface
is unlikely to wiggle for densely-spaced data.
Details of digitized file formats (see page 29)
Format of digitized files

Details of DXF digitized file formats:
Example of digitized data format for a 3D point
Example of digitized data format for a two point curve
Example of digitized data format for a spline curve
Example of digitized data format for a surface defined by four corner
points
Importing IGES files

FeatureCAM can read *.iges files of version 5.3 or earlier.
It is helpful to set the export settings of your CAD system for proper
import.
SolidWorks settings (see page 34)
AutoCAD settings (see page 36)
Import/Export 29
For other systems try and ensure that 3D surfaces are exported as
trimmed NURBS.
If you are working with Pro/Engineer from Parametric Technology
Corporation set the following IGES import options:
Physically dependent - OFF
Logically dependent - ON
Both physically and logically dependent - ON
See Import/Export Options for more details on these parameters
Import/export options are divided into two tabs:
The General tab (see page 32) contains mainly IGES import options.
The Digitized Data (see page 28) tab contains information on importing
digitized curves and surfaces via DXF.
FeatureMILL can read the following IGES entities. If the 3D column is
checked, then FeatureMILL3D or the Solid Modeling option is required
to read these entities.
Entity IGES Description
FM Object Type
3D
100
Circular Arc
Circle and arc
102
Composite Curve
Curve
104
Conic Arc
Curve
106
Copious Data
Line
108
Plane
Not supported
110
Line
Line, multiple lines
112
Parametric Spline
Curve
Curve
114
Parametric Spline
Surface
Surface
116
Point
Point
118
Ruled Surface
Surface
120
Surface of Revolution
Surface
122
Tabulated Cylinder
Surface
126
Rational B Spline
Curve
Curve
128
Rational B Spline
Surface
Surface
30 Import/Export
141
Boundary
Curve
142
Curve on Parametric
Surface
Curve
143
Bounded Surface
Surface
144
Trimmed Surface
Surface
186
Brep
Solid with Solid

Modeling, Surfaces
without Solid Modeling
304
Line Font Definition
Not supported
408
Subfigure Instance
Geometry, curves, or
surfaces
410
View
Not supported
502
Vertex
Point
504
Edge
Curve
508
Loop
Curve
510
Face
Surface without Solid

Modeling
514
Shell
Surfaces without Solid

Modeling,
Solid with Solid
Modeling
All other IGES entities are ignored. Look in the status bar and the log file
for feedback about the IGES file import. After importing a *.iges file you
will be told either The IGES file has been imported successfully or
The file example.iges is corrupted and cannot be imported. A log file
is created which details the IGES import process. The name of this file is
specified in the Import Settings dialog which is displayed with the
Import Settings option of the File menu.
Working with imported geometry

Imported geometry is often less exact than geometry you create directly
in FeatureMILL. End points may not match and you may find that you
have a lot of extraneous data on your screen. Deleting or hiding the
extraneous data greatly speeds up the display of your part. You may also
want to chain your data one piece at a time instead of using automatic
chaining.
Import/Export 31
Gaps in your data make chaining your geometry into curves more
difficult. With small gaps you may have to adjust the Chaining
tolerance set in Chaining in the Options menu. This tolerance
represents the distance between endpoints that will automatically be
bridged by the chaining algorithm. By increasing this tolerance you may
be able to automatically close the gaps between endpoints during
chaining. You can change this tolerance in the Chaining dialog. With
some data you may find that you must manually insert line segments or
arcs to close the gaps in the data. After closing these gaps, you should
find that the data will chain more easily.
General Import/Export Options

Set these options to control how FeatureCAM imports or exports files.
Always replace object on import when selected, overwrites objects
of the same name when you import. Deselected prompts for every
replacement. You cant have two objects with the same name.
Smooth EZ-MILL curves sets how to improve EZ-MILL curves on
import as FeatureMILL has a higher resolution curve format.
Keep IGES import log file sets whether to keep a log of the import
process for later review or troubleshooting.
Review IGES log displays the log file (in Notepad) after importing a
file.
IGES log file name sets the path and filename for saving a record of
the import process.
32 Import/Export
Physically dependent - generally, this check box should be deselected

to indicate that you do not want physically dependent entities to be
imported. But if you are having trouble with your IGES file and it isn't
importing properly, then try selecting this check box and reimporting.
Entities in an IGES file are marked to be either physically dependent or
not. Those that are marked to be physically dependent are entities that are
used in the construction of other entities. For example, a trimming loop is
physically dependent upon the trimmed surface that uses it. The trimming
loop isn't important all by itself, but is instead a building block of
something else. The trimmed surface will in turn be marked physically
dependent to indicate that it is a building block of a parent entity, a solid.
By selecting Physically dependent, you will be causing FeatureCAM
to show everything in the IGES file - not just the top-level entities that are
usually shown, but also all of the lower-level building blocks. This is
generally not what you want. Generally you want only the top-level
entity, for example the solid. But if you are having trouble importing,
then consider turning on Physically dependent.
Logically dependent can exist by itself but is also referenced by
another entity (case of groups or grouping situation).
Both physically and logically dependent meets both logically and
physically dependent criteria (is referenced by at least two other entities the parent for the logical link can not be the parent for the physical as
well).
Number of decimal places in IGES export determines how finely
data is exported to the IGES format.
Center stock automatically will alter the stock to automatically size
and position itself so that it covers the imported data. See also Resizing
the stock.
Heal Catia solid will try and repair the faces or surfaces contained in
the CATIA *.mod file. This option can be time-consuming since it
attempts to:
retrim the surfaces/faces against each other
force edges of a surfaces actually lie on the surface
simplify surfaces like converting a general surface into a cylinder
Import hidden Catia V5 solids will import all parts contained in the
CATIA file even if those parts are hidden.
Import/Export 33
Import .SAT .SLDPRT, .MOD, .DXF and .X_T as solids will

import these files as solid models. If this option is deselected, the models
are imported as surface models. We recommend that you import these
models as solids. If this option is selected and the solid fails to import
properly, you are asked if you would like to attempt to heal the solid to
try and fix the import problem.
Stitch IGES surfaces into solids/sheets will attempt to create one
or more solids or sheets from an IGES file. If an IGES file contains more
than one solid or sheet, this is the most efficient way to create the
multiple objects from the file. If you want to create a solid from an IGES
file, we generally recommend that you also select the option, Optimize
stitched IGES solids/sheets. This option is compute intensive and
will attempt to recompute sloppy intersections between surfaces.
More about Importing IGES files (see page 29)into FeatureMILL.
Import/Export Options
SolidWorks Export settings

Use the following steps to set the IGES export settings in SolidWorks
before exporting for FeatureCAM:
1. In the Tools menu, choose User Preferences.
2. Click the Import/Export tab.
3. Under Output as, choose Curves (3D).
34 Import/Export
4. Choose B-splines as shown below.
5. Under Output as, choose Trimmed Surfaces.
Import/Export 35
6. Under Output to, select ANSYS as the Settings For field as shown
below.
7. Click OK.
8. Use Save As to export the part to a *.iges file.
AutoCAD Export settings

Use the following steps to set the IGES export settings in AutoCAD
before exporting for FeatureMILL:
1. Select IGES Out from the File menu.
2. Select Edit Options.
3. Select Geometry.
36 Import/Export
4. Set the parameters as in this figure.
Exporting files
Exporting DXF and DWG files
The DXF and DWG files exported are version 11 files. DXF files are
exported in the ASCII form, the binary form is not exported.
FeatureMILL Object
DXF Entity
Point
POINT
Circle
CIRCLE
Arc
ARC (Note that all arcs

are modified so that the
normal points in the +Z
direction)
Line
LINE
Layer
LAYER
UCS
UCS
Import/Export 37
Exporting IGES Files

The different FeatureMILL categories of geometry, curves, features and
so on are exported to IGES as shown in the following table. FeatureCAM
exports IGES v4 files for easy compatibility with other systems.
FeatureMILL Entity
IGES Entity
2.5D Feature
144 = Trimmed surface(s)

or
142 = Curve(s) on
parametric surface
Surface
128 = NURBS surface
Curve
126 = NURBS curve
3D feature
144's and 142's
Point
116 = Point
Line
110 = Line
Arc/Circle
100 = Circular arc
Layer
Dimensions, & other attributes
not exported
Save STL dialog

This option is available after you run a 3D simulation. It lets you create a
*.stl file of the final simulation. A *.stl file is a triangle file used by
layered manufacturing machines. The accuracy of the model is controlled
by the 3D simulation options.
To save an STL file:
1. Run a 3D simulation.
2. Select Save simulation results from the Simulation submenu
of the View menu.
3. Click Save to current directory to write to the same folder as
your part is being saved in or click Save to other directory and
specify the folder.
4. Enter the Stl file name.
5. Select Create subdir if you want to create a subdirectory with the
same name as your part.
38 Import/Export
6. Select Save STL using a short filename to limit your filename

to 8 characters.
7. Select Overwrite existing file to automatically overwrite any
file with the same name.
8. Click OK.
Import/Export Options
Import/Export 39
Generating/simulating
toolpaths
Simulating parts
FeatureCAM provides several types of simulation:
Centerline simulation. Lines are drawn that represent the center of
the tip of the tool. Rapid moves (G0) are shown in green, and lines
and arcs (G1, G2, G3) are shown in black. These colors can be
changed if desired. This simulation method is usually the fastest.
2D Simulation. For turning, this style shows a cross section of the
part. For milling this style shows a flat (from the top) view of the
part, with each tool being shown in a different color.
3D Solid Simulation (sometimes called Visicut). This style shows a
three-dimensional shaded rendering of the initial stock and
simulates material removal in 3D. You can optionally display the
holder. Any gouge caused by holder interference or the tool hitting
the part during a rapid move is displayed in pink. For turning
simulation a 3/4 cut-away view is optionally available to view ID
cuts.
3D RapidCut. Shows a very fast simulation of a 3-axis milling job.
Can also be used for 2.5-axis milling, but is best for 3-axis milling.
Full Machine Simulation (see page 536). Allows the user to show
the motion of the entire machine tool.
With all simulation methods, video-style controls are used to pause, stop
and step through the toolpath, providing the user with fine control over
the process.
40 Generating/simulating toolpaths
Interaction between viewing and

simulation
Show centerline - uses the current view to draw the toolpaths over
whatever is currently displayed. If Keep toolpaths with view change (see
page 52) is selected, you can view the part and the toolpaths
dynamically. If Keep toolpaths with view change is not selected,
the toolpaths are erased when the view is changed.
2D simulation - the view is changed to the top view automatically
and anything on the screen is temporarily erased until the simulation is
complete. The view cannot be changed during the simulation. After the
simulation is complete you can change the view, but the toolpaths are
erased.
3D simulation - the simulation is performed in the current view.
You can dynamically change the view of the simulation at any point
during or after the simulation. The simulation does not have to be
recalculated, so the view change is instantaneous.
Rapidcut simulation - this simulation can be viewed dynamically.
For zooming, the image must be recalculated, but this calculation time is
quick. For panning or rotating, the image does not have to be
recalculated, but a lower resolution version is displayed while you are
transforming the part. This lets you change the view more interactively.
How to generate toolpaths

Simulating toolpaths requires three steps:
1. Display the Simulation toolbar by selecting the Toolpaths step
from the Steps toolbar.
2. Select a simulation type.
3. Click the Play button.
See also Using simulation VCR controls (see page 42) for full
information on VCR controls.
Generating/simulating toolpaths 41
Using simulation video-style controls

When you generate toolpaths, they are displayed in the graphics window
using the technique (centerline, 2D, and so on) that you selected. You can
control the simulation using the video-style buttons in the Simulation
toolbar.
The Eject button removes the Simulation toolbar from the screen
and erases the simulation from the graphics window.
The Stop button cancels a simulation.
The Play button restarts a paused simulation.
The Pause button pauses the simulation. The Play button transforms
into the play button after it is clicked. If the Pause button is clicked
during a simulation, it pauses the graphics.
The Single step button moves the simulation ahead one tool move.
The keyboard accelerator for this button is Alt+F3.
The Next operation button continues to simulate until the next
operation. This button is actually a pull-out menu. By clicking the triangle
to the right of the button the following additional options are revealed:
The Next rapid button simulates until the next rapid tool
move.
The Next tool change button simulates until the next tool
change.
The Next Z level button will simulate the next Z of a Z level
toolpath. For other toolpaths it will play the entire next operation.
The Clear toolpath button erases any centerline toolpaths on the
screen.
The Region of interest button limits the portion of part that is
simulated (see page 43).
The Show tool load button indicates whether or not to display a
graph of the tool load (see page 61) when the next 3D Simulation is
performed.
To adjust the speed of a centerline, 2D or 3D simulation, use the Sim

Speed slider on the right-hand side of the controls. Slide to the right to
speed up, and move to the left to slow the simulation down. The slider of
the simulation toolbar also affects the display for rapidcut simulation. If
the slider is all the way to the right, only the final simulation result is
displayed. Position the slider bar further to the left to see intermediate
results.
See also Manufacturing operations sheet (see page 64).
Pausing a toolpath simulation

You can pause a simulation using any of the following techniques:
Click the Pause
button in the Simulation toolbar.
Set a break point (see page 66).

Use the Single step
Next tool change
, Next operation , Next rapid

buttons in the Simulation toolbar.
or
See also Using simulation video-style controls (see page 42).
Region of interest
The Region of Interest
button in the Simulation toolbar lets you
limit the portion of the part that is rendered during a 3D solid
simulation or 3D Rapidcut
simulation. There are two main reasons
to do this:
The rest of the part is not simulated and so it is faster to simulate
your region.
If you are using RapidCut, the region is simulated at a finer
resolution.
There are three different types of region:
Stock: This is the default type of simulation where the entire stock is
rendered during simulation:
Feature: Select the name of the feature from the drop-down list and a
region around the feature will be selected as the region.
XYZ Location: The region is defined by either a box you drag or by two
points whose coordinates you can enter.
The sides of the box are aligned with the X and Y axes.
See also Simulation types, Using simulation video-style controls (see

page 42) and Generating/simulating toolpaths.
Preview simulation button

Simulations are normally performed on all features in a setup. To
simulate a single feature or operation:
1. Double-click a feature.
2. The Properties dialog comes up.

3. Select the feature or an operation in the tree view.
4. Click the Preview button. The Properties dialog is hidden. A
special version of the Simulation toolbar is displayed.
5. Click the Play Feature button. See Using simulation video-style

controls (see page 42) for more information.
6. Click the Eject button. The Properties dialog is redisplayed.
Part Compare
Part compare is a feature of Rapidcut simulation that lets you compare
the results of a toolpath simulation with the actual part model. Regions
that are properly cut are displayed in green. Regions where extra material
remains are shown in light or dark blue. Gouged regions are shown in
yellow or red. Click here (see page 46) for an example.
To run part compare:
1. Set the desired Part compare parameters (see page 54) tolerance.
2. Run a rapidcut simulation.
3. Select View > Simulation > Show part compare from the
menu.
To view the actual part model that the simulation is compared with, select
View > Simulation > Show target part from the menu.
If you adjust the view after a part compare has been performed, a
new rapidcut simulation is performed automatically, but you must
run another part comparison.
Part compare also works with the region of interest (see page 43).
Part compare example

In the example you can see that the trough is undercut.
Examining the trough more closely, you can see that the bottom of the
trough is greatly undercut. This is indicated by the dark blue color. The
light blue regions indicate a slightly undercut region.
See also part compare (see page 45).
Simulation options
The behavior of the Centerline, 2D and 3D simulations is controlled by
the settings in the Simulation Options dialog, available in the
Options menu. You can open this dialog while a simulation is running
and refine or coarsen the simulation on-the-fly. If you open Simulation
Options during a simulation, the simulation pauses until you close the
dialog. You will get an error message if you run the 3D simulation in a
display showing fewer than 256 colors. The simulation will still run, but
won't look as good.
General simulation options
2D/3D shaded simulation options
Centerline simulation options
Part compare options (see page 54)
Wire simulation options

Tool colors
This simulation option simulates the cuts of each tool with a different
color. This lets you graphically view which portions of the part are cut
with which tool. After you run a 3D simulation, you may toggle this
setting without re-running the simulation. The figure below shows an
example of tool colors.
For Centerline simulation this option will display each tool in a different
color during the simulation.
Show holder
Show holder toggles the display of the tool holder during Centerline
and 3D solid simulation.
See also Overview of spindles and toolholders (see page 110).

Show spindle
Show spindle toggles the display of the spindle during Centerline and
3D solid simulation.
You must also set Show holder (see page 47) in order to view the
spindle.
See also Overview of spindles and toolholders (see page 110).
Simulation speed
Control the speed of the simulation with the simulation speed slider. This
slider controls the speed of 2D and 3D solid simulation.
Status options
The Status section of the Simulation Options dialog shows the
information that is displayed in the status bar during simulation. Check
boxes show which information in the status bar.
Time turns on the display of the machining time estimate.
Feed displays the feed rate for the operation being simulated.
Speed displays the spindle speed rate for the operation being simulated.
Operation displays the name of the operation currently being simulated.
Tool displays the name of the tool performing the current operation.
Position shows the X, Y and Z positions of the tool on the screen. If you
are using indexing, the angle you are rotated around the axis is also
shown.
This option can slow the simulation.
2D/3D simulation options

Resolution
Resolution controls the quality of the image and affects the speed of the
simulation. Set it to a positive value. The default value is 1. If you double
the value (by setting it to 2.0), the tool is subtracted from the block half as
often. If you decrease the value, the tool is subtracted from the block
more often. If the simulation is too chunky, decrease Resolution by
half. If the simulation quality is acceptable, but it is running too slowly,
double the Resolution.
Power graph sample/min
The tool load graph is determined by measuring the tool load a certain
number of times per minute. The power graph samples/min is the
number if samples to take per simulation minute.
See also Tool load (see page 61).
3/4 view with lathe ID work
This option enables a 3/4 cut-away view for ID work for turned setups.
This figure shows an example of the 3/4 view:
Translucent part
Select this check box to change the stock of a 3D solid simulation to be
slightly transparent.
Translucent tool
Select this check box to change the tool of a 3D solid simulation to be
slightly transparent.
Pause on gouge
Pause on gouge toggles the pausing of the 3D simulation if a gouge is
detected with the part or tool holder. See Detecting gouges (see page 58)
for more information.
Show pause on gouge dialog
This option turns on the display of a dialog to warn you that a gouge has
taken place. If this option is deselected, then the simulation just pauses
without displaying a dialog when a gouge is detected.
Tool cutting tolerance
This tolerance affects the fineness of the 3D simulation. If this is set high,
the simulation will appear more faceted. The lower this tolerance is set,
the smoother the simulation will appear.
Tool visual tolerance
This tolerance affects the appearance of the tool. By increasing this
tolerance, the tool appears chunkier. By decreasing the tolerance the tool
will look rounder and smoother, but the simulation will take up more
memory and may be slower.
Rotate view when indexing
This setting applies to 4th or 5th axis indexed parts and turn/mill parts.
With Rotate view when indexing selected, the simulation will rotate
the part for an A-axis or B- axis indexing move in milling or for a C-axis
rotation in turn/mill. While these rotations provide for a more accurate
simulation, they can slow down the simulation especially with
simultaneous X- and C-axis moves in turn/mill. To speed up the
simulation, deselect this setting and the part will stay fixed and the tool
will move around the part.
3/4 view with lathe ID work (see page 49) must be deselected for
Rotate view when indexing to work with turn/mill parts.
View independent
This attribute is normally selected. In this state, you can pause a 3D
simulation and change the view at any time. This simulation method uses
a solid model and should be used for all 3D simulations except animated
simulations of ballend tools. For simulating ballend tools, we recommend
that you deselect View independent. It will not allow you to rotate the
model, but the simulation will run considerably faster. Remember this is
for ballend tools only.
Save result files during rapid cut
This option must be turned on to view intermediate shaded simulations
(see page 68) in rapid cut mode. This option is useful if you want to have
quick access to images of the part at the conclusion of each operation.
This option requires a lot of memory and slows down the simulation
process, so we recommend that you use it only when you want to study
the results of each operation carefully.
Steps % of Normal
Steps % of Normal is a value between 0 and 200 that changes the
animation step size for 2D Simulation. Set it to less than 100 to decrease
the step size and to more than 100 to increase it.
5-axis simultaneous wrap tol
This tolerance controls the linearization of the 3D simulation. If this is set
larger, the simulation of 5-axis simultaneous features will be faster, but
may not be entirely accurate as the tooltip of the machine will tend to
travel in arcs instead of straight lines. (See Linearization (see page 297).)
If this tolerance is set smaller, the simulation of 5-axis simultaneous
features will be more accurate, yet the simulation will be slower.
This control is only visible if the 5-axis simultaneous product is available
(licensed or in evaluation mode).

Show centerline prior to 2D/3D simulation
If the 2D or 3D simulation button is selected without performing a
centerline simulation first, the toolpaths must be generated. If Show
centerline prior to 2D/3D simulation is selected, a centerline
simulation is shown while the toolpaths are being generated and then the
2D or 3D simulation is then performed. If it is deselected, then the initial
toolpaths are generated without display and then the 2D or 3D simulation
is performed.
Keep toolpaths with view change
Keep toolpaths with view change leaves the toolpaths on the screen
while you change the view of the part. Without this setting, the toolpaths
are erased when the view changes.
Saving the toolpaths for interactive viewing needs extra memory.
See also Simulation options and Centerline simulation options.
won't look as good.
Show tool animating
Select Show tool animating to view the tool as a line drawing as the
centerline toolpaths are displayed. This setting must be selected to see the
toolpaths in an incremental manner. If Show tool animating is not
selected, the toolpaths for the entire part are shown all at once at the
conclusion of the calculation.

won't look as good.
Smooth animation
Smooth animation controls the display of the tool during Centerline
simulation. With Smooth animation selected, the tool will be
displayed without flickering during the simulation. With this setting
deselected, the simulation will need less memory, but will flicker some
during the simulation.
won't look as good.
At maximum animation speed, only update display every

Only update display every controls the display of the centerline
toolpath as it is calculated. This number controls how often the toolpaths
are displayed. This number is specified in minutes of tool travel, that is, if
the feed rate is 100 inches per minute and Only update display every
is set to 0.5 minutes, then the screen will be updated after the tool has
moved 50 inches. A zero setting causes the screen to be updated for every
block of NC code. If the speed control slider is not set to the maximum
value the Only update display every setting will be ignored.
In previous versions of FeatureCAM, this was called Toolpath
update.
won't look as good.
Rapidcut conversion tolerance

When mixing 3D solid and rapidcut simulations (see page 57), the images
must be converted from one type to the other by FeatureCAM. If you
want to improve the quality of the part when it switches representations,
decrease this tolerance.
Part compare rest material

The tolerances are located on the Part compare tab of the Simulation
Options dialog.
Rapidcut conversion tolerance (see page 54)
Regions that have extra material greater or equal to the Show rest
material parameter are shown in blue. The more rest material there is,
the darker the shade of blue.
Regions with gouges greater than or equal to the Show gouge
parameter are shown in yellow. Larger gouges are shown in red.
Regions with rest material less than the Show rest material parameter
or gouges less than the Show gouge number are shown in green. These
areas are considered correctly cut.
If either the Show rest material value or the Show gouge value
is set too small, then the part comparison will be very noisy and
difficult to interpret.
Target part tessellation tolerance (see page 55)
See also Rapidcut simulation and Generating/simulating toolpaths.
Target part tessellation tolerance

Rapidcut works by comparing the part cut by the toolpaths with the actual
surfaces of your part, known at the target part. The target part is
approximated by triangles for the comparison. If this tolerance is too
coarse, then the part compare will report gouges or rest material where
there actually is none and the model will have streaks. Decrease this
tolerance to remove such streaks.

Wire visual diameter
The wires used in wire EDM are often quite thin and difficult to see
during a 3D toolpath simulation. Set the Wire visual diameter to a
larger diameter so that the wire is easier to see during the simulation.
Note that the width of the actual cut being simulated is not affected by
changing this number. The cut is always simulated using the actual wire
diameter that is specified in the condition dialog.
Tool cutting tolerance
This tolerance affects the fineness of the 3D simulation. If this is set high,
the simulation will appear more faceted. The lower this tolerance is set,
the smoother the simulation will appear.
Tool visual tolerance
This tolerance affects the appearance of the tool. By increasing this
tolerance, the tool appears chunkier. By decreasing the tolerance the tool
will look rounder and smoother, but the simulation will take up more
memory and may be slower.
Simulating 3D toolpaths
Due to the large number of moves in the toolpaths for a typical 3D part,
animating the entire toolpath using 3D solid simulation is often timeconsuming. Instead, consider one of the following techniques:
Mix 3D solid and rapidcut simulation (see page 57).
Use centerline simulation and pause the simulation periodically and
erase the displayed toolpaths to clear the screen.
Use rapidcut and use the Next operation
see the results of each operation.
button to quickly
Use rapidcut and slow down the speed control so that you see some
intermediate results.
Use a region of interest (see page 43) in combination with either
3D solid simulation or rapidcut.
See also Simulation types and Using simulation video-style controls (see
page 42).
If you are doing a 3D simulation of a large part, you can simulate

two different views at the same time. Before you start the
simulation, select Window > New Window. Arrange the windows
as you want and have one zoomed right into an area to view
detailed simulation and the other showing the whole part. For
example:
Mixing 3D simulation and rapidcut

You can switch between 3D simulation and rapidcut any time the
simulation is paused.
To switch between these two simulation modes:
1. Begin the simulation.
2. Pause the simulation (see page 43).
3. Change simulation types to either 3D solid
4. Click the Play
or Rapidcut
button to restart the simulation.
By using this technique, you can use rapidcut to fast forward to a point
and then use 3D simulation to more carefully study a particular set of
toolpaths.
See also Using simulation video-style controls (see page 42).
Detecting gouges
Using 3D simulation, you can visually detect gouges with the tool (during
rapid moves), the tool holder or the spindle. Any gouge is displayed in
pink. If you want the simulation to pause when it detects a gouge, set the
Pause on gouge simulation option. If this option is set, the simulation
will automatically pause if a gouge is detected. Click the Play button in
the simulation toolbar to continue the simulation. See Simulation options
for additional options.
won't look as good.
Fixture and clamp collision detection

Normally, only the part model is rendered during a 3D simulation. If
Pause on gouge (see page 50) is set, the simulation will stop if the tool
rapids into the part. In FeatureMILL3D, 3D simulation can help you
detect collisions with models of clamps or fixtures that you create as solid
models. To detect these collisions:
1. Create a solid model of a fixture. It can be as elaborate as you need
it to be.
2. Right-click the solid in the graphics widow. Select Use solid as
clamp from the context menu.
3. If you want the simulation to alert you to gouges, select
Simulation from the Options menu. Click the 2D/3D simulation
tab and select Pause on gouge (see page 50).
4. Run a 3D simulation. During the simulation both the part and the
clamp model are rendered. It may take longer for the simulation to
start up because the clamp model is being rendered.
Remember, FeatureCAM does not come with a library of clamps, but the
3D solid modeling capabilities of FeatureMILL3D lets you create these
models from scratch. You can also import clamp models for other solid
modeling systems (see page 15).
If a clamp is defined in a *.fm part file, this clamp will be displayed
during 3D simulation in a tombstone document (see page 458).
Simulating multiple setups

Many parts have more than one setup. Follow these steps to simulate a
part with multiple setups.
1. Arrange the view of your part so you can see the manufacturing
involved in all stages as you can't change the view after you start
the simulation.
2. Click the Toolpaths step in the Steps toolbox to display the
Simulation toolbar.
3. Click the Part View at the bottom of the Steps toolbox.
4. Click the first setup in the Part view.
5. Click 3D simulation from the Simulation toolbar and click
Play.
6. Click the second setup in the Part view.
7. Click Play again.

8. Repeat steps 6 and 7 until you have simulated your entire part.
Manufacturing errors
Manufacturing errors occur when FeatureMILL is unable to complete the
tool path generation for a part. When an error occurs, the user is unable to
run any simulation, post to NC code or save NC code. Errors appear
between lines of asterisks (*) in the operation sheet listed after the
operation in which the error occurred. Errors are also displayed in the Op
List tab with a red exclamation point icon in the left margin. Warnings
are also tagged using an exclamation point on a yellow triangle icon.
If an error is detected during toolpath generation, the Code generation
failed dialog is displayed.
If you click Yes in this dialog, the first error in the operations list will be
highlighted. If you click No, the errors will still appear in the operations
list, but you must explicitly ask to step through the errors by clicking
Next Error.
If an error occurs during toolpath generation, three error buttons appear in
a separate toolbar in the left-hand corner of the window to enable you to
read and fix the errors. The buttons perform the following functions:
Selects the next error in the operations list.
Selects the previous error in the operations list.
Provides options for fixing the error that is selected.
If you click Hint while an error is selected in the Manufacturing
Operations Sheet, a series of dialogs appears to help you fix the error.
See also Error hints dialog (see page 576).
Tool load
3D toolpath simulation can be used to estimate and graph horsepower
requirements. These estimates can be used to fine-tune your program for
maximum performance. By clicking the Show tool load
button on
the simulation toolbar, the Tool Load dialog is displayed when a 3D
simulation is performed. This dialog graphs the horsepower requirements
of the part program and displays the current simulation time and
instantaneous horsepower.
Click the Settings button to display the Power Settings dialog.
Max. Power displays the maximum horsepower value required by the

program so far. If you display this dialog at the end of a simulation, you
can view the maximum horsepower required for the entire program.
Power Limit sets the top power value that is displayed in the Tool
Load dialog.
Pause simulation will pause the 3D simulation every time the power
limit is exceeded.
Show this dialog will display the Power Settings dialog when the
power limit is exceeded.
Clear will clear the graph when the simulation resumes.
The horsepower values are estimates. If you are approaching the
power limits of your machine, you should lower your feed rates, or
decrease the width or depth of your cuts.
The simulation option, Power graph samples/min (see page 49), controls
the accuracy of the graph.
If you have run a feed optimization, the Tool Load graph shows the
current loads in black and the previous (unoptimized) feedrates in white.
Power graph sample/min

The tool load graph is determined by measuring the tool load a certain
number of times per minute. The power graph samples/min is the
number if samples to take per simulation minute.
See also Tool load (see page 61).
Part documentation
Manufacturing reports
Reports
After you generate a toolpath for a particular part, you can get feedback
through the Manufacturing Feedback window or printouts by
clicking the Details tab located at the bottom of the Results window.
At the top of the Details tab, there are two options.
Operation List displays a detailed report on each manufacturing
operation. Click here for Detailed explanation (see page 64).
Shows the Manufacturing Operations Sheet. This option
corresponds to the Operations option of the Show Reports submenu
of the View menu.
Tool List displays a report on the automatically selected tools. See
Tooling groups (see page 83) for specific parameters for each tool
type.
To view the NC code for your part click the NC Code tab. This posts the
part program and shows the M & G-codes. It is not a report in the normal
sense, but is often reviewed as a report by those who understand NC
code. You can also display the NC code by clicking the NC Code
icon in the Steps toolbox.
If you hold the Shift key down and then click the NC Code tab, the
underlying ACL code is displayed in the Manufacturing
Feedback window.
Part documentation 63
You can not click the NC tab unless you have a dongle installed. Clicking
one of the report buttons shows you the documentation, but it doesn't save
it to disk. Use Save NC (see page 138)from the File menu to save the
documentation.
The Turrets tab (see page 523) is used for synchronized turning.
See also Changing the fonts for the reports in the Manufacturing
Feedback window (see page 65).
Operation List
The Operation List sheet lists information for each manufacturing step
on cut type, cut depth and center point, tool details, speed/override,
feed/override, and estimated manufacturing time. It is displayed when
you click the Op List tab at the bottom of the Results window.
Part name
Part name shows the file name of the part. If you have not saved your
part, the default part name is FM1.
Setup name
Computed at
Stock
Stock material
Step no
Cut type
Feature
Pass
Tool slot no.
Tool diameter
Cut depth
Cut step
Speed
Feed
Feed is the feed of the tool that performs the currently selected operation.
The feed can be in IPR or IPM units depending on the unit set on the
operation
Est. HP and Power
Priority
64 Part documentation
Manufacturing tool detail sheet

Whenever you simulate a part, the Manufacturing Tool Detail sheet is
automatically generated. The Manufacturing Tool Detail sheet
provides in-depth information on the following three items:
Tool name shows name of the tool.
Tool slot no. shows the tool slot (or tool pocket) that contains the
tool.
Tool offset no. shows the tool cutter comp. offset register. If the
offset register has the same number as the Tool Slot No. it is not
reported.
More information on changing the Tool Slot No. or the Tool Offset No
(see page 108).
Changing the fonts for the reports in the

Manufacturing Feedback window
You have a choice of three fonts for the text in the Manufacturing
Feedback window.
To change the font:
1. Right-click in the window.
2. Select either Small Font, Medium Font, or Large Font.
Op List tab
Clicking on the Op List tab in the Manufacturing Feedback window
brings up a table of operations.
Each row displays the operation, the feature that the operation came from
and the tool that will be used to cut the feature.
If there is a or a icon in the left hand margin, you have an error or
warning (see page 60) for this operation.
This tab has three main functions:
Simulation control (see page 66)
Operation ordering
Operation editing (see page 69)
Simulation control using the Op List

tab
As the toolpaths are simulated, the current operation is indicated with a
yellow arrow in the left-hand margin. You can also set break points in the
simulation. A break point will pause the simulation at a particular
operation. You can then use the video-style controls (see page 42) to
control the simulation.
Breakpoints in op list tab (see page 66)
Display a single Z level (see page 66)
Viewing centerlines for an operation (see page 67)
Viewing intermediate shaded simulations (see page 68)
Breakpoints in Op List tab

To set a breakpoint:
1. Click the operation that you would like to pause on.
2. Click the Breakpoint
button. A maroon dot will appear in the
left-hand margin. The simulation will now pause when it reaches
this operation.
To remove a breakpoint:
1. Click the operation that has a breakpoint set on it. (It will have a
maroon dot in the left-hand margin.)
2. Click the Remove breakpoint
button.
To perform a centerline simulation of a single operation:

1. Click the operation that you would like to simulate.
2. Click the Preview toolpaths
button top of the Operation List.
The simulation toolbar is displayed. Follow the steps explained
here (see page 44).
Display a single Z level

To display a single Z level of a Z rough or Z finish operation:
1. Click the Show Centerline

button and click the Play
button to simulate all of the toolpaths for your part.
2. Click the Clear toolpath
button.
3. Click a Z level operation in the Op List tab. All of the toolpaths of

that operation will be displayed and a menu is available under the
operation name.
4. Click a Z level from the menu and the toolpaths from that level will
be displayed.
Viewing centerlines for an operation

To view all the centerline toolpaths for an operation:
1. Click the Centerline simulation

button.
2. Click the Clear Toolpath
button, then click the Play
button.
3. Click any operation in the Op List tab.
Viewing intermediate shaded

simulations
To view intermediate shaded simulations:
button or the Rapid cut simulation
1. Click the 3D shaded
button, then click the Play
button.
2. Click an operation to display the machined model up to that point
in the process.
3. At the end of the list of operations is the word, Result. Click this
word to view the final simulation image for your part.
You must turn on the 2D/3D shaded simulation option Save result
files during rapid cut (see page 51) for this procedure to work for
rapid cut simulations.
Turn operation order

The Turn operation order option of the Manufacturing menu
displays the general outline that is used for ordering turning operations if
the Use operation template default ordering attribute is set. The dialog
that displays lists the types of operations that are created in a general
turned part. The order of the list determines the order that the operations
in your part will be cut. If your part does not have a particular operation
in it, that operation is skipped.
By selecting an operation type and using the arrow keys, you can change
the order in which the features are manufactured. After rearranging the
list, click OK. This order will be remembered for all of your parts.
Feature and operation editing using the

Op List tab
The Op List tab also lets you edit features and operations. Doubleclicking on a column brings up the following dialogs:
Column Dialog
Operation
Mill or Drill tab for the operation. Here you can modify
manufacturing attributes.
Feature
Dimensions tab for the feature. Change dimensions for

the feature or click the Strategy tab to alter the types of
operations that will be used to manufacture the feature.
Tool
Tools tab for the operation. Review tooling details or

modify the tooling for the operation.
Feed
F/S tab for the operation.
Speed
F/S tab for the operation.
Retract
Single-click this column to change the retract plane for

drilling features. See Combine with similar holes into
canned cycle for more information.
If a manufacturing error is detected for an operation that would prohibit

generating toolpaths, a stop sign icon is displayed in the left-hand side
of the row. Click this icon to try and fix the error.
You can also right-click a row of the table and a menu of feature
tabs is displayed. Select the tab name to go directly to that tab. See
also Overriding the tool, feed or speed for multiple operations at
once (see page 70).
Overriding the tool, feed or speed for

multiple operations at once
1. Select the first operation in the Op List tab in the Results
window.
2. Hold down the Shift key and select the last operation so that a
block of operations are selected.
3. Right-click the selected group. A context menu will be displayed
with three items that begin with the word Override. Select the
menu item to override the tool, feed or speed of all operations so
that they are identical to the first selected operation.
Printing
You can print the tooling lists, operations sheets, NC programs, and
drawing for a part using Print from the File menu. You can also preview
these documents with Print Preview. Some options may be grayed out
in the dialog if you haven't generated toolpaths and thereby created the
lists and some of the graphics options. The files are all ASCII text files
that print like a text document.
1. Select what you want to print in the Print Range section of the
dialog. See FeatureCAM file types for more information.
2. If there is a toolpath displayed and you want to print it, click Print
tool path.
3. If you want to print so that the units of your part are honored, click
Print to scale. This means that a 1 inch line segment will
measure 1 inch on the paper. If your part is larger than your
physical sheet of paper only a portion of your part will be printed.
If Print to scale is deselected, your drawing will be scaled to fit
the paper.
4. Set your Print Quality. The specific options depend on your
printer.
5. Set the Number of copies to print.
6. Click OK.
Setup opens the standard Windows printer configuration window.
File Print Preview command

Use this command to display the active document as it would appear
when printed. When you choose this command, the main window will be
replaced with a print preview window in which one or two pages will be
displayed in their printed format. The print preview toolbar gives you
options to view either one or two pages at a time; move back and forth
through the document; zoom in and out of pages; and start a print job.
File Print Setup command

Use this command to select a printer and a printer connection. This
command displays a Print Setup dialog box, where you specify the printer
and its connection.
Tooling
FeatureMILL has extensive tooling databases and automatically selects
tools for each manufacturing operation.
Overview of tooling (see page 73)
Previewing the automatically selected tool (see page 73)
Tooling database (see page 75)
How to import tooling (see page 78)
How to export tooling (see page 79)
How to explicitly set a tool for an operation (see page 80)
Assigning tool numbers (see page 108)
Spindles and toolholders (see page 109)
Tool life management (see page 114)
72 Tooling
Overview of tooling
For each manufacturing operation in created for the features of a part, a
tool must be selected from the internal tooling database. This database is
broken into separate tool cribs to represent individual collections of tools
that your organization might have. The figure below shows the structure
of the tooling database.
FeatureMILL comes with two different built-in tool cribs. The Basic crib
is the default crib that contains standardly available tools that most shops
will own. The Tools crib is a large, crib containing thousands of tools.
This crib is most often used as a source to copy from into custom tool
cribs or into the basic tool crib. Only one tool crib is available at a time
and all tools are selected for a part from only the current tool crib. Tool
cribs contain individual tools and they are classified into tool groups such
as drills, end mills, and boring bars. You cannot create new tool groups,
but you can create new tools to reflect the specific tools that your shop
owns.
Each feature type has rules for tool selection. By double-clicking a
feature and clicking the Tools tab, you can see the specific tool that has
been selected to perform the operation. A feature's Tools tab is also a
convenient place to override the tooling choice if you prefer another tool.
Previewing the automatically-selected

tool
To see the parameters of the tool that was selected for an operation:
1. Double-click the feature to bring up the Properties dialog.
2. Click the operation in the tree view.
Tooling 73
3. Click the Tools page.

4. For a turned feature the selected tool is highlighted in the list and it
has a D in the check box.
5. For a milling feature, the diameter of the tool is listed on the Tools
page.
Tool numbering
FeatureCAM automatically selects tools from the active tool crib. These
tools are assigned a tool number (also referred to as a tool slot or tool
pocket) for an automatic tool changer. The numbering is assigned
according to the following rules.
1. Use the number assigned in the Tool Mapping (see page 108)
dialog.
Note that this numbering is in effect for the current part only.
2. If no number has been assigned via tool mapping, then the number
assigned to the tool in the crib (the Tool number field for milling
tools or the Tool slot for turning tools), is used as the tool
number. If two tools have the same permanent number in the crib,
the first tool used is assigned the preset number and the other tool
is given a new number.
3. If no number has been assigned via tool mapping or in the crib,
FeatureCAM assigns a tool number.
See also:
Milling tool overrides tab
Tool Mapping (see page 108)
Turning tool overrides tab (see page 92)
74 Tooling
Tooling database
The tooling database defines the set of tools from which FeatureMILL
selects tools to perform manufacturing operations. These tool sets are
called cribs. FeatureMILL comes with two standard tool cribs, the Tools
tool crib and the Basic tool crib. The Tools tool crib is a comprehensive
tool crib that contains more tools than your shop probably owns. The
Basic tool crib contains a smaller set of tools such as HSS endmills and
standardly available drills. By default FeatureMILL is set to use the Basic
tool crib. You should modify the cribs to reflect the tools your shop has.
You might also want to construct some cribs of commonly-used tools that
you use over and over again. This can simplify setting up for making the
part.
The currently active tool crib is displayed in the status bar. To change
which tool crib you are currently using, click the crib name in the status
bar. A menu of cribs is displayed that you can select from.
To create or modify a tool crib, you must have a part file open. Then
access the Tool Manager dialog by selecting Tool Manager (see page
76) from the Manufacturing menu.
Initializing FeatureCAM databases

The tooling and feed/speed databases are created using the INITDB
Initialization program in FeatureCAM. This is the program that is run the
first time you run FeatureCAM to create your initial database. You may
also want to use INITDB for the following reasons:
Adding default tools and feed/speed tables to the database (see
page 125)
Recreating tooling and feed/speed databases if they become corrupt
(see page 129)
Support for shared network databases (see page 75)
Shared Network Database

FeatureCAM supports the sharing of the tool and feed/speed database on
a network so that multiple computers have the ability to use the same tool
cribs and feed/speed information. Presently, the shared network database
is provided as an empty MDB format database, created by Microsoft
Access and accessed using the Microsoft Jet database driver.
Tooling 75
The database must be set up properly before it can be used. Follow these
steps:
1. Establish a location on your network for the database and copy a
blank database from the FeatureCAM CD-ROM to that location.
2. Fill the database with default tooling and feed/speed information.
Do this by running INITDB on any computer that has access to the
database and point INITDB to the database.
3. When installing FeatureCAM on user computers, instruct them to
reference the shared network database during the installation
process. Or, if FeatureCAM is already installed on the user system,
then instruct the FeatureCAM user to use the File options dialog
to switch from a local database to a shared network database
Tool Manager
Use the Tool Manager to view, modify or add tools to a tool crib. Tools
are separated into groups. The Tool group drop-down list box contains
the groups supported by FeatureMILL.
The Tool Manager only shows one type of tool at a time. The dialog is
arranged so it's convenient to move tools from one crib to another. In
general you want to have the Tools tool crib listed as the From crib and
the Basic tool crib listed as the To crib.
The fields of the Tool Manager dialog are explained below.
Tool manager list options
Tool Groups (see page 83) list for tool cribs are separated into related
groups, according to the type of manufacturing operation that class of
tools typically performs.
From crib list
Available tools list
To crib
New tool
New crib
Delete crib deletes the current tool crib. See How to delete a tool crib
(see page 78) for more information.
Select all
Add
76 Tooling
The Import button brings up the Tool Import dialog. This allows you to
import tools from other FeatureCAM users.
The Export button brings up the Tool Export dialog. This allows you
to export tools so that you can share them with other FeatureCAM users.
There are two different file types that are supported, *.xml and *.tdb. We
recommend that you use the *.xml format as it supports exporting form
tools and custom drawn holders.
Remove
Current tools
OK
Cancel
Tool grades
Properties: Select a tool in the Available Tools or Current Tools
list and click Properties to see more details of the tool.
Default tool registers
Tooling Speed and Feed overrides
Adding tools to an existing tool crib

To define or add tools to a new tool crib, you use an existing tool crib as a
basis - initially you'll use the resident Tools tool crib. You can either
copy a tool definition directly from an already defined tool crib (such as
Tools) to a new tool crib, or you can create completely new tools.
See Adding tools or New tools.
1. Select the name of the toolcrib that contains the tool definition in
the From Crib list.
2. Select the name of the destination crib in the To Crib list.
3. Click the name of the tool you wish to add in the Available Tools
list. You can select more than one tool definition at a time by
pressing the CTRL key while making each selection, or you can
select a tool group's entire tool list using the left Select All arrow.
4. Click Add.
Tooling 77
Adding a new tool grade for turning

operations
1. Select Feed/Speed Tables from the Manufacturing menu.
2. The Feed/Speed Tables dialog displays with the current
material type selected and the appropriate tab displayed based on
the type of setup you are in.
3. Click the Turning tab if not already displayed.
4. Click the Tool grades button.
5. Click the New button and enter the new tool grade name.
6. Under When F/S table is undefined select either:
Generate Toolpath Error if you want to define all table
entries.
Scale Existing Material to get values from another material.
Select the existing material from the drop-down list box and
enter the scaling values for speeds and feeds.
7. Click OK.
8. If you selected Generate Toolpath Error, fill in all table values.
9. Click OK.
How to delete a tool crib

1. Select Tool Manager from the Manufacturing menu.
2. Select the crib to delete as the Current Crib.
3. Click the Delete Crib button.
4. Confirm the deletion.
5. Click OK.
How to import tooling

1. Select Tool Manager from the Manufacturing menu.
2. Click the Import button. The Tool Import dialog comes up.
3. Enter the name of the file to import under Import File.
4. Select a tool crib to add the new tools to.
78 Tooling
5. Select an option for handling new tools with the same name as
existing tools:
Select Overwrite if you want the new tool to be copied over
the old one.
Select Add 2nd Copy to add the new tool under a different
name.
Select Skip Tool, to ignore any new tools with the same name
as old tooling.
6. Click Import.
7. Click Close.
See also How to export tooling (see page 79)
How to export tooling

1. Select Manufacturing > Tool Manager from the menu.
2. Click the Export button. The Tool Export dialog displays.
3. Enter the name of the file to export under Export File. There are
two different file types that are supported, *.xml and *.tdb. We
recommend that you use the *.xml format as it supports exporting
form tools and custom drawn holders. To change the type, click the
button and select *.xml as the type.
4. Select the Tool crib to be exported from the drop-down list.
5. In the Tool Groups list select the groups you want to export.
6. Use the Include all items
button to select all groups. Use the
button to deselect all groups.
Exclude all items
7. Click Export.
8. Click Close.
The file created is tab delimited text. You can edit the file in a
spreadsheet if desired. This file can now be imported into FeatureCAM.
See How to import tooling (see page 78) for more information.
Tooling 79
How to explicitly set a tool for a milling

operation
For milling operations you can specify the tool by diameters (see page
92) using the feature's Tools tab.
See also Tool Mapping (see page 108) and Tooling database (see page
75).
How to explicitly set a tool for a turning

operation
1. Double-click the feature to bring up its Properties dialog.
3. Select the tool name in the table to select a specific tool.
See Tools page for more information.
How to put two tools in the same tool

slot
There are situations in turning when two different tools are loaded in the
same tool slot. For example, two drills may be loaded with one facing the
main spindle and the other facing the subspindle. Use the following steps
to implement this tooling setup.
1. Program the part as if the tools are in separate tool slots.
2. Open the Tool mapping (see page 108) dialog.
3. Set the Tool number of the two tools to the same number.
4. Set the Length offset register number to different values for
the two tools in the same tool slot.
How to use an insert drill to drill and

bore in the same program
1. Create the hole feature and override the tool for the drilling
operation to be an insert drill.
80 Tooling
2. Create the bore feature and override the tool to be the same insert
drill.
If you view the tools in the Tool mapping (see page 108) dialog, you see
that there are two drills listed in the same tool slot, but they have different
Length offset registers.
Form tools
The FeatureCAM tool cribs contain thousands of industry-standard tools
in a wide variety of types. Custom-shaped form tools are not included in
the default tool cribs, but you can create these tools and use them to cut
features. The pictures below show examples of form tools.
Using these tools does not change the toolpaths generated for features,
but the 3D simulation does simulate the proper shape of form tools. Form
tools are never automatically selected, but they can be manually selected
by the user.
Form tools have unique shapes, but their type must be endmill, twistdrill
or sidemill. If you want to use the form tool to perform a milling
operation it must be an endmill form tool. Drilling operations can be
performed with endmill form tools or twistdrill form tools. OD/ID
grooves can only be performed with sidemill form tools.
Creating a form tool (see page 81)
Displaying a profile of an existing tool (see page 82)
Using a form tool or insert drill for drilling operations (see page 82)
Creating a form tool

1. Create a tool using either the New tool button of the tool manager
button of the tools page.
(see page 76) or the New tool
Tooling 81
2. Make sure you are creating an endmill, sidemill or twistdrill by

having a tool of that type selected before clicking the button.
3. Click Use curve to define tool shape.
4. A drop-down list box is displayed. Select the name of the curve
you would like to use.
Only curves that meet the requirements for form tools are
listed.
5. Click OK.
When you specify the shape of a tool with a curve, many of the
dimensions normally entered for a tool are no longer used, but the
diameter dimension is still critical for milling operations. The
diameter is still used for calculating stepovers and generating the
paths.
See also Displaying a profile of an existing tool (see page 82).
Displaying a profile of an existing tool

When creating form tools, it may be helpful to get the profile of an
existing tool to use as a reference. Use the following procedure to get a
tools profile curve:
1. Open the tool manager (see page 76).
2. Double-click the tool to bring up its Property dialog.
3. Click the Paste copy of curve button.
4. Click Cancel in the Property dialog.
Using a form tool or insert drill for

drilling operations
When drilling with a standard twistdrill, extra depth is added to the
operation to account for the drill tip geometry. When a form tool or insert
drill is used for drilling, no extra depth is added automatically. You can
still use the Drill depth attribute to manually add extra depth if desired.
82 Tooling
Using an insert drill for both drilling

and boring
1. Create both the drilling and boring operations.
2. Override the tool for the drilling operation to use an insert drill.
3. Override the tooling for the boring operations to use the same
insert drill.
If you look at the Tool Mapping dialog, you see that the insert drill is
listed twice. Each listing has the same tool slot, but the Length offset
registers are different. See also How to put two tools in the same tool slot
(see page 80).
Iscar Cut-grip tooling

FeatureTURN has special support for these tools. To activate this support:
1. Create a turning feature. Note that using this tool on a grooving
feature does not create specialized toolpaths.
2. On the Strategy tab, set toolpath type to Cut-grip to generate
specialized rough and finishing strategies.
3. Override the tool to a cut grip tool. This is a tool with the Cut grip
tooling attribute selected.
4. After cutting a part measure the deflection, set this parameter on
the Turning tab and regenerate toolpaths.
Milling tools
Tooling groups
Tool Groups lists for tool cribs are separated into related groups,
according to the type of manufacturing operation that class of tools
typically performs. The following tool-group divisions are defined for
FeatureMILL. The following figures illustrate the parameters that define
all of the tooling groups.
Boring bars for milling (see page 85)
Chamfer mills (see page 85)
Counter bores (see page 86)
Tooling 83
Counter sinks (see page 86)

Endmill tools (see page 87)
Face mills (see page 88)
Reams (see page 88)
Rounding mills (see page 88)
Side mills (see page 89)
Spotdrills (see page 89)
Centerdrills (see page 90)
Taps (see page 90)
Thread mills (see page 91)
Twist drills (see page 91)
Turning tools
Common milling tool parameters

All milling tools have the following parameters:
Name is a string that identifies the tool.
Measure indicates the units that are used for reporting the tools
dimensions. Check the inch check-box for inches or deselect the box for
millimeters.
Material indicates what the tool is made out of. This information is
important when calculating the feeds and speeds (see page 118).
Finish is the coating or finish on the tool. This information is also used
in feed/speed calculations.
Exposed length is the amount of the tool that sticks out of the holder if
the holder is simulated. See Spindles and toolholders (see page 109) for
more information.
84 Tooling
Boring bars for milling

Boring bars are used in milling for boring operation for a hole or for a
step of a step bore feature. The tip radius is only taken into account for
step bores. It is assumed that the user has an adjustable boring bar. For
boring operations, if there is not an appropriate tool in the tool crib
FeatureCAM creates a tool with the name user_adjust. See also
Hole: Tool Selection.
See also Common tool parameters (see page 84).
Chamfer mills
Chamfer mills are used for chamfer features or for chamfering large
diameter holes.
Tooling 85
Counter bores
Counter bore tools are used for the counterbore operations of counter
bored holes. See also Hole: Tool Selection.
Countersink
Countersink tools are used for counter sink operations on holes.
See also Hole: Tool Selection.
- Shank Diameter
- Body Diameter
- Overall Length
- Angle
- Flat Diameter
86 Tooling
Common tool parameters (see page 84)
Endmill tools
Endmill tools are used to represent flat endmills, ball endmills, bull-nose
mills and tapered endmills. The basic parameters on shown below.
Common tool parameters (see page 84).

For ball end tools, enter the diameter, select the Ball end check box and
the radius is calculated.
For flat end tapered tools there are three different ways to specify the
taper angle, cutter length and diameters:
Enter the Taper angle, Diameter (which is the diameter of the
tool at the top of the taper) and the Cutter length.
Enter the Taper angle, select the Diameter at Bottom check
box, enter the Bottom diameter and enter the Cutter length.
Enter the Taper angle, select the Diameter at Bottom check
box, enter the Diameter (which is the diameter at the bottom of
the taper) and click the Compute from Shank button to have the
Cutter Length computed for you.
Tool End Type and Flute Angle are only used to document the tool
and are not referenced in toolpath generation. Set Tool end type
to Single if it has flutes only on one end and to Double if it has
flutes on both ends. Set Flute Angle to Standard for normal mills
and to High for high helix mills.
Tooling 87
Face mills
Face mills are used for facing features.
Reams
Reams are used for reaming operations on holes. See also Hole: Tool
Selection.
Rounding mills
Rounding mills are used for round features.
Note that the programming point is at the top of the radius.

88 Tooling
Side mills
Side mills are used for OD and ID grooves. The Slitting saw parameter
is only used as documentation on the tool.
Spot drills
Spot drills are used for spot drilling starter holes. Note that center drills
(see page 90) are preferred for spot drill operations. See also Hole: Tool
Selection.
Tooling 89
Center drills
Center drills are used to drill starter holes. They are preferred over spot
drills for spot drilling operations. Spot drill tools (see page 89) can also
be used for spot drill operations. See also Hole: Tool Selection.
Taps
Taps are used to tap holes. For inch tools, you specify the threads per inch
(TPI), and for metric tools, you specify the pitch of the threads.
Spiral-style taps have twisted flutes while Gun-style taps have straight
flutes. Bottom taps have a flat bottom, while plug taps come to a point.
If a bottom tap is required for a blind hole, a warning is issued in the
operations sheet. Regardless of the type of tool used for tapping, the hole
must allow enough clearance for the tap. If the hole violates this rule, an
error message is generated when you enter the hole dimensions. See
Hole: Threading, boring, and reaming for more information on tapping
depth and Hole: Tool Selection for information on tool selection
preferences.
The Limit parameter is ignored for tool selection. It is used only to
document the tool.
Drill diameter
90 Tooling
Tap types
Tapered taps
Thread mills
Thread mills are used for OD and ID thread milling operations.
For single point tools, set Max Pitch equal to Cutter Length.
Twist drills
Twist drills are used for drilling operations.
For insert drills, select the Insert drill check box and enter the Insert
Depth instead of the Angle. If an insert drill is initially chosen for a
drilling operation, the spot drill operation is omitted. See Hole: Drill to
depth for more information on drill depths. See also Hole: Tool Selection.
See also Using a form tool or insert drill for drilling operations (see page
82).
Common tool parameters (see page 84)
Tooling 91
Using a form tool or insert drill for drilling

operations
When drilling with a standard twistdrill, extra depth is added to the
operation to account for the drill tip geometry. When a form tool or insert
drill is used for drilling, no extra depth is added automatically. You can
still use the Drill depth attribute to manually add extra depth if desired.
Selecting tools by diameter

In the Tooling tab of each feature, you can specify the diameter of the
tool to use for each operation. For more information, refer to Tools
Attributes.
Turning tools
Turning tool overrides tab
Use the default tool registers if you want to permanently assign tool
registers for this tool every time it is used. If the tool number is 0, then
this indicates that no default value is assigned to this tool and that
FeatureCAM automatically assigns a tool number when the tool is used.
If you want to change these values only for a particular part, use the Tool
Mapping dialog (see page 108).
Tool number is the current tool slot number for that tool. Tools can
occupy the same tool slot (see page 80).
Diameter offset register number is the diameter cutter comp. offset
register for that tool.
Length offset register number is the tool length offset register. Most
lathe controllers have a single register that contains the length and
diameter offset values. In this case, the Length offset register
number is the important field to set in FeatureCAM.
Tool ID is the tool ID register for the tool. This is a seldom used field
that is used by Bridgeport lathes and occasionally for Cincinnati
Machines lathes.
Coolant is the type of coolant to use for the tool.
Operations is the type of operation to use the tool for. This option is
used to limit the tool to be used for only specific operations.
Max depth of cut is the maximum cut depth that is allowed for this
tool.
92 Tooling
Comments are random comments that can be associated with a tool. A

post processor can be configured to output these comments.
Insert tab
The Insert tab describes the characteristics of the tool's insert. The
specific values contained in this tab are dependent on the type of tool. See
the tool type (listed in the title of the dialog) below for more information.
Lathe - turn tool properties:
Inscribed circle diameter (see page 94)
Insert shape (see page 96)
Name (see page 98)
New material button (see page 98)
Tip angle (see page 94)
Tip radius (see page 95)
Lathe - bore tool properties:
Inscribed circle diameter (see page 94)
Measure (see page 98)
Name (see page 98)
Lathe - groove tool properties:
Cut-grip grooving tool (see page 83)
Name (see page 98)
Tooling 93
Width (see page 98)

Lathe - thread tool properties:
Max TPI (see page 99)
Measure (see page 98)
Min TPI (see page 99)
Name (see page 98)
Inscribed circle diameter
The diameter of a circle that fits inside the insert shape.
Graphic explanation
Tip angle
The included angle of the insert.
94 Tooling
Graphic explanation
Tip radius
The radius of the cutting tip of the insert.
For threading tools, 3D simulation simulates the tool with a tip
radius of 0.0. This is just for visualization purposes only. The NC
code or tool selection is not affected in any way.
Graphic explanation
Tooling 95
Insert shape
The valid insert shapes are listed. For the custom diamond shape, the tip
angle (see page 94) is entered by the user.
Holder tab
The Holder tab describes the characteristics of the tools holder and how
the insert is oriented relative to the holder. The specific values contained
in this tab are dependent on the type of tool. See the tool type (listed in
the title of the dialog) below for more information.
Lathe: turn tool properties
End angle (see page 100)
End clearance (see page 100)
End cut (see page 101)
Length (C) (see page 102)
Shaft Height (A) (see page 103)
Side angle (see page 100)
Side clearance (see page 101)
Side cut (see page 105)
Lathe: bore tool properties
Min diameter (see page 102)
Shaft Height (A) (see page 103)
96 Tooling

Lathe: groove tool properties
Cut depth (see page 105)
Holder type (see page 105)
Shaft height (A) (see page 103)
Lathe: thread tool properties
Holder type (see page 105)
Shaft height (A) (see page 103)
Tooling 97
Measure
The unit of measure of the insert. Select the Inch check box to specify
the insert in inches. Deselect the Inch check box to specify the insert in
millimeters.
Name
The name of the insert. The name must be unique among all the tools in
the crib.
New material button
Click this button to create a new material name. To create a new material
from the Tools Properties dialog:
1. Click the New material button. The Turning Tools Material
dialog displays.
2. Click the New button.
3. Enter the new material name and click OK.
4. Click OK in the Turning Tools Material dialog.
You still have to define feed/speed tables for your new material. See
Adding a new material (see page 119) or Feeds and speeds (see page 118)
Width
The width along the Z axis of a grooving/cutoff tool.
98 Tooling
Graphic explanation
Max TPI
The maximum threads per inch that the tool can cut.
Min TPI
The minimum threads per inch that the tool can cut.
Holder drawing tab

The holders that are created automatically are simple rectangular shapes
that are created based on the holder dimensions. Tools with simple
holders are indicated by the Simple Rectangular Holder radio button
being selected.
You can also create custom holders by modeling a curve that more
accurately reflects the holder's shape. The main motivation for User
Defined Holders is that the simulations are more accurate enabling you
to visually verify holder collisions.
See also:
Creating holder curves (see page 106)
Associating curves with user defined holders (see page 106)
Displaying holder and insert geometry in the graphics window (see page
107)
Tooling 99
End angle
The angle, off of vertical, of the end of the insert.
Graphic explanation
End clearance
The distance from the end edge of the insert to the holder.
Graphic explanation
Side angle
The angle of the side of the insert.
100 Tooling
Graphic explanation
Side clearance
The distance from the side edge of the insert to the holder.
Graphic explanation
End cut
A classification of a tool that indicates that the tool will cut in a direction
parallel with the length of the holder.
Tooling 101
Min diameter
The Min diameter is the smallest diameter that accommodates an ID
tool.
Graphic explanation
Length (C)
The length of the holder.
Graphic explanation for boring tools
102 Tooling
Graphic explanation for turning tools
Graphic explanation for grooving tools
Shaft Height (A)

The height of the holder.
Tooling 103
Graphic explanation for boring tools
Graphic explanation for turning tools
104 Tooling
Graphic explanation for grooving tools
Side cut
A classification of a tool that indicates that the tool cuts in a direction
perpendicular with the length of the holder.
Cut depth
The maximum depth of cut for grooving tools.
Holder Type
Threading and groove/cutoff tools have additional subtypes listed under
the Holder Type parameter.
For threads possible holder types are:
OD Threads - Enter this value for outer diameter threading tools
ID Threads - Enter this value for inner diameter threading tools
For grooves possible holder types are:
OD Groove - Enter this value for outer diameter grooving tools
ID Groove - Enter this value for inner diameter grooving tools
Face Groove - Enter this value for face grooving tools
Cutting - Enter this value for cutoff tools
Tooling 105
Min plunge diameter and Max plunge diameter

Many face groove tools have curved holders. Due to the curvature of the
holders the tools have a limited set of diameters at which they can plunge.
The figure below illustrates the curved shape of the supporting holder.
These two diameters are the minimum and maximum diameters between
which the tool can plunge.
The tool inside edge of the groove must be between the Min plunge
diameter and Max plunge diameter if the groove is being cut in the
positive direction. The outside edge must be between these two diameters
if the groove is being cut in the negative direction.
Creating holder curves
1. If you want to display the insert and current holder shape for a
particular tool, see Displaying holder and insert geometry (see page
107) in the graphics window. This enables you to have a reference
to draw on top of.
2. Regardless of the eventual orientation of the holder in the machine,
draw the holder curve in the XZ plane with the length of the tool
holder in the +Z direction and the leading edge of the insert at the
origin. The curve you draw must be a closed curve. Graphic
explanation
3. Name the curve appropriately so that you can remember is later
when you associate the curve with a user defined (see page 106)
holder.
Associating curves with user-defined holders
Remember that you must create the curve first. See Creating holder
curves (see page 106) for more information.
1. Bring up the Tools Properties dialog for the desired tool. Click
here for specific instructions.
106 Tooling
2. Click the Holder Drawing tab.

3. Select the User-defined holder radio button.
4. Select the name of the curve from the drop-down list box.
5. Click the Set button.
6. Click OK.
The curve is saved in the tooling database independently from the part
file. Any subsequent use of this tool in any part file uses the custom
holder.
Displaying holder and insert geometry in the graphics window
1. Bring up the Tools Properties dialog for the desired tool. See
specific instructions.
2. Click the Holder Drawing tab.
3. Click the Paste to part file button. The holder and insert
geometry are pasted into the graphics window as two separate
curves.
Orientation tab
On the Orientation tab, select the orientation of the holder in the
machine and the handedness of the tool. To set the options on this tab:
1. Select an orientation by clicking the button at the end of the tool
that indicates the desired orientation. Nothing is implied by the
shape of the inserts in the icons. The actual insert of the tool can be
any shape.
2. Select the Handedness of the tool from either Right Hand or
Left Hand.
Program point tab

On this tab you set the point of the insert that is actually programmed.
You can set both the X Programming Pt and the Z Programming Pt.
If they are both set to 0.0 then the center point of the tip arc is
programmed. In this case it is expected that you perform insert radius
compensation at the machine tool.
You should also set the default Tool Programming Point
attribute to Tool Tip Center.
Tooling 107
If you wish to perform insert radius compensation in FeatureMILL, set X

Programming Pt and Z Programming Pt to the radius compensation
values provided with your tool.
You should also set the default Tool Programming Point
attribute to Tool Tip Edge.
See Tool programming point(default attribute) for more information.
Tool Mapping
Tool Mapping is where you change the tool slot assigned to the selected
tool. You can change the Cutter comp. offset register for any tool
here too. Access this dialog by selecting Manufacturing > Tool
Mapping from the menu.
The dialog has a table at the top. Each row of the table represents a tool.
Click the name of a tool to modify its values in the following fields below
the table.
Tool number
Diameter offset register number
Length offset register number
Tool ID
The Tool Mapping dialog has these options:
Set
Clear in crib
Set All
Reset All
Same
You can perform the following operations in the Tool Mapping dialog:
Dragging and dropping tools
Toggling operations for a tool
Increasing tool slots listed
Changing offset registers per operation
108 Tooling
Instructions (see page 109) for changing the Tool number or Cutter
comp. offset register for a tool.
See also How to use an insert drill to drill and bore in the same program
(see page 80) and tool life management (see page 114).
Instructions for changing Tool number

or Cutter comp
1. Click Tool Map in the Post Options dialog.
2. Click the row of the table with the tool you want to change. The
tool slot number and cutter comp offset register appear in the Tool
and Comp text boxes.
If you want to change the Cutter comp. offset register
and the Comp text box is dimmed, click the Same check
box. This box indicates that the Tool slot number and the
Cutter comp. offset register have the same value.
3. Enter the new values in the Tool text box and the Comp text box.
4. Click Set.
Spindles and tool holders

During toolpath simulation spindles and tool holders can be displayed.
This lets you see how the spindle and holders interact with the part and
detect any interference between the holders or spindle and the part.
Overview of spindles and tool holders (see page 110)
Displaying spindles and tool holders during simulation (see page 111)
Setting the length of tool extending past the holder (see page 111)
Detecting of gouging with tool holders and spindles (see page 111)
Spindles and tool holders dialog box (see page 111)
Creating or modifying tool holders (see page 113)
Creating or modifying spindles (see page 112)
Tool holder selection (see page 113)
Tooling 109
Overview of spindles and toolholders

During toolpath centerline or 3D toolpath simulation, the tool is always
displayed. This lets you see the tool moving relative to the part and with
the 3D simulation to detect gouging of the part with the tool. For some
parts, that have closely-spaced features or that approach the part from an
angle, it is possible that the tool holder or spindle might gouge the part. In
these cases, you can simulate the toolpaths while displaying the tool, tool
holder and spindle to ensure that you can clear the part properly. The
figure below shows a 3D simulation in which the spindle and tool holder
are displayed during toolpath simulation.
Spindles and tool holders dialog

This dialog displays the current spindle and the holders that are defined
for it. To change the current spindle, select the spindle from the Current
Spindle list. Click a tool holder to display the spindle and tool holder
combination.
The spindle buttons are:
Create a new spindle. The dimensions of the current spindle are used
as initial dimensions. Creating or modify (see page 112)ing spindles.
Displays the dimensions of the current spindle and lets you alter them.
Delete the current spindle and its tool holders.
The tool holder buttons operate on the selected tool holder:
Create a new tool holder for the current spindle. The dimensions of
the current tool holder are used as initial dimensions. See Creating or
modifying tool holders (see page 113).
Displays the properties of the current tool holder and lets you alter
them.
Delete the current tool holder.
See also Spindles and toolholders (see page 109).
110 Tooling
Displaying spindles or tool holders during

simulation
1. Select the Simulation option from the Options menu.
2. To display the tool holders, select the Show holder check box.
3. To display the spindle, select the Show spindle check box. Note
that you must also select Show holder to display the spindle.
4. Click OK.
Setting the length of tool extending past the holder

Each tool has a parameter called Exposed length. This is the length of
the tool that sticks out past the holder. The properties of a tool can be
accessed in the tool manager (see page 76) or by selecting the Tools tab
of a feature's property dialog.
Detecting gouging with tool holders and spindles

By displaying the tool holders or spindles, they are automatically
included in the 3D simulation gouge detection. See Detecting gouges (see
page 58) for more information.
Spindle properties dialog

Spindles each have a unique name and are defined by the following linear
dimensions.
See also Spindles and toolholders (see page 109).
Toolholder properties dialog

Holder Name - Each toolholder must have a unique name.
Measure - Select the Inches check box if the toolholder dimensions are
in inches. For millimeter dimensions deselect this check box.
Holder type - Holders are either Endmill or Collet. The major
difference between these two types of holders are that collets are
adjustable to fit a range of tool diameters.
Tooling 111
Tool Groups - This button displays a list of tooling types that use this
holder.
Use curve to describe holder shape - If you want to make a custom
holder shape, select this option and select a curve in the drop-down menu
that describes the shape. This curve must be in the XZ plane with one
endpoint at the origin.
Paste copy into graphics window - Click the Paste button to copy
into the graphics window a set of lines and arcs for the current holder
shape. This can be useful as a reference if you are going to draw a custom
holder shape.
Tip diameter - This is the outer diameter of the holder at the tip for
collets. For convenience, you can set the Tip diameter for endmill
holders to Based on tool dia so that the holder is scaled to fit a tool.
Tool Diameter - For collets this can be specified as a minimum and
maximum value, to accurately reflect actual collets, or it can be set to Fit
any tool so that the diameter is adjusted to fit any tool with a diameter
less than the Tip Diameter.
Dimensions - The other dimensions of the holders are shown below.
The following dimensions control the shape of a collet.
See also Spindles and toolholders (see page 109) and Creating or
modifying tool holders (see page 113).
Creating or modifying spindles

To create or modify spindles:
112 Tooling
1. Select Manufacturing > Spindles and Toolholders from the

menu.
2. To modify a spindle, select the desired spindle as the Current
button. The
Spindle and click the Edit spindle definition
spindle properties dialog (see page 111) displays.
3. To create a new tool holder, select an existing spindle as the
Current Spindle (the dimensions of this spindle are used as the
initial dimensions for your new holder) and click the Create new
button. The spindle properties dialog (see page 111)
spindle
displays.
Creating or modifying toolholders

To create or modify toolholders:
1. Select Manufacturing > Spindles and Toolholders from the
menu.
2. Select the desired spindle as the Current Spindle. The tool
holders for that spindle are listed.
3. To modify a toolholder, double-click the toolholder name or select
the toolholder name and click the Edit toolholder definition
button. The Toolholder Properties dialog (see page 111)
displays.
4. To create a new tool holder, click an existing toolholder name (the
dimensions of this holder are used as the initial dimensions for
your new holder) and click the Create new toolholder
button. The Toolholder Properties dialog (see page 111)
displays.
Tool holder selection

Tool holders are selected from the set of Defined tool holders in the
Spindles and tool holders dialog box (see page 110).
In general, if a tool holder that exactly matches your tool cannot be found,
FeatureCAM scales an existing tool holder to fit the tool. If you are just
looking for an approximate tool holder shape, this scaling should create
sufficient simulation of the holder.
Tooling 113
Selection details
Certain operations are associated with collets and others with the endmill
holders. See Creating (see page 112)or modifying spindles for how to
change this association.
Once the holder type is determined, tool selection is based solely on
matching the diameter of the tool with the tool diameter parameter of the
holder. For endmill holders, the holder with the smallest tool diameter
that is greater than or equal to the tool's actual diameter is preferred. For
collects, the tool's diameter must be within min. and max. tool diameter
of the collet. For both the endmill and collet holders, if a match cannot be
made from the existing tool holders, an existing holder is scaled by
adjusting the tool diameter and tip diameter.
Holders are associated with tools in the holders tab of the Tool
Properties dialog.
Tool life management overview

Tool life management lets you limit the use of a tool and automatically
switch to another tool when that limit is reached. It is useful when cutting
hard material that may wear out a tool during a single program run. The
Tool Mapping dialog displays the number of holes that are cut by each
drilling tool and the number of minutes that each milling tool is used
during a single run of the NC program.
To specify tool life information for a tool:
1. Select the tool in the tool mapping dialog (see page 108).
2. Click the Tool Life button.
3. The Tool Life dialog (see page 115) is displayed.
See also Restrictions for tool life management (see page 114) and
Removing tool life restrictions on a tool (see page 116).
Restrictions for tool life management

1. Tool life management is active for milled parts, multiple fixture
parts and tombstone parts.
2. You must generate toolpaths to activate tool life management.
114 Tooling
3. For milled parts, tool life management is only active for the
creation of a single program. Therefore it is active for single setup
parts, or 4-axis or 5-axis indexed parts. For 4-axis and 5-axis parts,
if you have Setup dominant selected, you must also select
Generate single program to enable tool life management. See
the Index tab of the Stock dialog for more information on
indexing. If you have a multiple setup milling part without
indexing, you must deselect all but one setup in the Part View to
enable tool life management for this setup.
4. It is not active for turning, turn/mill or wire EDM parts.
5. Tool life only applies to the use of a tool during the running of a
single program. Tool life information is not stored permanently in
the tooling databases.
Tool Life dialog

Use this dialog to limit the use of a tool during the running of a single
program.
The choices for each tool are:
Use a single tool - Select this option to disable tool life management
for this tool. A single tool performs all operations that are scheduled for
this tool slot.
Divide the cutting time equally between a specified number of
tools - This option divides the work of the tool, equally among
additional tools. For drills, the number of holes drilled is divided among
multiple tool slots. For mills, the milling minutes is divided the same
way.
Limit each tool to a specified number of minutes. Create as
many tools as needed. - For this option you specify a limit (in
number of holes for drills, milling minutes for mills) and additional tools
are assigned when the limit is reached.
Divide cut distance equally between a specified number of
tools - You specify the Number of tools and FeatureCAM divides the
cutting time for this size tool, equally among the tools.
Limit each tool to a specified distance. Create as many tools
as needed. - No tool will cut more than the Distance you specify.
Additional tool slots are then assigned to the same tool and the work is
divided among those slots. When the NC code is created, a tool change is
inserted when the limit is reached.
Tooling 115
Time measurements only consider cutting times. Time spend in

rapid moves are ignored.
See also Tool life management overview (see page 114), Restrictions for
tool life management (see page 114), and Removing tool life restrictions
on a tool (see page 116).
Removing tool life restrictions on a

tool
1. Select Manufacturing > Tool Mapping from the menu.
2. Select the tool and click the Tool life button.
3. In the Tool life dialog select Use a single tool and click OK.
The additional tool slots that were assigned to this tool are deleted.
Turret location
The Turret location is now kept in the *.cnc file, since there may be
multiple turret locations with the advent of multi-turret turning.
To change the location(s):
1. Select Manufacturing > Post Process from the menu.
2. In the Post Options dialog, click the Turn/Mill tab.
3. Click the Edit button and XBUILD opens. Select CNC-Info >
Turrets... from the menu.
See also Tools page for turning.
116 Tooling
Feeds and speeds

Feed and speed values are calculated automatically for each operation
based on FeatureMILL's built-in feed/speed databases. You can also
explicitly set the feed or speed value for any operation.
Overview of feeds and speeds (see page 117)
Feed/speed database (see page 118)
How to explicitly set a feed or speed value for a turning operation
Default feed/speed values for turning (see page 124)
How to explicitly set a feed or speed value for a milling operation (see
page 124)
See also Stock Material
Overview of feeds and speeds

Each feature is automatically broken down into a collection of operations.
Feeds and speed settings for each operation are automatically calculated.
To view the recommended feed or speed value for an operation, click the
operation in the tree view and then click the Feed/speed tab for turned
features or the Tools tab for milling operations.
The recommended feed and speed values are extracted from a built-in
database in FeatureCAM. The combination of the stock material, the tool
material and the manufacturing operation are used to find the suitable
values in the FeatureMILL feed/speed tables.
You can customize this database by changing the values for an existing
table or by creating a new table for an additional material. By
customizing the database in this way, you are ensuring that FeatureMILL
makes future decisions about feed and speed values just as you would.
Feeds and speeds 117
You can also explicitly set the feed rate or spindle speed for an individual
operation, but these changes only affect a single feature in a single part
file.
Feeds and speeds tables

You can access the Feed/Speed database in two different ways:
Click Feed/Speed Tables from the Manufacturing menu.
Click F/S Tables in the Material dialog.
For further information:
Viewing feed/speed tables (see page 118)
Modifying existing feed/speed tables (see page 119)
Wire EDM cut data (see page 119)
Adding a new material (see page 119)
Adding a new tool grade for turning operations (see page 78)
Deleting a feed/speed table (see page 121)
How to import feed/speed or cutting data tables (see page 121)
How to export feed/speed or cutting data tables (see page 123)
Undefined tool finishes
How feedrates are scaled (see page 124)
See also stock material and Initializing FeatureMILL databases (see page
75)
Viewing feed/speed tables

3. Select the desired stock material from the drop-down list box.
4. Select either the Milling/drilling tab or the Turning tab.
5. For turning, select the desired tool grade. If the tool table is
displayed dimmed, click the Tool Grades button to see which
other table is being scaled to obtain values for this tool grade. Click
OK.
118 Feeds and speeds
6. For milling, select the desired tool grade and tool finish.
7. For certain materials there are actually two tables, each associated
with a hardness value. If there are two tables, the Hardness 2
button will be available. Click Hardness 2 to see the other table.
Feeds and speeds are interpolated for hardness values in between
the two hardness values associated with the two tables.
8. Click OK when you have finished viewing the table.
See also Undefined tool finishes.
Modifying existing feed/speed tables

To modify existing feed/speed tables:
1. View the appropriate table. See Viewing feed/speed tables (see
page 118).
2. Adjust the values as desired.
3. Click OK.
Wire EDM cut data

FeatureWIRE has material databases that describe the cutting conditions
for various materials. Each database entry is uniquely identified by the
material type, material thickness, wire type, wire diameter, and machine
type. The values for each entry are the feed, water and cutter
compensation registers (see page 518) on the machine. The database is
used to fill in the values in the Cutdata dialog, if the current cutting
conditions match. The material thickness does not have to be an exact
match. The values for the closest thickness will be used.
See also Feed and speed tables (see page 118).
Adding a new material

3. Click the New Material button.
4. Enter the name of the new material and click OK.
The first character of the material name must be an

uppercase letter (A-Z) or an underscore (_).
5. Click the New button to add values.
6. For milling, select the tool grade and tool material. For turning,
select the tool grade.
7. Enter speeds and feed values (for a 1 inch tool) for each operation
type.
8. For initial values you can click the Copy Values button to select
a table to copy from.
9. If the feed or speed are dependent on the hardness:
Click the Use Range button and enter the upper hardness value
as Hardness 2.
Enter the lower hardness value as Hardness1.
Go to step 7.
10.Click OK.
See also Undefined tool finishes.

operations
3. Click the Turning tab if not already displayed.
4. Click the Tool grades button.
5. Click the New button and enter the new tool grade name.
6. Under When F/S table is undefined select either:
Generate Toolpath Error if you want to define all table
entries.
Scale Existing Material to get values from another material.
Select the existing material from the drop-down list box and
enter the scaling values for speeds and feeds.
7. Click OK.
8. If you selected Generate Toolpath Error, fill in all table values.

9. Click OK.
Deleting a feed/speed table

1. View the appropriate table. See Viewing feed/speed tables (see
page 118).
2. Click Delete.
3. Click OK when asked for confirmation.
4. Click OK.
How to import feed/speed or cutting

data tables
1. Select Feed/Speed and Cut Data Tables from the
Manufacturing menu.
2. Click the Import button. The Feed/Speed and Cutting Data
Import dialog displays.
3. If you know the name of the file, enter the name of the file to
import under Import File.
4. If you want to browse for the file click the Browse
button.
Under Files of type select *.fdb to read the file exported from
FeatureCAM earlier or select *.dxx to import a text file containing
only wire EDM cut data (see page 122).
5. Click the Import button.
6. If you are importing a *.dxx file, you are prompted to enter the
wire type, machine name and unit before the file is imported.
7. Select an option for handling new materials with the same name as
existing materials:
Select Overwrite if you want the new material to be copied
over the old one.
Select Skip Material to ignore any new materials with the
same name as an existing tool.
8. Click Import.
9. Click Close.
See also How to export feed/speed tables (see page 123).
Creating a text file for wire material

databases
A material database can be imported as an ASCII (readable text) file that
can be created using any convenient text editor (Notepad, Wordpad and
so on). When the file has been written it should be saved as plain ASCII
text (if your editor offers more than one option) with a name that has the
extension *.dxx such as Copper.dxx. This file can be imported into the
Feed/Speed and Cutting Data Tables dialog.
Format of the File:
2.0
This value is a version number. It has no special

function but should always be entered to maintain
the file format
COPPER 10.0
0.25 3
This line is the first line of a new material

definition. The fields have the following functions:
COPPER - the name of the material
10.0 - The material thickness
0.25 - The wire diameter
3 - the number of cuts
1 1 1 0.1
This line specifies the generator and water settings

etc. for the first cut. The fields are as follows:
1 - the generator setting register number
1 - the water setting register number
1 - the compensation register number
0.1 - The value of the compensation
2 2 2 0.2
The parameters as above but for the second cut
3 3 3 0.3
The parameters as above but for the third cut
COPPER 20.0
0.25 3
New Material
11 11 11 0.11
12 12 12 0.12
13 13 13 0.13
COPPER 30.0
0.25 3
21 21 21 0.183
22 22 22 0.173
23 23 23 0.163
COPPER 40.0
0.25 3
31 31 31 0.184
32 32 32 0.174
33 33 33 0.164
STEEL 20.0
0.25 4
41 41 41 0.185
42 42 42 0.175
43 43 43 0.165
44 45 46 0.155
How to export feed/speed tables

1. Select Feed & Speed Tables from the Manufacturing
menu.
2. Click the Export button. The Tool Export dialog displays.
3. Enter the name of the file to export under Export File.
4. In the Material Types list select the materials you want to export.
5. Use the Include All
button to select all materials. Use the
button to deselect all materials.
Exclude All
6. Select the units to express the tables in. Either Inch units or
Metric units.
7. Select Milling to export milling tables. Select Turning to export
turning tables. Select Wire EDM to export the cutting data for
FeatureWIRE.
8. Click Export.
9. Click Close.
The file created is tab delimited text. You can edit the file in a
spreadsheet if desired. This file can now be imported into FeatureCAM.
See How to import feed/speed tables (see page 121) for more
information.
How feedrates are scaled

Feedrates are specified for a 1" (or 20mm) tool. For tools that are other
diameters, the feedrates are scaled linearly. For example, the feedrate for
a 0.25 tool is 1/4 of the table rate.
Setting a feed or speed value for a

milled operation
1. Double-click the feature to display the Properties dialog.
3. Click the Tools tab.
4. Delete the current speed or feed value.
5. Enter the desired speed or feed value.
6. Click OK to set the value and close the dialog or click Apply to set
the value and leave the dialog open.
Default feed/speed values for turning

The default values for feeds and speeds are calculated from the
feed/speed tables. If the feed is specified in Feed per minute (IPM for
inch units), then the feed rate is dependent on the speed value. A change
in the speed will result in a change in the recommended feed rate to see
the newly recommended feed rate:
1. Change the speed.
2. Click OK. The feed rate will be updated.
Show/hide material
FeatureCAM comes with a long list of materials. Some of these materials
might not be applicable for your shop. You can delete materials from the
database, but when you upgrade to a new version these deleted materials
reappear. The solution is to hide an unwanted material. When the
materials database is updated, hidden materials will not reappear.
To hide or show a material:
1. Select Manufacturing > Materials > Show/hide from the
menu.
2. Select any material you would like to show.
3. Deselect any material you would like to hide.
4. There are also buttons located to the right of the material list that
can be used to select all or deselect all of the material names.
Initializing FeatureCAM databases

The tooling and feed/speed databases are created using the INITDB
Initialization program in FeatureCAM. This is the program that is run the
first time you run FeatureCAM to create your initial database. You may
also want to use INITDB for the following reasons:
Adding default tools and feed/speed tables to the database (see
page 125)
Recreating tooling and feed/speed databases if they become corrupt
(see page 129)
Support for shared network databases (see page 75)
Adding default tools and feed/speed

tables to the database
Each tool is identified by a tool name and each feed/speed table is defined
by a combination of the stock material name, tool material and tool grade.
Any tool or feed/speed table that you add to the database will remain even
if you re-run the INITDB program. INITDB will not overwrite any
existing tools or feed/speed table in the database. The only way to remove
them is to explicitly delete them in the Feed/speed table dialog or the
Tool manager. See Deleting a feed/speed table (see page 121) or
Deleting a tool from a toolcrib for more information.
The two most common reasons for re-running INITDB are:

Restoring default tools or default feed/speed tables that you have
deleted.
Adding tools specified in other units. You may have elected to only
load the inch tools the first time and you may now want to add the
metric tooling.
To perform these tasks:
1. Exit FeatureMILL if you are running it.
2. Run INITDB from the FeatureMILL group in the Start menu.
3. Select the units of tools you want to add. Remember FeatureMILL
will not alter any items that you changed or delete any items that
you added.
4. Click OK.
5. If you added tooling of both units, you will be asked which unit
you will use most often to model parts.
Macro programming options

The type of macro code that is created by a specific post processor
depends on whether the post processor supports incremental
programming, local coordinate systems or both.
Incremental
Local
File type
coordinate
No
No
Code created
*.fm
Pattern instances are cut with

absolute coordinates relative
to the current setup.
*.mf with
multiple
fixture
Each FM part is cut with

to the global fixture. Pattern
instances in each FM part are
cut with absolute coordinates
relative to the global fixture.
Yes
No
No
Yes
*.mf with
global
fixture

to its local fixture (G54).
Pattern instances in each FM
part are cut with absolute
coordinates relative to the
part's local fixture (G54).
*.fm
Each pattern instance calls a

macro with incremental
pattern instance location.
*.mf with
multiple
fixture

to the global fixture. Pattern
instances in each FM part are
cut with incremental
pattern instance location
based on the global fixture.
*.mf with
global
fixture

to its local fixture (G54).
part are cut with incremental
based on the part's local
fixture (G54).
*.fm
A local coordinate system is

established for each pattern
instance. A macro is called
with absolute coordinates
relative to the pattern
instance location.
Yes
Yes
*.mf with
multiple
fixture

established for each FM part.
instance location which is
based on the global fixture.
*.mf with
global
fixture

to it's local fixture (G54). A
local coordinate system is
instance location which is
based on the local fixture
(G54).
*.fm
Local coordinates are not

used.
*.mf with
multiple
fixture

established for each FM part.
part are cut with incremental
based on the part's local
coordinate system.
*.mf with
global
fixture
Local coordinates are not

used.
Recreating tooling and feed/speed

databases if they become corrupt
If your tooling or feed/speed database becomes corrupt, you can recreate
the databases using the INITDB program.
This procedure will erase any changes you have made to existing
tools or feed/speed tables and will delete any custom tooling or
new feed/speed tables that you have created. Contact your
FeatureMILL support person before performing this task.
To remove your database and recreate it:
1. Exit FeatureMILL if you are running it.
2. Run Windows Explorer.
3. Open the directory in which you installed FeatureMILL.
4. Open the database directory.
5. Click in the right-hand contents window.
6. Click Select All from the Edit menu.
7. Press the Delete key on the keyboard.
8. Run INITDB from the FeatureMILL group in the Start menu.
9. Select the units of tools you want to add. FeatureMILL will not
alter any items that you changed or delete any items that you
added.
10.Click OK.
11.If you added tooling of both units, you will be asked which unit
you will use most often to model parts.
Shared Network Database

FeatureCAM supports the sharing of the tool and feed/speed database on
a network so that multiple computers have the ability to use the same tool
cribs and feed/speed information. Presently, the shared network database
is provided as an empty MDB format database, created by Microsoft
Access and accessed using the Microsoft Jet database driver.
The database must be set up properly before it can be used. Follow these
steps:
1. Establish a location on your network for the database and copy a

blank database from the FeatureCAM CD-ROM to that location.
2. Fill the database with default tooling and feed/speed information.
Do this by running INITDB on any computer that has access to the
database and point INITDB to the database.
3. When installing FeatureCAM on user computers, instruct them to
reference the shared network database during the installation
process. Or, if FeatureCAM is already installed on the user system,
then instruct the FeatureCAM user to use the File options dialog
to switch from a local database to a shared network database
Feed optimization
Feed optimization is an optional process that evens out the tool load by
adjusting a program's feedrates. This optimization is performed so that
the horsepower required for the cuts approximates a target horsepower. In
the graph shown below, the initial feedrates are shown in white. The
optimized feedrates are shown in black. Notice how the black curve
removes the spikes in the tool load.
To optimize the feedrates of your program:

1. Generate toolpaths.
2. Set the target horsepower (see page 134) milling attribute for the
operations you would like to optimize.
For 2.5D finish milling operations, we recommend that you use
Peripheral feeds instead.
3. Select Manufacturing > Feed Optimization from the menu.
4. Set the parameters (see page 131) appropriately.
5. Click OK.
6. For complicated parts this task can take several minutes.
If the NC code is regenerated, the optimized feedrates will be lost.

It is helpful to graph the tool load (see page 61) during 3D simulation
before and after the optimization to see the changes.
To remove the optimized feed rates without regenerating the NC code,
select Clear Optimized Feeds from the Manufacturing menu.
See also Peripheral feed dialog box and Feedrate optimization example
(see page 133).
Feed optimization parameters

The following parameters are in the Feed Optimization dialog:
Increase feed when load is below % of target horsepower - the

programmed power is the estimated horsepower displayed in the
Operations List. This percentage is applied to the estimated
horsepower and the feedrate is increased for any move that requires less
power.
But do not increase feed beyond % of programmed feed - the
maximum amount to increase the feedrate over the operation's initial
feedrate.
Decrease feed when load is above % of target horsepower the programmed power is the estimated horsepower displayed in the
Operations List. This percentage is applied to the estimated
horsepower and the feedrate is decreased for any move that requires more
power.
But do not decrease feed below % of programmed feed - the

minimum amount to decrease the feedrate.
Perform super sampling to calculate instantaneous tool load setting this option creates a more accurate sampling of the tool loads by
sampling the loads at a number of points along the toolpath and then
averaging these loads for each NC block. If this option is turned off a
single tool load is calculated for each block of NC code.
Number of times to measure tool load - if Perform super
sampling is selected, then you can enter how many times per minute to
calculate the tool load. To calculate the load for each NC block, the loads
are averaged. The larger this number is, the longer the feed optimization
will take.
This number is relative to the running time of your NC program. If
your program will run more than an hour, we recommend that you
set this number to 100 or less.
Use different feed rates on a single block - a long cut may have
varying tool loads. If you want to break up NC blocks so that you can
more finely control the feedrates, check this option.
This option will increase the size of your NC program.
Distance to split toolpath - if you select Use different feed rates
on a single block, then this parameter controls how often the toolpath
will be broken up. It is specified as a percentage of the tool diameter.
See also feed optimization (see page 130), target horsepower (see page
134) tool load (see page 61), and feedrate optimization example (see page
133).
Feedrate optimization example

The top boss of this brake caliper will be used in this example.
When cutting this feature in aluminum with the default stepover and
feed/speed table, the horsepower is estimated at 2.0 for the roughing pass
and 0.3 for the finishing pass. A 0.5" tool is selected. Let's assume that
you would like to keep the horsepower requirements for this cut to less
than 2.5. When a tool load is run on this example, the maximum
horsepower actually required is shown to be 5.9. In order to stay under
the stated horsepower requirement, the feed rate for the roughing pass
must be reduced by 50%. Without feedrate optimization, your only choice
for lower the horsepower requirements are to adjust the width or depth of
cut for the entire operation or change the feedrate for the entire operation.
When you examine the actual toolpaths of this boss there are light cuts, as
shown in the narrow cut on the left and heavy cuts, as shown in the wide
cuts on the right.
Feedrate optimization looks at the tool load for each move and adjusts the
feedrate to even out the load. Instead of reducing the overall feedrate for
the roughing pass, let's keep the feedrate for the roughing feature the
same and use feedrate optimization to adjust the feedrates of the
individual moves of the toolpath. The table below shows that feedrate
optimization allowed us to reduce the machining time by 47% while
maintaining a more constant cutter load.
Before Feedrate
Optimization
After Feedrate
Optimization
Roughing
2:57
1:21
Finishing
0:30
0:27
Total
3:27
1:49
Time
Savings
47%
Max
2.4
Horsepower
2.4
Target horsepower
Set this milling attribute to the desired horsepower for the operation. This
n (see page 130)umber is then used in feed optimization to even out the
tool loads. This attribute is automatically set to the estimated horsepower
for 2D roughing passes performed with flat end tools. For 3D roughing
passes performed with flat end tools, this attribute is also set to the
estimated horsepower as long as the Z increment (see page 424) attribute
is set. For all other operations, this attribute has no default value.
If the Target horsepower is not set for an operation, then its feedrates
are not (see page 130) modified by feed optimization. This means that if
you do not explicitly set the target horsepower for individual operations,
feed optimization will only affect 2D roughing operations and 3D
roughing operations with flat end mills and the Z increment parameter
set.
For 2.5D finish milling operations, we recommend that you use
Peripheral feeds instead.
Creating NC code
Posting your program

After you have run a simulation, the NC Code tab becomes active.
You cannot post without the dongle connected to the computer.
The post processors are configured using the XBUILD program.
The documentation for XBUILD , FeatureCAM's post processor, is
available in a formatted electronic version by selecting Post
Processing Guide from the Help menu in FeatureCAM. It is
available directly form the XBUILD program in online form by
selecting Using Xbuild from the Help menu in XBUILD. The
formatted electronic version is available by selecting Post
Processing Guide from the Help menu in XBUILD. XBUILD
and all of its reserved words are documented in this separate
documentation.
See also Post Options for options including the selection of controllers.
Post options
Post options for milling
The available CNC files are described here. Click the Browse button to
select the post processor.
Edit will start XBUILD for the current CNC file.
Post Options in the Options menu controls the type of CNC machine
that FeatureMILL targets for NC output.
Creating NC code 135
The dialog contains some auxiliary parameters used in post processing.

CNC file is the file name for the kind of machine. The file is either one
that comes standard with FeatureMILL or one that you created with the
Mbuild program. Click Browse to select your CNC file from the list of
available files. Browse presents a list of on disk. You may put your files
anywhere on disk, but look in the M-LBRY subdirectory of the EZFM
directory to find the CNC files that come standard with FeatureCAM .
For example, if you installed FeatureMILL in c:\ezfm, the pre-defined
CNC files are in one of the following directories:
c:\ezfm\m-lbry\inch
c:\ezfm\m-lbry\metric
Select the file name and click OK to select a CNC file.
Defaults returns all the Post Options to their default values.
Max. speed is the maximum spindle speed of your machine.
Min. Arc defines the limit for any arc whose radius is transferred to the
CNC machine as a line. Arcs greater than this limit are sent as arcs.
Max. Arc defines the maximum arc radius. Arcs greater than this limit
are translated into lines.
Block Start sets the starting line number for your CNC programs.
Block Increment sets the increment between line numbers in your CNC
programs.
Disable macros turns off macro generation for the NC code. This
option is not available for all posts. Refer to Hole macros for more
information about setting up macros.
Enable Cut Comp enables output of cutter compensation NC code.
Tool Change Location is the point where the tip of the tool moves to
prior to a tool change.
Non-modal Decel override is an optional setting for the G-code for
overriding the automatic deceleration of a control.
OK accepts your changes.
Cancel discards your changes.
Post options for turning

The available CNC files are described here.
Post Options in the Options menu controls the type of CNC machine
that FeatureTURN targets for NC output.
136 Creating NC code
The dialog contains some auxiliary parameters used in post processing.

CNC file is the file name for the kind of machine. The file is either one
that comes standard with FeatureTURN or one that you created with the
XBUILD program. Click Browse to select your CNC file from the list of
available files. Browse presents a list of files on disk. You may put your
files anywhere on disk, but look in the T-LBRY subfolder of the EZFM
folder to find the CNC files that come standard with FeatureTURN. For
example, if you installed FeatureCAM in "c:\ezfm," the pre-defined CNC
files are in one of the following directories:
c:\ezfm\t-lbry\inch
c:\ezfm\t-lbry\metric
Select the file name and click OK to select a CNC file.
Defaults returns all the Post Options to their default values.
Max. speed is the maximum spindle speed of your machine.
Min. Arc defines the limit for any arc whose radius is transferred to the
CNC machine as a line. Arcs greater than this limit are sent as arcs.
programs.
A number of system features are enabled at the bottom of the dialogs.
These settings allow these options to be individually set on features. Note
that these settings must be set on the feature to be activated. By turning
off these settings, the options is turned off system-wide. These options
include:
Enable Tool Nose Radius Comp
Enable Hole Canned Cycle activates canned cycles for drilling. This
is a global setting and cannot be set on individual hole features. Note the
post processor must support canned cycles.
Enable Groove canned cycle activates canned cycles for grooving.
This is a global setting and cannot be set on individual groove features.
Note the post processor must support canned cycles.
Enable Part catcher
Enable Turn Canned Cycle activates canned cycles for turning and
boring. It must also be turned on for individual features. See Use canned
cycle for more information.
Tool Change Location is the point where the tip of the tool moves to
before a tool change.
Post options FeatureWIRE

programs.
Block Maximum is the maximum block number for the CNC program.
Agie Control should be set if you are posting to a machine with a
control from Agie. If Yes is selected, the lines of NC code that
correspond to cutter compensation are output in a different order.
Skip moves that travel less than x% of wire diameter. This
parameter prevents moves that are too small from being sent to the EDM
control. If a move is too small, it is not output. As soon as the program
advances the wire to a point that is more than this threshold, then a move
is output directly to that position. For example if move 2, as illustrated in
the figure, is too short, it is not output. If the distance from the end of
move 1 to the end of move 3 is sufficiently long, then move 5 inserted
between moves 1 and 4.
Saving an NC part program to disk

Open the Save NC dialog in one of these ways:
Click the NC Code
icon in the Steps toolbox and then click
the Save the NC code...
icon.
Select File > Save NC from the menu.
The Save NC dialog opens:
1. Change the NC Output Directory if you wish.

2. If you want the NC code file to have a different name that the part
name, enter a different name for the NC file name. If you omit the
file extension, it will default to *.txt.
3. If you want to save the NC code for only the current setup, click
Current Setup. Click All Setups if you want to save separate
NC programs for each setup.
4. Select what you would like to save to disk from: Operations list,
Tools List of All Setups, Tools List of Each Setup, NC
Program, Tool data, F/S data, Machining Configuration.
See FeatureCAM file types for an explanation of the types of files
that are saved.
5. Click Create subfolder if you want to create an additional folder
below the NC Output folder. This folder will have the same name
as your part.
6. If you know you want to overwrite all existing folders with the
same names, click Overwrite Existing Files. Otherwise you will
be asked to confirm before overwriting any file.
7. Click OK.
Save Options
In FeatureCAM, you can save a number of previous versions of your part
as you work. To activate this feature:
1. Select File > Save Options from the menu.
2. Select Create backup copies.
3. Enter the Number of Copies to Keep.
Now when you save your work, the previous version(s) will be saved to
disk under a name that begins with 'Backup'. The latest version of your
work will always be saved using the name of your FeatureCAM part.
Save computed toolpath
For certain parts, generating toolpaths can be time-consuming and you
may want to save them for the next time you open a part. The setting of
Save computed toolpath controls the default behavior for saving
toolpaths. Select from Never save, Always save, or Ask me to be
prompted each time you save a part. Note that this is different than saving
the NC text file that the NC machine reads. Instead you are saving the
FeatureCAM internal toolpath representation.
Compressed file
If you select Compress file, the size of the FeatureCAM files are
reduced on disk. Note that compressed files cannot be read into earlier
versions of FeatureCAM.
Save preview picture in file
Select Save preview picture in file to store an image of the part in the
file. If the part is stored, then this image is displayed in the Open file
dialog.
Milling macros
Macros can be generated in the NC code for multiple Z levels of a milled
feature. To generate these macros, your post processor must support
them, and you must turn this function on for the post.
1. Open the Post Options dialog by selecting Post Process in the
Options menu.
2. Select your post processor.
3. Select the Enable Macros checkbox.
4. Click OK.
5. Select Default Attributes from the Options menu.
6. Set the Minimize tool changes check box.
You could set Minimize tool changes in the Ordering dialog
instead. Using the Default Attributes setting includes macros for
any parts you create.
Minimize tool changes groups operations together that use the same
tool. This saves time for you by eliminating or reducing needless tool
changes. You must select this check box if you want to generate hole
macros in the NC code.
1. Turn off Minimize rapid distance.
This attribute only affects milling setups and is the only ordering option
that will change the order of features specified in the part view.
Minimize Rapid Distance moves to the next closest feature that uses
the same tool as the last operation. This check box must be deselected if
you want to generate hole macros in the NC code.
1. Click OK.
Now when you generate NC code, you will get macros for the milled
features that are milled at multiple Z depths.
Incremental programming and local

coordinate systems
These topics apply to the use of milling macros (also called subprograms
or subroutines) and are activated by selecting the Use macro calls for
each instance in the pattern on the Pattern strategy tab.
Incremental programming means that the moves in the subroutine are
relative instead of absolute. Instead of moving to a particular absolute
location inside of the macro, the moves are relative to the current
position, such as move two additional inches in X. An example g-code
would be Fanuc's G91 for relative programming.
When using local coordinate systems, the coordinate systems are
constantly being redefined outside of the macro and the moves within the
macro are absolute. Examples of this concept are Fanuc's G92,
Heidenhain's Datum Shift and Siemen's G58.
The actual g-code created for a particular pattern depends on the macro
programming options (see page 126) that are supported by the post
processor.
Turning canned cycles

Canned cycles can be generated in the NC code for nearly every turned
feature. To generate these macros, your post processor must support
them, and you must turn this function on for the post and for some
features you must also activate the canned cycles on the feature level.
Hole features
If Enable drilled canned cycles is deselected in the Post options
dialog, then all hole drilling operations will be computed in the post. This
includes, spotdrilling, drilling, bore, ream and tapping operations. If
Enable drilled canned cycles is selected, then canned cycles will be
output if the post you are using has g-codes defined for the hole canned
cycles. If the post does not have these g-codes defined, the hole
operations will still be computed.
There is no way to control the output of canned cycles on an individual
feature basis.
Turn/Bore features
Canned cycles for turn and bore features must be enabled by selecting
Enable turn canned cycles in the Post options dialog. You must
then go to the Properties dialog for each turn/bore feature, click the
Strategy tab and select Use canned cycle. Also select Reuse path
in canned cycle if you want to output the path geometry only once for
both roughing and finishing. You can also set these values in the default
attributes, but remember these values will only apply to features you
create after making this change.
Groove features
Enable grooving canned cycles in the Post options dialog by selecting
Enable groove path canned cycle. Then turn on canned cycles for each
groove by bringing up the feature's Property dialog, clicking the
Strategy tab, and then clicking Use path canned cycle. You can also
set this attribute on the Groove tab of the default attributes, but this will
only apply to features you create after changing this setting.
Thread features
Thread features will always use canned cycles.
4th Axis (2.5D & 3D)

You must have a CNC control that supports a 4th axis, and a rotary table
or native 4th axis that can be controlled by the CNC machine. The 4th
axis can be used in two different ways. It can be used as an indexer, to
rotate the part between machining operations so that the machining takes
place on different planes of the part. This is called indexing.
The second use of the rotary table is as a continuously moving axis.
Rotation occurs during the machining operation and the tool movement is
limited to either the X- or Y-axis and the Z-axis. The part itself is rotated
to take the place of the axis not used. This feature is called wrapping and
is capable of wrapping any feature while the part is rotated.
Another method of using the rotary table's rotational axis is to use all four
degrees of freedom at once with FeatureCAM's 4-axis simultaneous
product. This will allow you to directly machine surfaces without the
need for 'unwrapping' and may result in the machine moving in X, Y, Z,
and A (for instance) all at once.
More about indexing (see page 143)
More about wrapping (see page 150)
More about 4-axis simultaneous (see page 160)
Indexing
Indexing uses the 4th axis to rotate the part between machining operations
so that the machining takes place on different planes of the part.
Overview of indexing (see page 144)
How to create an indexed program (see page 144)
4th axis indexing - How the clearance plane is calculated (see page 149)
4th Axis (2.5D & 3D) 143
Restrictions of indexing (see page 149)

See also Fourth axis wrapping (see page 150)
Overview of indexing
Indexing uses the 4th axis to rotate the part to access each feature. In
FeatureCAM each face of the part can be assigned to a separate setup (see
page 147) or features can be placed radially (see page 146) around the
center of rotation by using only one setup.
Parts whose features can be accessed by rotating around a single axis are
candidates for 4th axis wrapping.
See also 4th axis indexing - How the clearance plane is calculated (see
page 149).
You must have a CNC control that supports a 4th axis, and a rotary
table or native 4th axis that can be controlled by the CNC machine
in order to use indexing.
How to create an indexed program

1. Display the stock axis (see page 150). This will be used for
reference.
2. Click the Stock
step.
3. Click Next twice.

4. Select the 4th Axis Positioning radio button.
144 4th Axis (2.5D & 3D)
5. Decide what world coordinate axis you will rotate about. The Xaxis is recommended since the majority of the post processors
support only X-axis indexing. (For the rest of this description we
have assumed that you have selected the X axis.) For the X-axis,
click Index around the X-axis. For the Y-axis, click Index
around the Y-axis.
6. Position the stock appropriately.
7. Specify the tool change position (see page 148).
8. If you want to create setups on each face:
a. Create the setups for indexing (see page 147).
b. Switch to each setup and create your features.
9. If you want to use a single setup, create each feature and follow
this procedure (see page 146) on the location page to orient each
feature.
10.Generate the tool paths.
11.Click Post Process in the Manufacturing menu and select a
post from the 4thxs directory.
12.Click the NC tab in the Manufacturing Results window.
4th-axis rotation
In this example, the part is indexed around the X-axis.
4th Axis (2.5D & 3D) 145
The X-axes of each setup are parallel to the X-axis of the Stock
Coordinate System.
4th-axis indexing with a single setup positioning features

When creating 4th-axis indexing or turn/mill parts, the Location dialog
box of the Feature wizard provides an option for positioning called
Radial about the X axis (or Radial about the Y axis if indexing
around the Y axis). Use this method of positioning 4th-axis features,
unless you want to create setups on each face you want to machine. Use
the angle and radius dimensions to orient the feature on the proper face.
146 4th Axis (2.5D & 3D)
In the case of indexing around the X axis, the X coordinate will move the
feature along the X axis and the Y coordinate will translate the feature in
the perpendicular direction.
In the case of indexing around the Y axis, the Y coordinate will move the
feature along the Y axis and the X coordinate will translate the feature in
the perpendicular direction.
See also 4th-axis indexing - positioning the stock and 4th axis overview.
4th-axis indexing with multiple setups

Normally each setup generates a separate program. If the setups of your
part are a simple rotation around your machine's fourth axis as shown
below you can use indexing to combine all the setups into a single
program that rotates each setup into position using the 4th axis.
4th Axis (2.5D & 3D) 147
Indexing can be performed around the X or Y axis of the stock axis. The
post processor you use must have the same indexing axis as your part. For
each setup the corresponding axis must be parallel to the indexing axis.
For example, if you are indexing around the world coordinate X axis, the
X axes of each setup must be parallel to the stock axis. See Overview of
setups for more information on setups.
When using indexing, the part documentation is combined for all setups.
This means that you will have just one operations list, one tool list and
one NC part program for all setups.
When positioning features in the Location dialog box, use the XYZ or
polar types of positioning.
See also 4th axis indexing with a single setup - positioning features (see
page 146).
4th-axis indexing - specifying the tool

change position
The tool change position must be set correctly for the simulation of 4thaxis indexing parts to be accurate.
This does not affect the NC code, only the graphics.
The distance from the stock axis origin to the tool change point must be
long enough so that the tool clears the part as it rotates. The figures below
show the circle that would be formed by sweeping a tool change location
around the stock axis. Notice that this circle clears the entire part.
See also Post options dialog box.
148 4th Axis (2.5D & 3D)
4th axis indexing - How the clearance

plane is calculated
In 4th-axis positioning and 5th-axis positioning, the tool must retract to a
safe distance so that it will not collide with the part while it is indexing.
To achieve this, FeatureCAM calculates the maximum stock radius and
adds to that the Z index clearance to determine the appropriate retract
distance.
Restrictions of indexing
You must use a post from the 4thxs directory. Normal posts do not
support indexing.
The post CNC files have the indexing axis hard-coded. Most are
setup to rotate about the X axis. The axis of rotation in your
program must match the rotation axis of the post.
If you are using multiple setups and are rotating about the world X
axis the X axes of the setups must be parallel to the world X axis.
If you are using multiple setups and are rotating about the world Y
axis the Y axes of the setups must be parallel to the world Y axis.
4th Axis (2.5D & 3D) 149
The Stock axis

The Stock axis corresponds to machine zero and the axis of rotation for
an indexer. It is not normally displayed, but it can be shown using this
procedure (see page 150). It is displayed as two vectors. One shows the
axis of rotation and the other indicates the orientation of a 0 rotation.
Viewing the stock axis

To view the stock axis click the View menu and select Show stock
axis from the Show menu.
See also The Stock axis (see page 150).
Wrapping (3D)
4th-axis wrapping
4th-axis wrapping allows you to wrap a 2.5D feature around either the X
or Y axis. You must have a machine tool with 4th-axis capabilities to take
advantage of this feature.
Overview of 4th axis wrapping (see page 151)
Basic 4th axis wrapping requirements (see page 153)
How to create a NC program using 4th axis wrapping (see page 153)
Creating a 4th axis wrapped feature from a 3D model (see page 154)
Curve unwrapping (see page 155)
Cut side perpendicular (see page 157)
Restrictions of 4th axis wrapping (see page 159)
See also Indexing (see page 143)
150 4th Axis (2.5D & 3D)
Overview of 4th-axis wrapping

4th-axis wrapping uses the rotary table as a continuously moving axis.
Rotation occurs during the machining operation and the tool movement is
limited to either the X or Y axis and the Z axis. Wrapping is limited to
cylindrical stock shapes. A side effect of wrapping is that all arc moves
must be converted to linear moves for posting. See Wrap tolerance (see
page 151) for further information.
Any milling feature can be wrapped using 4th-axis wrapping or
turn/milling. The figure below shows a simple groove that is wrapped
around the X axis.
The features are not displayed as wrapped, but when you generate
toolpaths for a wrapped setup, the toolpaths are wrapped.
See also:
Basic 4th-axis wrapping requirements (see page 153)
How to create a NC program using 4th-axis wrapping (see page 153)
Creating a 4th-axis wrapped feature from a 3D model (see page 154)
Wrap tolerance
Arcs that are wrapped must be converted to small 3D line segments. The
Wrap tolerance is used to determine the acceptable distance between
the line segments and the initial arc. The figure on the left shows a lower
tolerance for a wrapped circular groove. The right-hand figure shows a
large tolerance. In this case the circle is approximated by a square.
4th Axis (2.5D & 3D) 151
The Wrap tolerance is also used to calculate toolpaths which are on a

cylinder, given a linear toolpath in unwrapped space. That is, if the
toolpath without wrapping is a straight line, then the wrapped toolpath is
an arc around the index axis. The Wrap tolerance controls the accuracy
of this arc.
This attribute is also used to control the polar interpolation on face cuts
for turn/milling. If FeatureCAM is performing the polar interpolation, any
linear move or off center arc move on the face of the part must be
interpolated by linear moves and rotations about the C axis. Wrap
tolerance is used to control the fineness of this linear interpolation. The
figure on the left shows a straight face cut with loose wrap tolerance. The
right-hand figure shows the same cut with a tighter tolerance.
When circular interpolation is turned off in post, then Wrap tolerance

is used to control fineness of toolpath.
152 4th Axis (2.5D & 3D)
Basic 4th-axis wrapping requirements

4th-axis indexing should be turned on in the Indexing tab of the
stock object.
The stock should be round, about the Y (or X) axis.
Indexing and wrapping occur about the stock axis. To help you
understand this, you should show the stock axis using the Show
stock axis option of the Show submenu of the View menu. The
stock axis will appear in blue.
All of your features need to be designed up off the stock axis, for
example, at the OD of your round stock. You can get them there by
translating the feature up in Z, or by making a setup that is up off
the stock axis.
Select the Wrap feature around X-axis check box of any
feature you want to wrap.
Use a 4-axis indexing post from .../M-LBRY/4THXS.
How to create a NC program using 4th-axis

wrapping
1. Select Show stock axis from the Show submenu of the View
menu. This is the wrapping axis.
icon in the Steps toolbox. This will walk
2. Click the Stock
you through the Stock wizard. During this process make sure
that:
a. On the Dimensions page of the Stock wizard, you create
round stock. For the Axis select the desired wrapping axis.
Click here for more details on the dimensions page.
b. On the Multi-axis positioning page of the Stock wizard,
click 4th-axis positioning and Index around X if you
chose X as your axis, or click Index around Y if you chose
the Y axis.
Most 4th-axis post processors provided with FeatureCAM
wrap around the X axis.
3. When creating a feature that you would like to wrap:
a. Position it using the Radial about X axis option in the
Location dialog box.
4th Axis (2.5D & 3D) 153
b. After creating the feature, edit it and select Wrap feature

around X axis.
4. Select Post Process from the Manufacturing menu.
5. Click the Browse button to specify your post processor.
6. Select a post from the 4thxs directory. Ensure that you select a
post processor that matches the index axis you selected in the
Stock wizard.
7. Click OK.
8. Generate the tool paths with Show centerlines. Notice that the
toolpaths are wrapped around a cylinder. Centerline and 3D solid
simulation will allow you to preview the wrapped toolpaths.
9. If the wrapped feature is too chunky, you may need to lower the
Wrap toler (see page 151)ance default attribute. It is located on the
Misc. tab of the default attributes.
10.Click the NC tab in the Manufacturing Results window.
See also fourth axis overview.
Creating a 4th-axis wrapped feature from a 3D

model
1. First, pick a single feature that you want to machine on the part.
2. Work out if it is actually a wrapped feature. Some features may
appear to be wrapped, but aren't. If the feature has all straight sides,
then it can be cut with a normal 2.5D feature.
3. Consider the restrictions of 4th-axis wrapping (see page 159) to
make sure it is appropriate for cutting the feature.
4. Do the sides go through the center axis of wrapping? If you really
need to cut these sides accurately, you will need to use Cut sides
perpendicular to index axis (see page 157).
5. Use surface edges to extract a curve from the solid model.
6. Unwrap (see page 155) the curve. Make sure you use the option to
project to the UCS. The curve may look strange to you, but it will
work.
7. Make the feature opting to wrap around the index axis.
This option is not available in the Feature wizard. If you use the
wizard, you must create a normal feature and edit it to change it
into a wrapped feature.
154 4th Axis (2.5D & 3D)
8. Generate the toolpaths. If you have any problems consider the

restrictions of 4th-axis wrap (see page 159)ping.
Curve unwrap
If you are working with a curve that has been wrapped around an axis and
you want to unwrap the curve into a planar curve, use Curve unwrap.
Wrapped features in FeatureCAM require a planar curve, so this function
is helpful if you want to generate toolpaths from data that is already
wrapped.
To complete this dialog:
1. Name the curve in Curve name field.
2. Select the curve in the drop-down list box or click
the source curve with the mouse.
and select
3. Select the axis that the curve is wrapped around. This setting will
default to your current wrapping axis that you specified in the stock
wizard.
4. The Tolerance will control the accuracy of the unwrapped curve.
All unwrapped curves are piece-wise linear, so the smaller the
tolerance, the more points your curve will have.
5. The Radial offset should normally be set to 0 since the curve is
unwrapped in place. If you have extracted the curve at the bottom
of the feature, then you will want to set the Radial offset to the
depth of the feature to offset the curve to the top.
6. Project to UCS plane should be selected if you are creating a
2D feature. The only time it should be deselected is if you want a
3D curve to result.
7. We recommend that you select Smooth/reduce to try and reduce
the number of points in your curve.
Cylindrical cams
You must have 4th-axis wrapping (see page 150) to cut cylindrical
cams.
Cylindrical, or barrel, cams are specified as you would a normal cam. See
Cams for more information on reciprocating cams. For simple cams, the
rise and fall are radial distance. On cylindrical cams the rise and fall
displacements are along the wrapping axis.
4th Axis (2.5D & 3D) 155
For example, if you create a barrel cam that is wrapped around the X axis
with the following parameters:
the following curve is created:
Notice that the displacement is in the X direction. If you create a groove

feature with using the barrel cam curve, you get the toolpath shown
below.
How to create a cylindrical cam (see page 156)

See also 4th axis overview.
How to create a cylindrical CAM

Follow the steps for How to create a NC program using 4th-axis
wrapping (see page 153). For Step 3, Create your part features, follow
these steps:
156 4th Axis (2.5D & 3D)
1. Bring up the Cam dialog from the Create menu or the Curve
wizard.
2. Select Cylindrical cam.
3. Specify the Radius as the the radius of your cylindrical stock. See
Overview of 4th-axis wrapping (see page 151) for more
information.
4. Specify either Wrap X Axis or Wrap Y Axis. Make sure that this
setting matches the wrapping axis you specified in your setup.
5. Enter the Segment parameters.
6. Click OK.
7. Use this curve to create a groove.
You now have a feature that you can use for 4th-axis wrapping.
Cut sides perpendicular to index axis

When milling features are wrapped (see page 150) around the index axis,
one coordinate axis is turned from linear moves into rotational moves.
For wrapping around the X axis, the Y axis moves are turned into C-axis
rotations. For simple wrapping the NC code is relatively simple, but the
walls of the resulting feature are not perpendicular to the index axis. The
following picture showing the front view of a wrapped pocket illustrates
why. The toolpath is calculated relative to the top curve causing the
pocket to be overcut at the bottom. The overcut regions are shown in red.
The blue lines show the extension of the cut walls and indicate that the
walls are no longer perpendicular to the index axis.
4th Axis (2.5D & 3D) 157
If instead, you wish to have walls that are perpendicular to the index axis,
as shown below, you must use the Cut sides perpendicular to Index
axis attribute.
If you require perpendicular sides, you must have a lathe or mill with X-,
C- and Y-axis motion. To program your feature to have perpendicular
sides you must select Wrap feature around X-axis and also select
Cut sides perpendicular to index axis. Features cut with this option
have sides that are perpendicular to the index axis. There are a number of
restrictions (see page 158) for this type of feature.
Restrictions for cut sides perpendicular

Simple slots and grooves are not supported.
The first move of the toolpath should be perpendicular to the axis
of rotation. Otherwise you end up with a really big offset move at
the beginning of the ramp-in which can actually result in the tool
traveling backwards with respect to the direction of the toolpath.
This is because on the initial plunge move, we don't know the
offset direction, so the Y offset is 0. The first move of the ramp
will be at close to 90 and will require almost a full tool radius
offset. If you are doing a linear ramp at the start of a roughing
operation, you will end up with a full tool radius offset change on
each ramp move.
The feature you are cutting should have no sharp corners.
Open profile sides should use the insert arc check box in the
Stepovers tab.
158 4th Axis (2.5D & 3D)
Roughing operations will create sharp corners on the inner

stepovers if you use too large a tool. The default tool is always too
large.
There is a limit on depth of cut with a given tool. It is related to the
no sharp corners rule. If you are cutting a rectangular pocket, when
the tool moves along one side, the Y offset is 0. The corner radius
must be large enough that the tool does not gouge the next side
wall when it finishes the current cut. The limit is:
R = Radius (feature location to index axis)
CR = Corner Radius of profile
TR = Tool Radius
Diff = CR - TR
A = atan(CR/R)
Max Depth = Diff/tan(A)
Max Depth = Diff*(R/CR)
Restrictions of 4th-axis wrapping

You must use a post from the 4thxs directory. Normal posts do
not support 4th-axis wrapping.
The post CNC files have the indexing axis hard-coded. Most are set
up to rotate about the X axis. The axis of rotation in your program
must match the rotation axis of the post.
If you are rotating around the stock X axis, the X axes of the setups
must be parallel to the world X axis.
If you are rotating around the stock Y axis the Y axes of the setups
must be parallel to the world Y axis.
4th-axis wrapping is not simultaneous motion of four axes. Only
three axes are active. In the case of X-axis wrapping, you get X and
Z translational motion and a rotation around Y.
2D simulation does not work for 4th-axis wrapping.
If you are using Cut Sides perpendicular to index axis (see page 157) the
following restrictions also apply:
It does not apply to simple slots and grooves.
The curve of the feature cannot have any sharp corners.
If you are wrapping an open profile side, the Insert arc check box
of the Stepovers tab should be selected.
4th Axis (2.5D & 3D) 159
If you preview the toolpaths and are getting wild moves at the
feature edges, select a smaller tool. Often the automatically
selected tool is too large. Most problems using Cut sides
perpendicular to index axis are related to using a tool that is
too large. Make sure the tool is small enough before making the
changes discussed below.
If the finishing pass for the walls of the feature does not
immediately follow the roughing pass, you may need to adjust the
plunge point for the finishing pass to ensure that it plunges near the
center of the feature. You want to avoid plunging near the outside
walls where the Y displacement is the greatest. If the initial move
of the finish pass gouge, adjust the plunge point for the finish pass.
See also 4th axis overview (see page 143).
4-axis simultaneous
A 4-axis simultaneous surface milling feature requires your machine to
have four degrees of freedom. For FeatureCAM, the four degrees of
freedom are restricted to moving in X, Y and Z, and a rotation about the
stock indexing axis (A, B, or C in the case of turn/mill). You may define
4-axis features in a turn/mill document with a tool that 'cuts from the OD'.
You may also use 4-axis features in a 4-axis indexed milling environment
in a milling document (see the Indexing tab of the Stock properties).
In an appropriate document type, with an appropriate post (*.cnc file),
some surface milling operations have a 4-axis tab. The 4-axis tab lets you
control or specify the tool orientation. The default value is Vertical
which is used for standard 3-axis milling. However, it can also be a
continuously changing orientation for 4-axis simultaneous machining.
With 4-axis simultaneous, FeatureCAM will try to machine the feature's
surfaces while tilting the tool axis in the way specified by the user.
FeatureCAM's 4-axis product is identical to its 5-axis (see page 465)
product (there are no new terms, dialogs, or concepts to understand) with
one important exception: during toolpath calculations, all tool axes are
projected onto the appropriate plane. For instance, if the current
document is an index-around-X type, then at a particular toolpath point,
the tool axis will be projected onto the STOCK YZ plane. This results in
the toolpath point at (XYZ), and a tool axis of (0JK) so that (0JK) can be
converted to an 'A' angle in the posting process.
160 4th Axis (2.5D & 3D)
Multiple fixture
documents (2.5D &
3D)
If you want to cut different parts on your machine at once, use the
Multiple Fixture Part. With multiple fixture parts, you can mix
different setups from FeatureCAM parts. FeatureCAM can then create a
single program for cutting all the parts and it can minimize tool changes
across all parts.
Example of multiple fixture part (on page 162)
Creating a multiple fixture part (see page 162)
Editing a multiple fixture design (see page 163)
Saving and opening multiple fixture parts (see page 166)
Multiple fixture documents (2.5D & 3D) 161
Example of multiple fixture part
Multiple fixture part

Selecting New from the File menu has an extra option not available from
the New button on the Standard toolbar. That option is for a Multiple
Fixture file. In this case, Setup can include other UCSs as well as
entirely different part files.
1. Select the system units you'll use for the multiple part document.
2. Choose whatever units match the parts.
When you create the new multiple fixture document, you select and orient
the parts in the Multiple Fixtures dialog.
1. The multiple fixture part can be either tool or part dominant. Tool
Dominant files use the currently loaded tool every where possible
before moving on to the next tool. It is a form of tool optimization.
Part Dominant files cut every part completely (within the limits of
the setup) before moving on to the next part.
2. Click Add to include parts in the multiple fixture part file.
162 Multiple fixture documents (2.5D & 3D)
Editing a multiple fixture design

Double-click the multiple fixture display to open a tabbed dialog
containing the information from the Name, Configuration (see page
163), Layout (see page 163), and Stock (see page 165) dialogs. You can
modify the spacing, shift spacing, nesting, and so on in the Properties
dialog. You can also change the setup name and fixture ID directly in the
Name tab.
Selecting a part and using the Alt+Enter shortcut opens the
Multiple Fixtures dialog.
Configuration
1. The XYZ part origin is read from the file and setup you selected.
You can also override it if you wish.
2. X and Y repeats define a rectangular array of the selected part
setup. Use these numbers to determine how many copies of the part
to mill at the same time.
3. X and Y spacing is the spacing between part origins. Depending on
your post, these spacing numbers might not have any effect on the
part as produced at the machine. That is controlled by the Fixture
ID and how the Fixture ID is used to locate other parts relative to
each other.
4. Click Next to open the Layout (see page 163) dialog.
Layout
This is where the multiple part file setup diverges. You can build each
part in its own piece of stock material, or build them from one larger
block of stock material.
Individual blocks (see page 164) are simpler to design, but perhaps
less efficient.
Single block (see page 164) may minimize waste, but is more
difficult to layout and fixture.
Individual blocks
1. Select Individual Block and click Next. FeatureMILL constructs
the layout in the Graphics window and displays the Preview
dialog.
2. Depending on your screen layout, drag the Preview box out of the
display as much as needed so you can preview your parts.
3. If you are happy with the layout, click Finish.
4. Otherwise, click Back until you reach the dialog with the settings
you want to modify.
5. Change those parameters and click Next until you return to the
Preview dialog.
6. Repeat this process until the part layout is correct, then click
Finish.
7. You can repeat the whole Add process to place more setups or
parts in the whole layout as needed to complete the task.
Single block
When you select Single block, the dialog changes. The Nested
(see page 164) option is described elsewhere.
Click Next to open the Stock (see page 165) dialog.
Nested
Depending on your part geometry, you might be able to make better use
of a given stock size by nesting your parts. Nesting involves flipping the
part around so that it can nest in the blank spots between other parts and
can minimize waste in cutting some parts.
Selecting Nested in the Layout dialog changes the picture and adds
some more parameter fields.
X/Y shift is set for the inverted row. The important concept is that you
don't set space directly between neighboring shapes. That parameter was
handled earlier when you specified how many repeated columns and rows
to use. For shift spacing, you are setting the distance between the two
rows' top edges (Y shift) and the columns' right edge offset (X shift). You
probably will need to adjust your X and Y spacing in addition to the X
and Y shifts to find the optimum spacing. Don't overlook negative values
either.
Stock
1. The part origin is read from the file. You can override it if you
wish.
2. Notice that the block is automatically sized based on the part size
and the spacing you specified. If your stock has a different size,
enter those dimensions here. Clicking Auto calculates the
minimum block the parts will fit in as described in the
Configuration dialog.
3. Click Next to open the Preview dialog. FeatureMILL constructs
the layout in the Graphics window and displays the Preview
dialog.
4. Depending on your screen layout, drag the Preview box out of the
display as much as needed so you can preview your parts. If the
layout is acceptable, click Finish.
5. Otherwise, click Back until you reach the dialog with the settings
you want to modify.
6. Change those parameters and click Next until you return to the
Preview dialog.
7. Repeat this process until the part layout is correct, then click
Finish.
8. You can repeat the whole Add process to place more setups or
parts in the whole layout as needed to complete the task at hand.
For more information, refer to Completing the multiple fixture (see
page 166) part.
Completing the multiple fixture part

When you click Finish in the Preview dialog, you return to the
Multiple Fixture dialog. You can continue to Add other parts and setups
as needed. You can even mix and match single and individual block
layouts if you need to.
Adding parts is only part of the process. Optimizing the manufacture of
these parts is another process you can perform in the Multiple Fixtures
dialog. Assuming that you already optimized the parts and setups, you
can select Setups in the list and move them up and down in the process
plan, or exclude/include them as needed.
After clicking OK, you can work with the view, run simulations, and fine
tune the manufacturing as you would for any other part. And you can
generate NC code for the multiple parts all in the same NC part program.
More about editing a multiple fixture design (see page 163).
More about the Parts List (see page 166).
Parts list
1. To open a part file for use in a Multiple Fixture part, use Parts
List in the Multiple Fixtures dialog.
2. Then Browse for the parts you want to include, one by one.
3. Perform the Add process.
Besides the browse and select functions, Parts List is also where you
update a Multiple Fixture document if the source files have changed:
1. Select the source file.
2. Click Reload.
Saving and opening multiple fixture

parts
Multiple fixture parts are saved in files with the *.mf extension. When
opening multi-fixture documents change the Files of type to be MF
Documents (*.mf) to view the multi-fixture documents saved on your
disk.
3D surface modeling
(3D)
Surface wizard
You can build surfaces from the Surface toolbar, the wizard or by
selecting Construct > Surfaces in the menu. With the Surface
wizard:
1. Select the category of surfaces:
From curves
Predefined surfaces
From one surface
From multiple surfaces
2. Pick a construction method from that category.
3. Click Next. The Surface Construction dialog appears.
4. Look through the construction methods and check that they will
construct the kind of surface you want.
5. If the methods don't match what you are trying to do, click Back
and use a different method. The same surface can often be made in
different ways.
6. When you have the construction method you want, fill in the fields
with the correct information. Surfaces use curves, other surfaces,
points, surface normals, and other kinds of user-specified
information to create your part model.
7. Click Finish to add the surface design to the part model.
3D surface modeling (3D) 167
Surface definition
To build and use surfaces in FeatureMILL, you need to understand how
FeatureMILL defines a surface. A surface is defined by a rectangular set
of points and a description of how the surface behaves at each point on
the surface which determines the smoothness of the surface. The set of
points determines the shape, or geometry, of the surface.
The rectangular nature of the control point mesh means that a surface has
four boundary curves. In some cases, surfaces are constructed where one
or two (opposite) boundary curves are degenerate or form a single point
such as the poles of a sphere. In other cases where surfaces wrap around,
such as a cylinder, two opposite boundaries can be the same curve and are
called seams. With seams and degeneracies, a surface may appear to have
only three, or two, or even no boundaries (a sphere), but the four
boundaries are always defined. With these four boundaries, you can break
a surface into rows and columns so surfaces have a table-like structure.
Surface design hints

Here are some concepts and techniques that have proved helpful in
designing 3D surfaces.
Design first, edit last. Put all the surfaces in place first, then trim
and fillet the surfaces together to create the final shape and
boundaries.
Use quality source curves. Quality curves have as much detail as
possible designed into the curves before the curves are used to
make surfaces. Curves are much simpler to design and edit. With
Parametric modeling active, changes to your source curves
propagate automatically into the surface.
Build as much detail into a single surface as possible. It's easier to
split and reduce surfaces than to merge and combine them.
Similarly, machining with isoline operations uses one surface at a
time and filleting and trimming work with two surfaces at a time so
the more detail the better.
Learn which surface methods are approximate and which are exact.
Approximate methods are not better or worse than exact methods,
but have more degrees of freedom in filling in the space between
input curves or surfaces. Other surface methods are conditional.
They are exact to what they do, but when used with approximate
surfaces, the resulting surface is still approximate.
168 3D surface modeling (3D)
Approximate: surface intersection, trim, untrim, fillet, lofting,

merge, modify, offset. (Another key is any operation that
includes a tolerance setting. That is a flag that the source
material is being approximated.)
Exact: extrude, surface of revolution, sweep, ruled, sphere,
cylinder, flat, from a feature.
Conditional: split, region, reverse, coons, cap. Coons is
neither approximate nor exact, but a mathematical definition of
how four boundary curves describe a surface. Learn which
dialogs give you the option to modify-in-place or create a new
object.
Learn when and how to use the option to Modify-in-place or
Create a new object. Both methods have their uses. Modifying
an object in place breaks the parametric link for which constructor
was used for the original object and prohibit parametric modeling
from updating an object in the future. This limits you to further
modification operations only. Creating new objects can result in
excessive clutter on the screen.
Do not use self-intersecting curves or surfaces. Curves and surfaces
with that characteristic are not viable for predictable editing,
construction or machining.
Surface editing
There are a number of ways to edit surfaces. FeatureMILL supports
filleting, merging, intersecting and direct modification of the surface. You
can also derive a surface from any 2.5D feature.
Surface editing hints

Here are some hints for using the Surface trimming, Trim,
Surface/Surface intersection and Untrim operations.
Do not include portions of the boundary when constructing curves
for trimming. Trimming curves may cross or end on boundaries.
Do not use surface/surface intersection to get a boundary of a
surface. Use surface boundary extraction.
Intersecting tangent surfaces produces inaccurate or broken
intersection curves, such as a fillet surface and the surface it's
tangent to. Instead, extract curves and trim with a curve instead.
Do not intersect coincident surfaces (surfaces that overlap). Extract

curves and trim with a curve instead.
Avoid cutting through the pole of a surface with a degeneracy such
as the tip of a sphere or surface of revolution.
Avoid cutting along a seam of a surface (across is fine). A seam
exists, for example, at the left/right boundary of a cylinder. You
can detect seams with the curve extraction dialog, and then
canceling out after you know where the seam is. Cutting a seam
can usually be avoided by rotating the object.
Surfaces can be trimmed multiple times.
Curves for surface/curve trimming can extend off the surface
and/or cut the surface multiple times.
Surfaces from curves

Extrude surface
Extrude creates a surface from a curve by extending that line sideways a
specified distance. Sideways can be a linear distance in any direction.
Extrudes are a shortcut to create a ruled surface between a curve and a
transformation of the curve.
An extruded surface requires a source curve as input. If you have no
curves or geometry in the drawing, you can't create an extruded
surface.
Follow these steps to create an extruded surface:
1. To start, either:
Click the Surfaces
icon in the Steps toolbox. In the
Surface Wizard, select From curves and Extrude.
In the Advanced toolbar, click the Surface Wizard
button. In the Surface Wizard, select From curves and
Extrude.
In the Curves and Surfaces toolbar, click the Extrude
button in the Surface from Curve menu.
2. Enter a Surface name for future reference.
3. For Curve, either:
Click the Pick curve or geometry

button and pick the
curve or geometry you are extruding in the Graphics Window
with the mouse pointer.
Select the curve or geometry from the drop-down list.
4. Specify the parameters of the extrude. You can do this in one of
two ways:
Enter the specific vector of the extrude construction.
Enter the point to extrude from and then enter the point where
the extrude ends.
5. Click Finish or OK.
More about extruded surfaces (see page 171).
Surface design hints (see page 168)
More about extruded surfaces
Extrude creates a surface from a curve by extending that line sideways a
specified distance. Sideways can be a linear distance in any direction.
This is important as the extrude doesn't have to be only in the direction of
an X, Y, or Z axis. Extruding along an axis is an easy way to build such a
surface which you could then move or transform into the final position if
you prefer. Extrudes are a shortcut to create a ruled surface between a
curve and a transformation of the curve.
Extruded surfaces are exact (see page 168).
An example of an extruded surface (see page 171).
Extrude sample
The handle on the blow-dryer is an extruded surface. The curve for the
handle was drawn with the arcs and lines tools. The geometry was
chained into a single curve which was then transformed down in Z to the
depth where the handle exists. This transform operation puts a bounding
curve in location for the top surface of the handle as well.
Then the handle curve was extruded as a vector -0.75 inches in Z.
Revolution
A surface of revolution is created by spinning a curve about a specified
axis. The revolution is any amount from -360 to 360 . These are similar
to a swept surface, and can be used to create other primitive shapes not
provided such as a torus or a cone. These surfaces are exact.
While you can use a 3D curve as the curve to spin around an axis, there is
a higher chance of creating a self-intersecting surface. Where possible, it's
best to use a 2D curve for input to this surface.
To create a surface of revolution, you need a curve and either the X
or Y axis for rotation, or a custom line for the axis.
Follow these steps to create a surface of revolution:
Click the Surfaces
Surface Wizard, select From curves and Surface of
Revolution.
Surface of Revolution.
In the Curves and Surfaces toolbar, click the Surface of

button in the Surface from curve menu.
revolution
3. For Curve, either:
Click the Pick curve or geometry
button and pick the
curve or geometry you are revolving in the Graphics Window
with the mouse pointer.
Select the curve or geometry from the drop-down list.
4. Set the Start angle in degrees.
5. Set the End angle in degrees.
6. Select the Construction method. This is where you set what is
revolved around, or the pole. Choose from Custom line, X-Axis,
Y-Axis or Z-Axis.
7. For Custom line, either select the line from the drop-down menu
or click the Pick line
button and select it in the Graphics
Window with the mouse pointer.
8. Click Apply.
9. Click Preview to see if you have the shape you wanted.
10.If you are happy with the shape click Finish, or OK. Otherwise
change some settings and preview again until the surface is right.
Revolved surfaces may have no cap on the ends depending on the
source curve. Depending on the milling technique you select, such
as Z-level roughing, you may need a cap surface (see page 189).
More about revolved surfaces (see page 173).
More about revolved surfaces
Surface of revolution is created by spinning a 2 dimensional curve about
an axis that you specify. The revolution is any amount from 0 up to 360
degrees. These are similar to a swept surface, but can be used to create
other primitive shapes not provided such as a torus or a cone.
These surfaces are exact (see page 168).
Revolved surfaces may have no cap on the ends depending on the source
curve. Depending on the milling technique you select, such as Z-level
roughing, you may need a cap surface.
An example of a revolved surface (see page 174).

Revolved example
The motor housing on the blow-dryer model is a surface of revolution.
The source curve for the housing was created from a top view and then
rotated 90 around the X axis to orient the curve for the revolve
construction. A line was drawn from the center of the housing down in Z
to act as the axis for the revolution. Later, this model uses a cap surface to
complete the housing as an example of the cap surface.
Set the surface for a full 360 of revolution. Select the axis and the curve
to pass around the axis and the result is shown in the second image. You
could also have created this same surface as a sweep around the circle.
If the source curve had extended all the way to the rotation axis, the
housing could be completed in one step. A drawback to this method is
that the central boundary would be degenerate (a point) and may not
provide good machining results.
Sweep
A sweep creates a surface by replicating the shape of the curve at multiple
positions along a path. The path is not necessarily a straight line. A sweep
moves one curve along another and is useful for making many shapes. By
creating complex curves for both the axis and the cross-section, complex
fillets and blends can be directly achieved in a single surface.
Swept surfaces are exact unless the path or axis curve is a spline curve,
not a curve built from lines, and arcs and chained together. Along a spline
curve axis, the shape may deform.
There are two kinds of sweeps: a regular sweep and a translational sweep.
Translational sweeps maintain the same relationship between the curve
and axis normals at all points throughout the sweep. Otherwise, the sweep
curve stays in its drawn position at all points on the axis.
The swept curve needs to be hooked to the axis curve at the start point of
the curve. This figure shows an example of a cross-section curve that is
properly defined. A UCS was created at the start point of the axis curve.
The cross section curve was then defined relative to this UCS. Note that
the setup axes were not changed. The UCS is used as a design coordinate
system only.
The simplest way to create a curve at this location is to create a UCS at

the start point of the axis curve and create your cross section curve in that
UCS. See How to create a User Coordinate System.
You must have two curves before you can create a swept surface.
Follow these steps to make a swept surface:
1. To start, either
Click the Surfaces
Surface Wizard, select From curves and Swept Surface.

Swept Surface.
In the Curves and Surfaces toolbar, click the Swept
Surface
3. For Axis, pick the curve that defines the axis the sweep will
follow.
4. Optionally select Translational sweep.
5. Pick the curve that defines the Cross section that will be swept
along the axis.
6. Optionally select Sweep from other end.
7. Click Preview to see whether you got the desired results. You
might need to toggle the Translational sweep setting to get the
surface you are looking for.
More about swept surfaces (see page 177)
An example of a swept surface (see page 178)
More about swept surfaces
Sweep (Constant Width) creates a surface by projecting a two
dimensional curve along a path. The path is not necessarily a straight line.
A sweep moves one curve along another and is useful for making many
shapes. By creating complex curves for both the axis and the crosssection, complex fillets and blends can be directly achieved in a single
surface.
You need to be sure and line up your cross section and your path curve.
One way to do this is to create a UCS aligned with the start of the path
curve and draw or transform your cross section curve into place.
Swept surfaces are exact (see page 168).
Sweep example
The speaker housing uses a swept surface to define the top, back, and
bottom sides in one surface. The source curves are a large diameter circle
segment (1000 inches) and a center line through the three sides (at
maximum diameter of the segment). The Translational sweep switch
was turned off for this surface to keep the bow in the same orientation
relative to the axis throughout the sweep. The slightly bowed bottom is
flattened later as a Modify surface operation.
Ruled
A Ruled surface creates a linear surface between two curves. The curves
can be open or closed, planar or non-planar. For closed curves, the
starting points of the curves should line up or the surface may twist in odd
ways.
You must have at least two curves before you can create a ruled
surface pull-out.
Follow these steps to build a ruled surface:
Click the Surfaces
Surface Wizard, select From curves and Ruled Surface.
Ruled Surface.
In the Curves and Surfaces toolbar, click the Ruled
Surface
3. Pick the curve on one bounding edge of the surface, curve 1.
4. Continue picking curves either with the Pick button and mouse or
from the drop-down list. If you use the list, use the Add item
from list button to add the curve to the list.
5. Use the Move item up , Move item down , Reverse
buttons to set the
selected curve , and Delete item
sequence and direction of the curves in the ruled surface.
6. Optionally select Reparameterize curves.
7. Click Preview to see how the current settings affect the surface.
Make adjustments as necessary until the surface is how you want it.
More about ruled surfaces (see page 180)
An example of a ruled surface (see page 180)
More about ruled surfaces

Ruled surface defines a surface by plotting rules between two different
curves. The curves can be open or closed, planar or non-planar. For
closed curves, the starting points of the curves must line up or the surface
may twist in odd ways. See Twists in surfaces or solids with closed cross
sections (see page 181) for more information. Ruled surfaces are useful
for filling a region and blending between two curves and can be used with
more than two curves to create a single surface where each section is the
same as if each pair of curves were used to create a ruled surface.
Chained curves behave differently in a ruled surface than spline curves. If
your surface does not look quite right in the Preview, select the
Reparameterize curves check box and try the Preview again.
Reparameterize curves analyzes the curves and may adjust the
control points of the curves to yield a better surface result.
Reparameterize affects both chained and spline curves, but the effect is
stronger on chained curves.
Ruled surfaces are exact (see page 168).
Ruled example
The blow-dryer uses a ruled surface as a parting surface in the model. The
two curves (lines in this case) are drawn along opposite sides of the stock
and are then translated down in Z to the appropriate depth.
Then they are selected as the two curves for the ruled surface which
passes under the other surfaces of the model to the extent of the part so
there is a complete surface for use in the mold.
Twists in surfaces or solids with closed cross sections
When creating ruled surfaces of lofted surfaces or solids with closed cross
sections, you want to make sure that the start points of the curves line up
with the way you would like to create the lines of your shape. The figure
on the left shows a ruled surface created from cross sections with
misaligned start points. After using Curve start/reverse to change the start
point of the square center curve, the twist is removed, as shown on the
right.
Coons
Coons defines a surface between four bounding curves. For planar curves,
Cap surface (see page 189) is probably a better option, although the
curves must be joined into a loop first. For a grid of curves, Coons
surfaces do not produce smooth results since each surface is not
influenced by its neighbors. Joining curves into cross-sections and using
Lofted (see page 186) surfaces will produce better results in that situation.
When using the three curve Coons option, the ordering of the curves
makes a difference in the appearance of the surface. Try different
sequences until the result is correct.
Chained curves behave differently in a Coons surface than spline curves.
If your surface doesn't look quite right in the Preview, select the
Reparameterize curves analyzes the curves and may adjust the control
points of the curves to yield a better surface result. Reparameterize affects
both chained and spline curves, but the effect is stronger on chained
curves.
Coons surfaces are not as common in practice as they are in mathematical
discussion. Coons surfaces are approximate (see page 168).
Coons example
You might use a Coons surface to create a trough shape that necks down
as shown below. This is easy to draw as two bounding curves on the stock
surface, and two arcing end curves. You don't have as much control over
the behavior of the surface between curves as if you had used a lofted
surface to create a similar shape.
Mesh
Surface from curve mesh creates a surface from a grid of curves.
Overview (see page 184)
How to create a surface from a curve mesh (see page 185)
Restrictions of surface from curve mesh (see page 186)
See also Coons (see page 182).
Overview of surface from curve mesh

The curve mesh constructor makes a smooth surface from a mesh of row
curves and column curves. For example, if you have the curves shown
below:
the curve mesh constructor will create the surface shown here:
The mesh of curves may only partially intersect. This allows the surface
to be built up incrementally. The figure below shows an example of such
a surface.
The surface is made up of Coons patches. If the input curves are smooth,
the surface will be smooth (equal tangent plane planes along the curves).
The input curves must intersect at crossing points, but explicit curve
points are not necessary at the crossings. The curves are reversed
automatically. Triangular patches are supported when a pair of row or
column curves meet at their ends.
How to create a surface from a curve mesh
The curves of your mesh must already exist in position in the
drawing before you can create a surface.
Click the Surfaces
Surface Wizard, select From curves and Curve Mesh.
Curve Mesh.
In the Curves and Surfaces toolbar, click the Curve Mesh
3. Pick the Row curves with the mouse and Pick button, or choose
them in the list and click Plus.
4. If you pick them out of sequence, change the sequence with the Up
and Down arrow buttons.
5. Pick the Column curves with the mouse and Pick button, or
choose them in the list and click Plus.
7. Enter an acceptable Tolerance. This tolerance is used in
approximating some of the curves.
8. Click Preview to view the surface.
9. Select Zero twists if you want the surface to be flatter.
10.Click Preview to see how the current settings affect the surface.
11.Click Finish or OK to create the surface.
Restrictions of surface from curve mesh

The input curves must intersect at crossing points, but explicit curve
points are not necessary at the crossings.
Loft
Lofting has its heritage from shipbuilders as they laid out ship hulls. They
passed imaginary lines between multiple sequential cross-sections. A
lofted surface creates a smooth surface from cross-sectional curve data.
The curves can be non-planar as well.
The curves for the lofted surface must already exist in position in
the drawing before you can create a lofted surface.
Follow these steps to create a lofted surface:
Click the Surfaces
Surface Wizard, select From curves and Lofted Surface.
Lofted Surface.
In the Curves and Surfaces toolbar, click the Lofted
Surface
3. Pick the curves with the mouse and Pick button, or choose them in
the list and click the Plus button.
5. Specify an acceptable Tolerance. Tolerance means that the
resulting surface may deviate from the exact offset by no more than
value you enter.
6. Click Preview to view the surface.
7. Select Interpolated or Spline. Use Preview to see the
difference.
8. Optionally select Uneven spacing. Use Preview to see the
difference.
9. It is quite possible that your surface will flip between adjacent

curves. Use Curve reverse to reverse the curve. If you have
multiple flips, do each curve separately as it is easy to get confused
about how the surface might flip after you have reversed many
curves.
10.Decide whether to set Reparameterize curves.
11.Click Preview to see how the current settings affect the surface.
Make adjustments as necessary until the surface is how you want it.
12.Click Finish or OK to create the surface.
More about lofted surfaces (see page 187).
An example of a lofted surface (see page 188).
More about lofted surfaces
Lofting defines surfaces that project between multiple curves. A lofted
surface is used to create a smooth surface from cross-sectional curve data.
The curves can be open or closed, but for closed curves the start points
need to line up for good results. The curves can be non-planar as well.
Lofted surfaces are commonly used when there are many uniformly
spaced cross-section curves available. A lofted surface has to fill in a lot
of data between the cross-sections and so is an approximate surface. The
data calculated to pass through the surface can be tweaked with the
Uneven spacing switch for a better fit when the data points are not
uniformly spaced.
The curves can be open or closed, but for closed curves the start points
for each curve need to line up with the other curve start points for good
results. See Twists in surfaces or solids with closed cross sections (see
Lofted surfaces are commonly used when there are many cross-section
curves available. A lofted surface has to fill in a lot of data between the
cross-sections so it is an approximate surface. The data calculated to pass
through the surface can be tweaked with the Uneven spacing switch
for a better fit when the input curves are not uniformly spaced.
Spline approximates the surface with input curves as control

points/curves. They are smooth between points. Interpolate uses the
input curves as explicit curves for the surface to pass through and the
surface may wave, or bend between points. Setting the Uneven
spacing switch might improve the fit if the input curves are not
uniformly spaced. A lofted surface may be ei (see page 168)ther exact or
approximate (see page 168) depending on your settings.
The Select degree spinner allows you to vary the tightness by changing
the degree of the polynomial used to calculate the resulting surface. A
degree of one passes straight lines between curves (like a ruled surface).
Higher degree curves allow a looser result between input curves. The
highest degree possible is three or one less than the total number of
curves, whichever is greater. If you are going to export the part file to
another CAD package, some other software does not support degree
values higher than three.
Chained or joined curves behave differently in a lofted surface than spline
curves. If your surface does not look quite right in the Preview, set the
Reparameterize curves analyzes the curves and may adjust the
control points of the curves to yield a better surface result.
Reparameterize affects both chained and spline curves, but the effect is
stronger on chained curves.
Lofting should not be used when a sweep, or other more exact
constructor could be used.
Lofted example
The soap dish model uses a lofted surface. Its source curves are worth
understanding. Using a UCS on the side of the stock as shown in the
diagram, simple geometry was drawn at depth (relative to the setup) in Z.
The geometry was then transformed in X to set the begin, middle and end
curves of the top surface of the soap dish electrode. These curves were
then used to build the lofted surface. The geometry may have to be
reversed, to get the right surface.
Cap
A cap surface takes a closed planar curve and makes a trimmed surface.
It's a shortcut to build a flat surface trimmed with a custom-fit edge and
for solid models. It is useful for making a planar trimmed surface to fill
the area inside a curve.
You probably need to extract the source curve from an existing

surface or surfaces.
Follow these steps to create a cap surface:
Click the Surfaces
Surface Wizard, select From curves and Cap Surface.
button. In the Surface Wizard, select From curves and Cap
Surface.
In the Curves and Surfaces toolbar, click the Cap Surface
3. Select the curves with the mouse and the Pick button, or choose
them in the list box.
4. Click the Plus button to add them to the list.
5. To remove a curve, highlight it in the list and click the Delete
button.
6. Click Finish or OK to create the surface.
More about cap surfaces (see page 190)
An example of a cap surface (see page 191)
More about cap surfaces
Cap surfaces can be used to make a cylinder into a closed solid, for
example. Extract the boundary curve at each end of cylinder and make a
cap surface out of each one. You can also create closed solids from
extrudes, sweeps, and revolutions.
Supporting multiple curves in the cap surface allows you to nest your
curves inside other curves. Depending on the direction of the curve, you
can then include cutouts and surfaces within cutouts all in one operation.
In the example below, the gray portion of the bullseye pattern contains
surfaces, while the reversed clear rings have no surfaces of surfaces. Use
Preview with this feature to get the curves directions right before you
close the dialog.
A cap surface may be either exact (see page 168) or approximate (see
page 168) depending on your settings.
Cap surface creates a surface to cover an 'open end' of another surface or
surfaces. The surface(s) to be capped should form a closed surface by
itself, or when considered as a group. While you can cap open surfaces, a
straight line is drawn between the open points of the surface, and can
generate inappropriate surfaces in cases where the endpoints cause the
closing line to cross the surface boundary.
Cap example
The blow-dryer has a cap surface on the handle, but the handle is an open
curve. So you have to close the curve and create a new curve from the
handle curve and the geometry you used to close the curve. Snapping a
line between the endpoints creates the needed geometry. Chain it all into
a curve and build the Cap surface.
Surface primitives
Sphere
Sphere constructs a spherical surface around a center point and of the
specified radius, or by using an existing circle as the 'equator' of the
sphere you want to construct. Spheres are exact surfaces, but contain
seams and degenerate curves at their poles.
Follow these steps to make a sphere surface:
1. Depending on the construction method you use, you may need a
circle of the correct diameter at the right location in the drawing to
create a sphere.
2. Use the Surface wizard or select Sphere from the Surface
toolbar pull-out.
3. Name the surface for future reference.
4. Pick one of the following construction methods:
5. Center and Radius method:
a. Enter the coordinates for the center point, or click Pick to pick
the point with the mouse.
b. Enter the Radius of the circle.
6. Circle method:
Select the circle (optional) from the drop-down list that represents
the circle's maximum diameter. Or click Pick and pick the circle
with the mouse.
More about spheres (see page 193)
An example of a sphere surface (see page 193)
More about spheres
Sphere constructs a spherical surface around a center point and of the
specified radius.
Spheres are exact surfaces, but contain seams and degenerate points at
their poles.
Sphere example
The blow-dryer could be redesigned to use a spherical motor housing. So
if the design called for 2.25 inch diameter sphere instead, you could
create such a surface by drawing the 2.25 inch diameter circle at depth in
the block. Now use that circle to construct a sphere, which you could trim
with the ruled parting surface.
Cylinder
Cylinder creates a tube specified as a radius around a center line of the
appropriate length. You can specify the length of the cylinder either by
begin and end points or by specifying a center point, a direction, length
and radius. It has no caps on the ends so you may need to use a Cap
surface to complete your design. Cylinders are exact surfaces and contain
a seam where two edge boundaries meet. Be careful not to trim across the
seam. Editing along the seam is fine.
Follow these steps to build a cylinder:
1. A cylinder requires no curves or geometry for input.
2. Use the Surface wizard or select Cylinder from the Surface
toolbar pull-out.
4. Pick one of the following construction methods:
5. Two points
a. Enter the coordinates for the Center point, or click Pick and
pick the point with the mouse.
b. Enter the coordinates for the end point, or click Pick and pick
the point with the mouse.
c. Enter the Radius of the cylinder.
6. Direction, length
a. Enter the Length of the cylinder.
b. Enter the Center point coordinates of the cylinder.
c. Enter the Direction coordinates.
d. Enter the Radius of the cylinder.
More about cylinders (see page 195)
An example of a cylinder surface (see page 196)
More about cylinders
Cylinders are exact surfaces but contain a seam where two edge
boundaries meet. Be careful not to trim across the seam. Editing along the
seam is fine.
Cylinder example
The vent tube of the blow-dryer can be modeled as a cylinder. Pick end
and center points with the mouse and Pick buttons, or enter explicit
coordinates. Remember to set the points 2 inches in Z in the stock to
create the cylinder at the right depth. Now set the radius to 1 inch. The
cylinder can be trimmed to the rest of the model with the ruled surface.
Flat surface
Flat creates a rectangle between two diagonally opposed corner points.
Follow these steps to create a flat surface:
1. Flat surfaces require no pre-existing curves or geometry.
2. Use the Surface wizard or select Flat surface from the
Surface toolbar pull-out.
4. Enter the coordinates for a corner point, or click the Pick point
button and pick the point with the mouse.
5. Enter the coordinates for the diagonally opposite corner point, or
click the Pick point
button and pick the point with the mouse.
6. Enter an (optional) Elevation offset for the surface. You can also
pick the Z coordinate of any point using the Pick point
button.
More about flat surfaces (see page 197)
An example of a flat surface (see page 197)
More about flat surfaces

Flat creates a rectangular surface between two diagonally opposite
corners. This surface is a shortcut to create a ruled surface without having
to build bounding curves if the desired surface is rectangular. Flat
surfaces are exact (see page 168).
Flat example
The blow-dryer's parting surface can also be built with a flat surface.
Simply create a flat surface at depth with corner points that align with two
opposing block stock corners.
Surfaces from one surface

Surface region
Surface region derives a second surface from an original surface. Follow
these steps to extract a region from a surface:
1. You must have an existing surface to extract a region from.
2. Use the Surface wizard or select Surface region from the surface
toolbar.
3. Set whether to create a new surface or modify the existing surface
as a sort of trim.
4. Name the new surface for future reference if you are creating a new
surface.
5. Click Pick and select the source surface with the mouse, or just
select the surface from the drop down list.
6. Enter coordinates, or pick a point on the surface to bound the row

or columns on one side.
7. Enter coordinates, or pick a point on the surface to bound the row
or columns on the other side.
8. Select either Rows or Columns to orient the selection region.
The display highlights your selection so you can visually verify
that you have the correct area selected.
9. Click Finish or OK to create the new surface.
More about surface regions. (see page 198)
An example of a surface region. (see page 198)
Surface editing hints (see page 169)
More about surface regions
Surface region derives a second surface from part of an original surface.
A subregion of a surface is sometimes necessary for an auxiliary surface
to use for surface/surface intersection, filleting, milling, and so on.
When you extract a region, you are getting a band of either columns or
rows and this is an exact operation within the limits of the source surface.
Surface region is an exact process, however, if the source material is
approximate, the resulting region can be no more precise than the source
material.
Region example
For the top surface of the soap model, you could extract a row or column
slice between any two points you choose. The picture below shows a
potential region of rows from the Top surface of the model.
Reverse surface
Surface reverse is an exact operation. Follow these steps to reverse a
surface:
1. You must have an existing surface to use Surface reverse.
2. Use the Surface wizard or select Surface reverse from the
3. Set whether to create new surface or modify an existing surface.
4. Name the surface for future reference if it's a new surface.
5. Click Pick and select the source surface, or select the surface from
the drop-down list box.
6. Select whether you want to:
reverse normals
transpose row/column
reverse trim loops
7. Click Finish or OK to create the new surface or edit the existing
surface, whichever matches your settings.
Sheets (see page 230) can also be reversed using the Surface reverse
operator. They cannot be selected with the mouse, but instead should be
picked from the drop-down list box in step 5 above.
More about surface reverse (see page 200)
More about surface reverse
Because of the rectangular definition of surfaces, you have three options
in the surface reverse process.
You can keep the same surface, but reverse the direction of the
calculated normals, thereby turning the surface inside out. This is
perhaps the most common function as it affects isoline milling (see
page 358).
You can reverse the layout of the surface by swapping all the row
and column layout with each other.
You can also reverse the trim loops of the surface. This process
takes a trimmed surface and changes the trim operation so that
what was trimmed away before is now the retained surface and the
discarded surface is the surface you selected for the surface reverse
operation.
Surface offset
This function offsets the surface along its surface normals. You may need
to reverse the surface normals to get the offset you desire. Surface offset
is an approximate (see page 168) operation.
You must have an existing surface to use Surface normal offset.
1. Open the Surface wizard and set it to perform a Surface
normal offset or select Surface normal offset from the
Surface toolbar.
2. Set whether you want to modify the existing surface or create a
new surface from the process.
3. If you are creating a new surface, name the surface for future
reference.
5. Set the Distance you want to offset the surface.
6. Specify an acceptable Tolerance. Tolerance means that the

resulting surface may deviate from the exact offset by no more than
the value you enter.
More about surface offset (see page 201)
More about surface offset
An offset surface is a constant distance away from the original. The offset
produces an approximation of this, which is why there is a tolerance. The
original surface must be smooth (no sharp corners) or the offset result is
not correct.
Use offsets to thicken an object or to account for shrinkage in moldmaking.
Use offsets to intersect two (offset) surfaces to get the center curve of an
implied fillet. This curve could be used for a groove milling operation to
cleanly mill a fillet without actually making the fillet surface.
If an offset can be produced by an exact operation, for example, offsetting
a curve and using revolution or a sweep, then use the exact operation.
Extend
Extend adds a linear extension to the selected surface similar to extruding
the boundary curve of the surface however far you set. The direction of
the extend is the tangent direction at the boundary. Remember that the
surface is defined with rows and columns as you select which boundary
to extend.
Follow these steps to extend a surface:
1. Extend requires an existing surface to work with.
2. Use the Surface wizard or select Extend surface from the
3. Set whether you want to modify the existing surface or create a
new surface from the process.
4. If you are creating a new surface, name the surface for future
reference.
6. Select the edge to extend either with the radio buttons, or click
Pick and select the edge with the mouse.
7. Set the distance for how far to linearly extend the surface.
More about extending surfaces (see page 202)
An example of an extended surface (see page 202)
More about extending surfaces
Surface extends create extra surface to fill gaps or to be trimmed away
cleanly by a nearby surface. For example, open fillets often have to be
extended slightly before they will cleanly trim the surfaces they fillet (and
so they can be cleanly trimmed by another surface).
Extend is an exact operation.
Extend example
Consider the fillet in the soap dish model. If the top surface were
undersized for some reason, or the fillet radius didn't reach to the top
surface, an extend operation could resolve the problem. In this case,
select the Extend surface option from the Surface toolbar.
Unless you are sure of your process, it's safer to create a new surface
instead of modify an existing surface. Select the Create new surface
radio button and name it. Working through column and row options and
previewing the results, the intended surface is achieved using First
Column and an extension of 0.1 inch.
Trim surface
Trimming cuts away a portion of a surface. The portion that is removed is
determined by a trimming curve that lies on the surface. Trimming is
useful for creating solid models or for simply removing an unwanted
portion of a surface.
How to trim a surface with a curve (see page 205)
Trimming restrictions (see page 206)
Comparison with Surface/surface trimming (see page 219)
See also Surface/surface intersection, Surface/surface trimming (see page
216), and Fillets (see page 210).
Overview of trimmed surface

A trimmed surface is a surface that has a portion removed by an
embedded curve. The curve will divide the surface into two pieces. For
example a square surface with a circular trimming loop will form either a
square with a hole in it or a disk depending on which portion of the
surface you want to keep.
This orange surface is the top portion of a soap bottle mold. It must be
trimmed by the red curve to reflect the correct shape.
This blue surface shows the result of trimming the orange surface with
the red curve.
See trimming restrictions (see page 206) for the rules for trimming
surfaces.
Trimming a surface with a curve
1. To trim a surface, you must have a surface and a curve that bounds
the area to be trimmed in the part model. The curve must cut across
the surface boundary at two points for an open trim, or be
contained completely within the surface.
2. Use the Surface wizard and set the first radio button to From
one surface and the second button to Trim. Or use the From
one surface pull-out and select Trim.
3. Set whether to Create a new surface or Modify the existing
surface.
4. Name the new surface for future reference.
the drop-down list box. The location that you select will determine
the portion of the surface that is kept.
6. Click Pick and select the trimming curve, or select the curve from
7. Use Preview to verify the surface. If it's not right, reset some of
the options and verify it again with Preview. You may need to
toggle the Side kept switch to trim the desired part of the surface.
Trimming restrictions
Trimming curves have two main restrictions:
1. The curve must lie on the surface. Convenient ways of getting a
curve on a surface are:
If the surface is a flat surface, model the curve in the plane of
the curve.
Project a curve onto the surface.
Intersect two surfaces to get a curve.
2. The curve must divide the surface in two distinct regions. If not,
you will get the error Cant trim, curve does not end on a
boundary. Think of the surface as a piece of paper and the
trimming curve as a path for a pair of scissors. After the cutting
operation, you should be left with two pieces of paper. The
trimming curve must do one of the following:
Form a loop in the interior of the surface
Cut across two surface boundaries
Cut across the same boundary twice
Trimming examples (on page 207)
Additional trimming restrictions (see page 206)
Additional trimming restrictions
Do not include portions of the boundary when constructing curves
for trimming. Trimming curves may cross or end on boundaries.
Avoid cutting through the degenerate boundary a surface such as
the pole of a sphere or surface of revolution.
Avoid cutting along a seam of a surface (across is fine). A seam
exists, for example, at the left/right boundary of a cylinder. You
can detect seams with the Curve Extraction dialog, and then
canceling out after you know where the seam is. Avoid cutting a
seam rotating the object because many objects with seams are
symmetrical.
Trimming examples
Untrim surface
Untrim removes one or all trimming loops from a trimmed surface and
consequently adds area back to a surface.
How to untrim a surface (see page 208)
See also Overview of trimmed surface (see page 204) and Surface editing
hints (see page 169).
Overview of untrimming surfaces
A trimmed surface is a surface with an embedded curve that removes a
portion of the surface. See Overview of trimmed surfaces (see page 204)
When you untrim a surface you are removing the trimming curve from
the surface and therefore adding the material back to the surface. The
trimmed surface in the first image becomes the surface in the second
image after you remove its circular trimming loop.
If you import a part model, it is often useful to untrim portions of the part
that you would like to machine with 2.5D features. For example, in this
simple part, surfaces are used to represent the geometry of the hole.
Since it is preferable to drill the hole using FeatureMILL's Hole feature,

we can untrim the surface by removing the entire trimming loop and mill
it as if the hole did not exist and then later add in a hole feature for
drilling the hole.
For some parts, a feature such as a hole may result in trimming edges in
multiple surfaces. In this example, a hole trims away two surfaces:
Removing the entire outer trimming loop is undesirable since the notches
at the top of the surfaces would also be removed. Instead, only the semicircular edges from both surfaces need to be removed as shown here:
How to untrim a surface or fill a hole

1. You must have a trimmed surface or face of a solid available to
untrim.
2. Use the Surface wizard or select Untrim surface from the
Surface toolbar pull-out. All of the trimming loops are displayed.

surface.
4. Name the new surface for future reference (if you are creating a
new surface).
5. To remove all trimming loops, click Untrim all.
6. To remove a single loop:
a. Click Untrim selected loop
b. Click the Pick loop
button and select the loop to remove
7. To remove a single edge:

a. Click Untrim edge(s).
b. The dialog warps into a button labeled Untrim a trimmed.
c. Select the trim curve(s) in the graphics window.
d. Double-click the button labeled Untrim a trimmed. The
dialog appears again.
8. Click Finish or OK to complete the operation.
Split surface
Split breaks an existing surface into two new surfaces along a row or
column division.
Follow these steps to split a surface:
1. You must have a surface in the model to use Split.
2. Use the Surface wizard or select Split surface from the
3. Name the first surface for future reference.
4. Name the second surface for future reference.
6. Select whether to split the surface along the rows or columns.
7. Click Pick or enter the XYZ coordinates of the point to split the
surface along.
8. Use the Preview feature to verify the surfaces. Change some
settings, such as the row/column option, or pick the split point
more carefully.
9. Click Finish or OK to create the new surfaces.
More about splitting surfaces (see page 210)

More about splitting surfaces
A subregion of a surface is sometimes necessary for an auxiliary surface
to use for surface/surface intersection, filleting, milling, and so on. Split is
an exact (see page 168) operation within the limits of the original surface.
Splitting the top surface of the soap dish model creates two surfaces. The
pictures show a split along a column of the surface.
Surface from multiple surfaces

Fillet
A fillet creates a smooth curved transition surface between two adjacent
surfaces.

How to create a fillet surface (see page 212)
Restrictions (see page 214)
See also surface surface intersection and Trimming a surface with a curve
(see page 203).
Overview of fillets
A fillet is a surface that creates a smooth tangent-continuous blend
between two surfaces. This figure shows a fillet surface that blends two
flat surfaces.
This figure shows the same fillet with the surfaces automatically trimmed
against the two fillet boundaries.
Just like the case of an arc between two lines, there is more than one
possible fillet between two surfaces. This figure shows the same two flat
surfaces with a fillet on another corner.
A constant radius or rolling ball fillet is created by setting the Begin

radius and End radius to the same value. A variable radius fillet is
created by entering different values for the two radii.
Filleting multi-step process:
1. Intersect the two surfaces. If you explicitly specify the intersection
curve this step is skipped. The most common reason for explicitly
entering the intersection curve is to calculate the curve separately
and then extend it so that the fillet extends beyond the surface
boundaries.
2. Construct fillet surface.
3. Optionally trim one surface against the top of the fillet. The top
boundary curve of the fillet must be a valid trimming curve for the
top surface.
4. Optionally trim the other surface against the bottom of the fillet.
The bottom boundary curve must be a valid trimming curve for the
bottom surface.
It is possible to create a valid fillet surface that does not allow you to trim
the surfaces against the fillet. In this example, the fillet is in the middle of
both surfaces and as a result the boundaries of the fillet are not valid
trimming curves. See Trimming restrictions (see page 206) for the rules
of valid trimming curves.
How to create a fillet surface
1. You must have two surfaces that intersect to create the fillet
between.
2. Use the Surface wizard or select Fillet surface from the

3. Name the surface for future reference
4. Click Pick and select surface 1, or select the surface from the
drop-down list box.
5. If you want to trim surface 1 with the fillet, select the Trim to
fillet check box. Set the Trim Tolerance to affect the accuracy of
your trimming. It is recommended for most parts (less than 1 foot
cubed) that you set this between 0.001 and 0.0001 inches (0.0254
to 0.00254 mm).
drop-down list box.
7. If you want to trim surface 2 with the fillet, select the Trim to
fillet check box. (See step 5 regarding trim tolerance.)
8. You may also set an Intersection to limit the range of the fillet,
or to clarify which intersection of the surfaces to consider.
Intersection places the fillet along the curve described by the
intersection of the surfaces. This curve must actually exist in the
drawing.
9. Select the Arcs only construction switch box if you want to
create just the arcs that would comprise the fillet. You could then
combine these arc curves to create other surfaces.
10.Choose the Corner for the fillet. Corner refers to the drawing in
the dialog to help you specify which of the four possible sides of
the intersection you want the fillet to be in.
11.Set Tolerance for how much the resulting surface may deviate
from the exact fillet. It will vary by no more than value you enter.
If you want high quality fillets for parts that are approximately 1
foot cubed, the recommended settings are between 0.001 and
0.0001 inches (or 0.0254 and 0.00254 mm).
12.Define the Arc step of the fillet. If you select Variable, the
spacing of the fillet cross sections will be calculated automatically
based on the Tolerance. More cross sections will be placed in
curved regions of the fillet as in this figure:
13.If you deselect the Variable button, you must set an Arc Step.
The spacing will then be constant between cross sections as in this
figure:
14.Set the Begin radius. Having two settings for radius lets you
create a fillet that grows or shrinks along the path of the fillet as
needed. For a closed fillet, the Begin and End radius need to be
the same.
15.Set the End radius of the fillet as applicable.
16.Click Finish or OK to create the filleted surface.
Fillet restrictions
The fillet constructor works with two surfaces only.
The surfaces must intersect.
If trimming, the top and bottom boundary curves of the fillet must
form a valid trimmed surface in the respective surfaces. See
Trimming restrictions (see page 206) for the rules of valid
trimming curves.
Fillet creation does not consider trimmed portions of a surface so if

you fillet a trimmed surface, the fillet will extend for the complete
length of the original surface. You can either trim the fillet away
after it has been created or use an intersection curve to limit where
the fillet runs.
The input surfaces must be smooth with no sharp corners.
The fillet radius should be less than the smallest radius of the
intersection curve. If it is larger, the fillet may overlap itself.
See Surface design hints (see page 168) for additional recommendations.
Merging surfaces
Merge combines surfaces together into a new surface. Follow these steps
to merge surfaces:
1. You must have at least two surfaces in the model to use Merge.
2. Use the Surface wizard or select Merge surface from the
3. Name the surface for future reference
drop-down list box.
drop-down list box.
6. Select the row/column option on surface 1 you want to merge into
surface 2.
7. Select the row/column option on surface 2 you want to merge into
surface 1.
8. Set whether the Merge should blend the two surfaces, which loses
some of the original surfaces that are merged. Setting exact
maintains all of the original surface in the final merge.
9. Use Preview to see what the merged surface will look like. If you
don't have the results you want, you may need to change the edges
you want to merge. The Flip surface check box for surface 2
might also help create the right surface.
10.Click Finish or OK to create the new surface.
More about merging surfaces (see page 216)
More about merging surfaces

You can merge with a blend so that the two surfaces transition into each
other more gradually. Or you can make an exact merge so that the new
surface keeps all of the original surface data of the two source surfaces.
Surfaces for a merge ideally have the same number of rows or columns so
the two surfaces meet. The Exact option is best when the two surfaces
share a common boundary curve. When they don't meet, exact inserts a
ruled surface between the boundaries being merged.
If you had two neighboring flat surfaces, you could combine them with
merge into one flat surface.
The Blend option is best when the surfaces don't meet. A fillet-like blend
is created to fill the gap. Merging automatically untrims trimmed
surfaces. Merged surfaces may be trimmed again as needed.
The Exact option is best when the two surfaces share a common
boundary curve. When they don't meet, exact inserts a ruled surface
between the boundaries being merged.
The Blend option is best when the surfaces don't meet. A fillet-like blend
is created to fill the gap. Merging doesn't work for trimmed surfaces.
Surfaces can be untrimmed, merged and then retrimmed.
Surface/surface trimming
Surface/surface trimming calculates the intersection of one surface
against one or more surfaces and trims the surfaces with this curve.
How to trim surfaces against each other (see page 218)
Comparison with Trim a surface with a curve (see page 219)
See also Trim a surface with a curve (see page 203) and Surface surface
intersection.
Overview of surface/surface trimming
Surface/surface trimming has two types of surfaces, trimming surfaces
and trimmed surfaces. The trimming surface is the surface that does the
cutting. Think of it as a pair of scissors or a knife. The trimmed surfaces
are the surfaces that are cut. Think of them as the paper. You can have
only one trimming surface, but you may have more than one trimmed
surfaces.
The first step of surface/surface trimming is calculating the intersection of

the trimming surfaces and the trimmed surface(s). This step happens
behind the scenes and is only visible if you are previewing your
calculation before actually performing it. This curve is then used to trim
away a portion of the trimmed surfaces. If these surfaces are the original
surfaces,
the blue curve in this figure is the intersection curve between the two
surfaces.
These surfaces are the result of using the vertical surface as the trimming
surface to cut the horizontal surface. If you select the Trim this surface
also check box, the trimming surface will also be trimmed using the
intersection curve as in this figure:
How to trim surfaces against other surfaces

1. You must have two surfaces in the model to use surface/surface
trimming.
surface.
3. If you are creating a new surface, name the new surface for future
reference.
4. Click Pick and select a trimming surface, or select the surface
from the drop-down list box. When you pick the surface with the
mouse, pick the surface in an area you want to keep.
5. Decide whether to select the Trim this surface also check box.
If so, then set the Side kept field to choose the correct side.
6. Click Pick to select the other surface, or select the surface from the
drop-down list box and click Add to add it to the list. You can add
more surfaces to the list the same way and trim multiple surfaces
all at once.
7. If the side you selected the surface from isn't the side you want to
keep, then set the Side kept field for the surfaces in the trimmed
list. The options for Side kept are:
Picked side - will keep the portion of the trimmed surfaces
where you picked with the mouse.
Normal - will keep the side of the trimmed surfaces that are on
the opposite side as the normal of the trimming surface.
Reverse - will keep the side of the trimmed surfaces that are
on the same side as the normal of the trimming surface.
8. Set the Tolerance for the operation. This value specifies the
distance between calculations along the intersection area. Set the
tolerance lower if the intersection curve appears too coarse.
9. Click Preview to check your results against your expectations.
You may need to work with the Side kept fields and multiple
Previews to get the final surface you expect.
10.Click Finish or OK to complete the operation.
Surface/surface trimming restrictions

The intersection curve is calculated using the surface/surface
intersection technique. If you receive the message No
surface/surface intersection, then FeatureMILL cannot
determine the intersection curve for your surfaces. For additional
details see these restrictions (see page 169).
If you receive the message Can't trim, trim curve does not
end on a boundary, then an intersection curve has been
calculated, but it is not a valid trimming curve for your surfaces.
This figure shows an example.
See Trimming restrictions (see page 206) for all the restrictions for
trimmed surfaces.
If you have multiple trimmed surfaces, the intersection curve must
form a valid trimmed surface for each of the trimmed surfaces.
If you have selected the Trim this surface also check box, then
the intersection curve must form a valid trimmed surface with
respect to the trimming surface.
Comparision of Surface/surface trimming and Trim a surface
with a curve
Surface/surface trimming is more accurate and is the preferred
method of trimming surfaces against each other.
Surface/surface trimming should be used if the intersection curve of
the two surfaces is a valid trimming curve for the surface to be trimmed.
Surface/surface trimming performs surface/surface intersection as its

initial step. The resulting curve is then used to trim the surfaces. This
curve must be a valid trimming curve for the surfaces to be trimmed. See
trimming restrictions (see page 206) for more information. If the
intersection curve does not cut all the way across the surfaces to be
trimmed, you may have to calculate the intersection curve separately and
then join it with other curves to form a valid trimming curve for the
surface.
Trim a surface with a curve should be used:
If you only have a curve with which to trim a surface.
If the surfaces are tangent at their intersection such as a fillet and
its blending surfaces. In this case, extract the boundary curve of the
fillet surface and use it to trim the other surface.
Where one surface needs to be trimmed by multiple other surfaces
before a complete loop is formed. You may need to extract
trimmed edges or calculate surface/surface intersection curves and
join them to create the trim loop. In this example, the orange
revolved surface cannot be trimmed by either the blue or red
surface alone.
Instead:
1. Calculate the intersection curve of the blue surface vs the
orange surface.
2. Calculate the intersection curve of the red surface vs the red
surface.
3. Join the two curves.
4. Trim the orange surface with the joined curve.
Surface from feature

You can create a 3D surface from any 2.5D feature. Follow these steps to
create a surface from a 2.5D feature:
1. You must have a 2.5D feature present in the part model.
2. Use the Surface wizard or select Surface from feature in the
4. Click Pick and select the source feature, or select the feature from
More about turning features into surfaces (see page 221)
An example of a surface from a feature (see page 221)
More about turning features into surfaces
You can use these surfaces in your part modeling or even to manufacture
them using the 3D techniques, or to modify with the Surface editing tools
so you can join your 2.5D features to your 3D features.
Features can be a shortcut to create swept and cap surfaces with the
familiar dimension driven feature interface. The draft angle, or radiused
features produce a swept surface for the side walls (including chamfer
and bottom/top radius) and a cap surface for the bottom in one operation.
Feature to surface example
The soap dish model can be built with a boss feature for the side. In that
method, you need to trim the fillet against the boss, but you have to create
a surface to trim against. Select Surfaces from feature, name the new
surface. Select the boss feature as the source feature. FeatureMILL
calculates the corresponding surface.
Modify surface
Modify works with the surface by manipulating links and surface curves.
Follow these steps to use Modify surface:
1. You must have a surface in the part model to use Modify surface.
2. Click Pick and select the surface, or select the surface from the
drop-down list box.
3. Set whether to show the isolines or not with the Show surface
option.
4. Select the type of operation you want to perform on the surface.
Choices are:
Change point (see page 222)
Change link to line (see page 222)
Change link to arc (see page 223)
Add surface curve (see page 223)
Delete surface curve (see page 223)
5. Click Finish or OK to complete the surface edit.
More about modifying surfaces (see page 224)
An example of a modified surface (see page 224)
Change point
Change point lets you change any intersection point on the surface to any
other point. Use the Pick button and the mouse to select the point. Then
enter the point's new coordinates. The surface is redefined to maintain the
overall smoothness of the surface so the shape is still tangent continuous.
This edit breaks the link between the surface and the method originally
used to construct it. You can't open the surface's Properties dialog now
and modify it based on the parameters that originally defined it as those
parameters no longer apply directly to this surface.
Change link to line
Change link to line takes any selected segment and changes it to a straight
line between the two points that bound the segment. The surface is
recalculated to properly incorporate this change in its definition.
Change link to arc
Change link to arc changes a selected segment to an arc that follows the
original segment path. This does not obviously change the shape of the
surface but you can use it to control surface behavior between defining
curves, for example.
Add surface curve
Add surface curve adds another surface curve to the surface you
selected with the mouse or defined by coordinates. This is often a
preliminary step for a subsequent modify operation based on the new
surface curve if there wasn't a surface curve or link where you needed
one.
Delete surface curve
Delete surface curve removes a surface curve from the surface. This
can drastically affect the shape of the surface. You cannot delete any
boundary.
More about modifying surfaces

Modify works with the surface by manipulating links and surface curves.
The links of a surface characterize the shape of the surface. The collection
of links in one direction across the surface is known as a surface curve.
When you select the surface to modify, a number of blue lines appear
with intersection points. These are the links and surface curves. A link is
any segment between two intersection points.
Isolines are displayed on the screen, but they are not the surface curves
that are edited. To see the isolines while editing, select the Show
surface option. With Modify you can change specific points in the
surface to fine tune your surfaces to match your needs. Changing the
surface with Modify breaks the parametric link of the surface to the
original construction data.
Modify example
The speaker case, for example, has a slightly bowed bottom. With
Modify, you can flatten that part of the model. Orient the model so you
can see the bottom. The view of the model is shown on the left. On the
right is an unshaded zoom of the model in the same orientation so you
can see the result of the Modify operation. Using Modify, set Change
link to line to make a straight line between the points and select the
front edge of the bottom. Click Apply. Notice how the bottom surface
flattened out in comparison to the source curve which is also visible. This
surface can no longer be edited from the Sweep operation used to create
it because the Modify operation breaks the relationship to the original
data. Another Modify operation is needed to flatten the back edge of the
surface.
Corner blend
Blend surfaces are surfaces that create smooth transitions between two,
three or four surfaces.
Overview of blend surfaces (see page 226)
How to create blend surfaces (see page 227)
Restrictions on blend surfaces (see page 228)
See also Fillet (see page 210), Surface/surface trimming (see page 216),
Curve from surface intersection, Curve from surface isoline, and Curve
projected onto a surface.
Overview of blend surfaces

A fillet (see page 210) is a type of blend surface, but it requires that the
two surfaces actually intersect. They also have the restriction that they
can only blend two surfaces. A blend surface is a more general blend of
two, three or four surfaces. This surface constructor requires that you be
familiar with creating curves on a surface and tangency, but it creates
complex blends if these concepts are mastered by the user.
Two-surface blends
This figure shows a two-surface blend example. For this blend you must
supply the curve on each surface to create this surface.
Three-surface blends
This figure shows a three-surface blend example. This blend is used to
create what is known as a 'suitcase fillet'. This means that you want to
create the intersection of three fillets like the corner of a suitcase. If you
create the fillets with FeatureMILL3D, the curves can usually be
automatically detected.
Four-surface blends
This figure shows a four-surface blend example. It is another suitcase
fillet. In this case one surface is not a fillet.
The curve for this surface must be specified. Four-surface blends can also
be used to join four distinct surfaces as in this figure.
How to create blend surfaces

1. Select Corner Blend from the Surface Wizard or Curve and
Surface pull-out.
2. Optionally name the surface.
3. Select the number of surfaces you wish to blend as the Surfaces
value.
4. Select each surface by either the drop-down list or by picking the

button.
graphically using the Pick surface
5. For each surface, select the Curve on the Fillet by either using
button. Select
the drop-down list or using the Pick curve
**Automatic to let FeatureCAM calculate the curves. See
Restrictions o (see page 228)n blend surfaces for further
information.
6. Click Apply to preview the blended surface.
7. If the edges of the fillet are too coarse set the Tolerance to a
smaller value.
8. If you want the fillets to be trimmed against the blended surface,
click Trim fillets.
9. Click Apply again to preview the final blended surface.
10.Click OK.
Restrictions on blend surfaces
For three or four surfaces, if you choose **Automatic as the curve to
indicate that the system should automatically calculate the curve then the
following restrictions apply:
The fillet surfaces must extend to where they intersect with the
other fillet surfaces. This figure shows an example of surfaces that
do not intersect.
If the surfaces are not a FeatureCAM-created fillet (either not a

fillet at all, or an imported surface), the automatic corner boundary
calculation may fail. In these cases it is better to specify the curveon-surface for that particular surface.
FeatureCAM attempts to find a closed loop across the three or four

surfaces by intersecting the rail curve boundaries of each fillet with
the other fillet's rail curves. This figure shows rail curves.
Therefore, if any of the curves on surfaces are specified, they must

intersect with these rail curves of the fillet surfaces where a curve
on a surface is not supplied.
If a fourth surface is supplied, it is usually not a fillet surface. For
these surfaces you must supply a curve on the fourth surface.
Remember that the curve supplied must be on the fourth surface
and should be tangent to the rail curves or the neighboring fillets.
If the automatic calculation fails, try a bigger tolerance, supplying
more curves on the surfaces or extending the fillet surfaces so that
they intersect. Sometimes it is helpful to recreate the fillet surfaces
with a tighter tolerance or a variable arc step.
General restrictions
With only two surfaces, you must indicate curves on each surface
to connect.
For three sided cases, if there is a natural pole as in this figure, it is
best to but the fillet surface that is furthest from the pole at the first
surface.
3D solid modeling
(Solid Modeling)
Overview of solids in FeatureCAM

The FeatureCAM support of solids allows you to work with imported
CAD designs from solid modeling systems and to create 3D solid models
using FeatureCAMs solid modeling tools. Solids are a convenient
representation for 3D parts since they group collections of surfaces into
3D volumes. By working with a solid instead of all of the individual
surfaces, you are provided with a more convenient representation and
more powerful modeling tools.
A solid is a collection of surfaces (called faces) that define a 3D
volume. The edges that join faces are shared between the faces. A solid
cannot have any holes. If you filled it with water and tumbled it around, it
would not leak. For example, a box is a solid, but a box with a missing
face is not. FeatureCAM automatically names these objects with a
"solid" prefix, for example "solid123".
230 3D solid modeling (Solid Modeling)
A face is an individual surface contained in a solid. FeatureCAM

automatically names these objects with a "face" prefix, for example
"face472".
An edge is a curve that connects two faces. FeatureCAM automatically

names these curves with an "edge" prefix, for example "edge857".
These curves are not normally displayed, but they are displayed by
dialogues that require an edge.
A sheet is a group of surfaces that are created using the solid modeling
tools, but that do not create a solid. Sheets have restrictions on how they
can be used since they do not enclose a 3D volume. FeatureCAM
automatically names them with a "sheet" prefix like "sheet902". When
you create a sheet, a dialog is displayed indicating that a non-solid
result was created from the design operation.
3D solid modeling (Solid Modeling) 231
A surface is a single 3D surface that is created with the tools of the

FeatureCAM Surface wizard or imported from a CAD system (usually
through IGES file transfer). These surfaces do not share edges with
neighboring surfaces even though the boundaries may overlap. The edges
individually defined in each surface. Certain collections of surfaces may
be converted into sheets or solids using the design features available in
the From surfaces category of the Solid wizard.
Comparison of surface and solid

modeling
The advantages of surface modeling are:
1. For representing curved shapes, surface modeling tools are more
powerful. Operators like Curve mesh, Ruled surface, Cap
surface and Modify surface are only available for surface
modeling. Surface lofting is more powerful than the solid fillet
design feature.
2. With surfaces you are not forced to always work with 3D volumes.
You can build your model face by face with surfacing tools without
having to worry about 3D volumes.
The advantages of solid modeling are:
1. Many surfaces are grouped together in a single solid, so solids can
be a more efficient way to model.
2. Modeling operations that need to know the connections between
surfaces are more powerful in solids. Filleting is stronger in solids
since you only need to pick shared edges.
3. Useful modeling tools like Shell, Combine Shells and
Silhouette Curves are only available for solids.
Part View for solids

All solids are listed under the Solid category of the Part View.
Underneath each solid is a sequence of design features that were used to
create the solid. The first design feature listed for a solid is the base
feature. Base design features define the initial shape of the solid. Base
design features have the suffix, base, in their name. Subsequent design
features listed under the solid, further modify the shape of the solid. The
prefix of a design feature name indicates the type of design operation that
was used to create it.
In the example below, solid11 is made up of three separate design

features. The first feature is named stkbase1. As the first feature of the
solid, it is the base feature. The prefix, stk, indicates that the stock was
used to create the feature. The second design feature is named extcut1.
The name indicates that an extrude design operation was used to cut out
the pocket shape. The final design feature is named fillet1 and was
created using a fillet design operation.
Note that the list of design features is only available for solids that are
created in FeatureCAM. If you import a solid, only the resulting solid
model is imported. You can access the faces of the solid, but you have no
history of how the model was constructed.
See also Unattached design features (see page 233).
Unattached design features

If a solid design feature becomes disconnected from the solid, a question
mark is displayed over its icon in the part view as shown below.
These disconnected design features are called Unattached features. They

can occur if you place a feature outside of the boundaries of a solid, or an
edit to the solid makes a feature become unattached. For example, if you
fillet an extrude feature and then delete the extrude feature, the fillet
feature becomes unattached.
Unattached features do not cause any harm, but they are no longer
contributing to the shape of the solid. If you select the solid, the faces of
the unattached features are not selected.
Selecting and deleting solids

Solids can be selected by:
Holding down the space bar and directly picking the solid in the
graphics window. To select multiple solids in the graphics window,
hold down the CTRL key and space bar and then select each solid.
Clicking on the name of the solid or one of its design features in
the part view; or
Right-clicking on a face of the solid and selecting Select Solid
from the context menu.
Clicking in the graphics window only selects a face of the solid.
Solids can only be deleted by selecting them and either pressing the
DELETE key or selecting Delete from the Edit menu.
Verifying that a solid is valid

Occasionally, a solid model can be imported that looks good, but is not a
valid solid. That can cause problems performing further solid modeling
operations or recognizing features from the solid. To check that the solid
is valid:
1. Click the Automatic Feature Recognition
Steps toolbox.
icon in the
2. Click the Verify button.

3. A dialog is displayed indicating if the solid is valid.
4. Click OK to close the dialog.
If you want to see a visual representation of where any problems with a

solid are:
1. Select Construct > Solid > Verify Solid from the menu.
The Verify Solid dialog opens.
2. Select the solid that you want to verify from the list.
3. Select the Color bad faces option.
4. Click Verify.
Any self-intersecting faces are shown in the color that is set for
Verify : self intersecting in the Default Colors dialog.
Any other bad faces are shown in the color that is set for Verify
solid bad face in the Default Colors dialog.
Transforming a solid
1. Select the solid (see page 234).
2. Click the Transform
button in the Standard toolbar.
3. The Transform dialog comes up. See Transform for information

on this dialog.
4. If you selected to move the solid, a solid operation is created in the
tree view.
5. If you select to copy the solid, a new solid is displayed in the tree
view.
Solid wizard and Solid toolbar

Solid modeling commands are available from either the Solid wizard or
the Solid toolbar.
To work with the solid wizard:
1. Click Solid wizard

the Solid wizard.
button on the Advanced toolbar to open
2. Select a method of solid construction.

3. Select a specific solid constructor.
4. Click Next to bring up the dialog for the specific solid constructor.
See Defining the base solid in the solid wizard (see page 237)
To work with the Solid toolbar:
Display the solid toolbar by selecting Toolbars from the View
menu and checking Solid from the Toolbars tab.
Select the constructor from the toolbar.
The specific solid constructors are:
From Curves:
Extrude Solid Design Feature (see page 237)
Revolved Solid Design Feature (see page 238)
Swept Solid Design Feature (see page 241)
Lofted Solid Design Feature (see page 242)
From Surfaces/Primitives:
Stitching
Solid From 2.5D Feature
Solid From Stock or Cube
Extrude a Surface (see page 246)
Revolve a Surface (see page 247)
Shape Modifiers:
Solid Fillets
Cut Solid With Parting Surface
Combine Solids
Shell Solid Design Feature
Manufacturing:
Silhouette Curves (see page 255)
Select Core/Cavity (see page 257)

Split Face (see page 261)
Delete Face (see page 262)
Explode (see page 263)
Parting Surface (see page 263)
Draft a Face (see page 264)
Defining the base solid in the solid

wizard
If you run the solid wizard without a base solid defined, a page is
displayed that helps you create the base solid. Your choices are:
Use the stock as the base solid - a dialog opens for you to
create the base solid from the stock or make another cube shape.
Define a custom shape - in this case, the normal solid wizard is
presented.
See Type of design feature for the definition of a base solid.
Extrude solid design feature

Extrude creates a solid design feature by pushing a curve in a straight
line. Below are examples of an extrude add with a circle as the curve and
an extrude cut with a square as the curve.
To create a solid extrude design feature:

1. Select Extrude from the Solid wizard or the Solid toolbar.
2. Select the curve name in the Curve drop down list or click the
button and select the curve in the graphics
Pick Curve
window. Note that the curve must be planar.
3. Select the type as New Base Solid, Add, or Cut. See Type of
design feature for further information.
two ways:
Enter the specific vector of the extrude.

the extrude ends.
5. If you want to draft the walls of the surface, enter a Draft Angle.
6. Click the Preview button to see a line drawing of the feature.
7. If you displayed this dialog from the Solid toolbar, you can click
Apply to preview the feature as a solid. If the cut is on the wrong
side of the curve, click Flip Side to Cut and click Apply again to
verify.
8. Click OK or Finish.
See also Using open curves for solid extrudes (see page 238).
Using open curves for solid extrudes

Open curves can be used for solid base extrudes or solid cut extrudes.
They cannot be used for solid add extrudes. For base extrude solids, a
sheet is created without any end caps.
For cut extrude solids, you must ensure that the cut will divide the solid
into two distinct pieces like in this figure.
When working with open curves, an additional check box called Flip
Side to Cut is displayed. After previewing your result, you can select
this check box if you want to keep the solid on the other side of the
extrude.
Revolved solid design feature

Solid of revolution creates a solid design feature by revolving a curve
around a line.
To create a solid of revolution design feature:
1. Select Solid of Revolution from the Solid wizard or the Solid

toolbar.
2. Select the curve name in the Curve drop down list or click the
Pick Curve
window. Note that the curve must be planar.
4. Set the Start Angle in degrees.
5. Set the End Angle in degrees.
6. Pick the Construction method. This is where you set what is
revolved around, or the pole. You can pick a custom axis, or X or
Y axis.
7. If you select Custom Line, select the name of the line in the Line
drop down menu or click the Pick Line
button and select the
line in the graphics window.
verify.
10.Click OK or Finish.
Examples of solids of revolution (see page 239)
Using open curves for solids of revolution (see page 240)
Examples of solids of revolution

This figure shows a base solid
created with a curve on the
axis revolved 360 degrees.
You can tell that the curve
was on the axis since there is
no hole in the middle.
This example is an extrude
cut design feature rotated 180
degrees.
This figure shows a base solid

created with a curve off the
axis (note the hole in the
middle) and revolved 270
degrees.
Using open curves for solids of

revolution
If the curve is open, a dialog is displayed with the following options:
Close curve using lines to axis - creates a straight line from the curve
endpoints to the axis.
Close curve by joining endpoints - creates a straight line between the

endpoints of the curve.
Continue with curve as-is - no change is made to the curve and a sheet is
created.
Swept solid design feature

A swept solid takes a curve and runs it along another curve. The example
below shows a circle swept along a curved path to create a groove shape.
To create a swept solid design feature:

1. Select Swept from the Solid wizard or the Solid toolbar.
2. Select the curve name in the Axis drop down list or click the Pick
button and select the curve in the graphics window.
Curve
Note that the curve must be planar.
3. Select the curve name in the Cross Section drop down list or
click the Pick Curve
button and select the curve in the
graphics window.
5. Click the Preview button to check out your shape.
6. If the sweep does not follow the Axis curve, click Sweep from
the other end and click Preview again. If you still receive an
error see Troubleshooting Swept Solids (see page 242).
verify.
Troubleshooting swept solids

If you use a cross section that is too large, it can result in surfaces that
self-intersect. If sweeping from both ends of the curve does not work,
cancel the swept solid and try creating a swept surface (see page 175) . If
the result shows overlapping surface regions like shown below, then the
cross section is too large.
Lofted solid design feature

This design feature takes a series of curves and fits a surface to them.
To create a solid lofted design feature:

1. Select Lofted from the Solid wizard or the Solid toolbar.
2. Select the curve name in the Curve drop down list and click the
Add
button, or click the Pick Curve
curves in the graphics window.
4. If you want to connect the first and last curves, click the Close
button. See Closed lofted solids (see page 243) for more
information.
5. Click the Preview button to confirm that the surface is correct.
6. If you are working with open curves and surface twists, click the
name of the curve in the curve list and click the Reverse
Selected Curve
button and click Preview again.
7. If you are working with closed curves and surface twists, you may
need to change the start point of some of the curves.
verify.
If you cannot get the desired shape, you may want to create the shape
with a lofted surface (see page 186).
Closed lofted solids

The Closed check box for lofted solid design features, connects the first
and last curves. Note that you cannot repeat curves in a loft. In this
example, the curves on the left are lofted. In the middle picture, the loft is
not closed. The loft on the right shows a closed loft.
Overview of stitching
Stitching converts well-trimmed surface models with shared edges and
shared boundaries into solid models. Once the surfaces have been stitched
together into a solid, you can perform any solid modeling operation on
the solid. The surfaces must not overlap or have gaps between
them. The surfaces on the left will not stitch because they overlap. The
right-hand figure will stitch because the overlap has been trimmed away.
Types of models that are good candidates for stitching are:

IGES files containing trimmed surfaces from solid modeling
packages
Surfaces that you model and trim using FeatureCAM surfacing tools
Stitching surfaces into solids

To stitch surfaces into solids:
button and select Stitching from the
1. Click the Solid wizard
From surfaces/primitives category or select the Stitch
button from the Solid toolbar.
button and pick the surfaces in the
2. Click the Pick Surface
graphics window. Each surface you pick will be entered in the
surface list. Note that if you have the surfaces already selected
before bringing up the dialog, these surfaces will be listed in the
surface list.
3. If the surfaces form a sheet instead of a solid, select the Non-solid
results OK check box. If you do not select this box, you are given
an error if the surfaces do not form a complete solid. See Overview
of solids (see page 230) for further information.
4. Click OK or Preview.
5. If the surfaces form a solid, a new solid will be listed in the part
view.
6. If the surfaces to not form a solid or a sheet, an error message is
displayed. See Troubleshooting stitching (see page 245).
Troubleshooting stitching
1. Make sure that no duplicate surfaces are displayed.
2. Make sure that the surfaces do not overlap. In this case, you must
trim the surfaces before stitching.
Overview of solid from 2.5D feature

When a 2.5D feature is created, a 3D surface representation is created for
display. While you can generate toolpaths and create a 3D shaded
simulation of the part, you must convert the features into solid modeling
operations to subtract them from a solid. In the example below, a boss
feature and three holes were converted to a solid. It is important to
remember that all solids created from 2.5D features are subtractive,
even boss features.
Creating a solid modeling operation from a 2.5D

feature
To create a solid modeling operation for a 2.5D feature
button and select Solid from 2.5D
feature from the From surface/primitive category or Select the
Solid from 2.5D feature
2. Select the feature name in the feature drop-down list or pick the
Pick Feature
button and pick the feature in the graphics
window. You can convert all 2.5D features except side features.
Patterns of features are also supported.
3. If you have more than one base solid created, select the name of the
solid.
Remember that all features are subtracted from the solid, even bosses.
Solid from stock or cube

Creating a solid from the stock dimensions
button in the Advanced toolbar and
select From Stock (cube) from the From surfaces/primitives
button in the Solid toolbar.
category or click the Stock
2. Select the Stock radio button.
Creating a cube solid design feature

select From stock (cube) from the From surfaces/primitives
category or click the Stock
2. Select the Cube radio button.
3. Enter the coordinates of each corner or click the Pick Point
button and pick the point in the graphics window.
4. Select the type as New base solid, Add, or Cut. See Type of
Extrude surface solid design feature

Extrude creates a solid design feature by pushing a surface in a straight
line. This operation is identical to Extrude solid design feature (see page
237) except it works with surfaces not curves as the input. Below are
examples of a surface and its extrusion.
To create a solid extrude design feature:

1. Select Extrude a surface from the Solid wizard or the Solid
toolbar.
2. Select the surface name in the Surface drop down list or click the
button and select the surface in the graphics
Pick Surface
window. Note that you cannot use a face of a solid.
3. Select the type as New base solid, Add,or Cut. See Type of
two ways:
Enter the specific vector of the extrude.
the extrude ends.
5. If you want to draft the walls of the surface, enter a Draft angle.
7. If you displayed this dialog from the solid toolbar, you can click
side of the curve, click Flip side to cut and click Apply again to
verify.
Revolved solid from surface design

feature
Solid of revolution creates a solid design feature by revolving a surface
around a line.
1. Select Revolve a surface from the Solid wizard or the Solid

toolbar.
2. Select the surface name in the Surface drop down list or click the
Pick surface
window. Note that you cannot use a face of a solid.
3. Select the type as New base solid, Add, or Cut. See Type of
4. Set the Start Angle in degrees.
5. Set the End Angle in degrees.
6. Pick the Construction method. This is where you set what is
revolved around, or the pole. You can pick a custom axis, or the X
or Y axis.
7. If you select Custom line, select the name of the line in the Line
drop down menu or click the Pick line
line in the graphics window.
side of the curve, click Flip side to cut and click Apply again to
verify.
Overview of solid fillets

Since solids share edges among faces, solid filleting is simpler and more
powerful than surface filleting. You simply select edges of the solid and
enter fillet radii. The surfaces are then blended across the edge and the
faces are automatically trimmed. You can create constant radius fillets as
shown on the left or variable radius fillets as shown on the right.
Creating a constant radius solid fillet

1. Select the solid (see page 234) in the part view.
2. Click the Solid Wizard
select Fillet Edges from the Shape Modifiers category or click
the Fillet
3. The edges of the solid are highlighted in blue.
4. Enter the Radius.
5. If you want to create a variable radius fillet, select the Variable
radio button and enter the End radius.
6. If you want to fillet all the edges of a Face, click the Pick
surface
button and pick the face in the graphics window.
7. If you want to set the radius for a single Edge, click the Pick
button and pick the edge in the graphics window.
curve
8. The name of the edges and their fillet radius is entered into the list
of edges and the edge is shown as a red arrow.
9. If you want to use a different radius on the next edge, enter a
different Radius.
10.Continue picking edges until you have selected all the desired
edges.
11.Click Preview if you want to preview the fillet before committing
to the changes.
12.If you need to change the radius on an edge, select the edge in the
edge list, enter a new radius and click the Set Radius on selected
button.
13.If you want to change the radius of all the edges, enter the new
button.
radius and click the Set radius on all
14.Click Finish or OK.
Also see controlling the shape of solid fillet joints (see page 250).
Controlling the shape of solid fillet joints

The joints where fillets intersect can either be mitered (as shown on the
left) or blended (as shown on the right).
To create a blended fillet, fillet the adjacent edges in a single fillet. The
blend will automatically be calculated based on the radii or the fillets.
To create a mitered fillet, fillet the adjacent edges in different fillets. The
fillets are intersected and trimmed against each other.
Overview of cut solid with parting

surface
Once you have a solid, you can cut it with a surface or a collection of
surfaces with common edges. This is a useful operation for separating the
solid into two mold halves. In the example below, the solid is a revolved
glass that was subtracted from a box.
This solid is then cut with a flat surface resulting in half of the solid being
cut away.
You can also cut a solid with a collection of surfaces that have common
edges. The surfaces are stitched together and the solid is then cut with the
resulting surfaces.
Cutting a solid with parting surfaces

select Cut with Parting Surface from the Shape Modifiers
button from the
category or Select the Cut with surface
Solid toolbar.
2. Select the name of the solid in the Cut this solid drop-down list
or click the Pick solid
button and pick the solid in the
graphics window.
3. Select the name of the surface in the Surface drop-down list and
button or click the Pick surface
button and
click the Add
pick the surface in the graphics window.
4. If you have additional surfaces to cut with, repeat step 3.
Remember that the surfaces must have common edge curves that
allow them to be stitched together.
5. If you wish to create a solid for both sides, check the Keep both
sides check-box.
6. Click the Preview to preview the cut. The result will be shown in
thick blue lines. If you want to cut on the other side of the
surface(s), click the surface name and click the Reverse
selected surface
button.
Overview of combine solids

Normally you work only on a single solid model. You start with a base
and create additional design features that alter the shape of the solid.
Sometimes it is convenient to work on two different solids separately and
then combine them into a solid. An example would be combining an
imported solid and a mold base. The figure on the right is a solid mold
base. The middle figure is the cavity solid. The left-hand figure shows the
result of combining the mold base and the cavity.
Combine solids allows you to combine solids in three different ways. See
Solid operations (see page 252) for more information.
Solid operations
A Difference B is A minus the portion of B that is inside of A.
A Union B is A plus the portion of B that is outside of A.
A Intersection B is the volume that is common to both A and B.
Initial solids
Square Difference Cube

Cube
Difference
Square
Cube Union
Cylinder
Cube
Intersection
cylinder
Or
Cylinder Union
Cube
Or
Cylinder
Intersection
Cube
How to combine solids

button and select Combine Solids
from the Shape Modifiers category or Select the Combine
solids
2. Select the name of a solid from the solid1 drop-down list or click
button and select the solid (see page 234) in the
the Pick solid
graphics window.
3. Select the name of a solid from the solid2 drop-down list or click
the Pic (see page 234)k solid button and select the solid in the
graphics window.
4. Select the Operation. See Solid operations (see page 252) for
details.
5. Click Preview to preview the results. Remember that for the
Difference operation, the order of the solids matters. Solid2 is
subtracted from Solid1.
Overview of shell solid design feature

Shell creates a thin-walled solid from another solid. In the example
below, all the walls of the box are offset to create a rectangular void in
the center of the solid.
If you are using a hidden line view or shaded view, results of the shell
design feature will not be visible, but if you cut the solid, you can see the
void.
You can optionally select faces of the solid not to offset. The faces that
are offset create openings into the void.
Creating a Shell Solid Design Feature

select Shell from the Shape Modifiers category or click the
Shell
2. Select the name of a solid from the Offset this solid drop-down
list or click the Pick solid button and select the solid (see page
234) in the graphics window.
3. Enter the Offset distance. A negative distance will offset the

faces into the solid. A positive distance will offset the surfaces out
of the solid. Note that for solids with tight regions or fillets, you
cannot offset the faces more than the smallest fillet radius or the
smallest gap between faces.
4. If you want to exclude any faces, select the name of the face in the
Surface drop-down list and click the Add
button or click the
button and pick the faces in the graphics
Pick surface
window. See Overview of shell solid design feature (see page 254)
for further information.
5. Click Preview to preview the results.
Troubleshooting shell solid design features

If the Offset distance is too large, the offset surfaces will intersect
with itself and cause an error. Your only choice in this situation is
to use a smaller Offset distance.
Silhouette curves
Silhouette curves represent the widest part of a solid and serve as useful
parting curves for molds. These curves can also be used to split the faces
of a solid.
Overview of silhouette curves (see page 255)

Creating silhouette curves or splitting faces of a solid at silhouette curves
(see page 256)
Overview of Silhouette Curves

One of the tasks in creating a mold for a solid model is determining the
parting lines and splitting the part into at least two parts. Silhouette curves
represent the widest extent of a part when viewed from the +Z direction.
These curves often are helpful for determining parting lines.
The left-hand figure shows a solid model. Initially, the side of the part is a
single surface. As a first step in creating two mold halves, we would like
to split the side face at its widest part. The right-hand figure shows the
silhouette curve for the solid.
In the silhouette curves dialog, you can also use the calculated silhouette
curves to split the faces of the solid. The figures below show that the side
face is now split into two separate pieces along the silhouette curve.
See Select core/cavity for more information on splitting solids into two
halves.
This curve can then be used to create parting surfaces (see page 263).
Creating silhouette curves or splitting faces of a

solid at silhouette curves
select Silhouette curves from the Manufacturing category or
click the Silhouette Curves
2. Select the name of a solid from the Solid drop-down list or click
the Pick s (see page 234)olid button and select the solid in the
graphics window.
3. The silhouette curves are determined from the +Z direction of the
UCS. Select the appropriate UCS from the UCS drop-down list.
4. If you also want to extract hidden silhouettes (see page 257), check
the Include hidden silhouettes check-box.
5. If you want to join the resulting curves that touch into a single
piece, click Join Resulting Curves.
6. Silhouette curves can often be made up of many small pieces. To
reduce the number of these pieces, check Smooth/Reduce. The
number after the Smooth/Reduce label is the tolerance for data
smoothing. The smaller the number, the tighter the curve will
approximate the original silhouette. This option can smooth out
sharp corners in your curve, so use it with caution.
7. If you want to split the faces of the solid at silhouette curves, check
the Split Faces at Silhouettes check-box.
8. The Tolerance affects how tightly the silhouette curve
approximates the actual silhouette. Reduce this number if the
silhouette misses regions of your part.
Include hidden silhouettes

With this check-box unchecked, only silhouettes that are visible from the
top will be extracted. With it checked, all silhouettes, whether visible or
not, will be extracted. The figure on the left shows a tube without the
hidden silhouettes. Both hidden and visible silhouettes are shown on the
right.
Select core/cavity
Select core/cavity uses surface orientation to extract surfaces for the core
or cavity portion of a mold.
Overview of select core/cavity (see page 258)
Selecting core or cavity faces from a solid (see page 259)
Creating a solid form core or cavity faces of a solid (see page 260)
Overview of select core/cavity

Select core/cavity segregates the surfaces of a solid into one of three
different groups.
Top
All surfaces (or portions of surfaces if the Automatic Split option is
enabled) that are visible from the top.
Bottom
All surfaces (or portions of surfaces if the Automatic Split option is
enabled) that are visible from the top.
Other
All surfaces that do not fall into either the top or bottom category. These
surfaces are usually referred to as the core.
It is recommended that the core/cavity separation be performed using the

Automatic Split option. This option will split the faces of the solid at
either the silhouette of the solid, along a parting surface that you provide
as the Parting Surface. With the Parting Surface option set to
**Automatic, the silhouette curve (see page 255) is automatically
calculated and used to split the faces prior to the classification into the
top, bottom or other category.
You can also specify a parting surface for the Automatic splitting. This
surface must pass all the way through the solid as shown in this figure.
See also Select core/cavity.
Selecting core or cavity faces from a solid

button and select Select
Core/Cavity from the Manufacturing category or select the
Select Core/Cavity
graphics window.
4. If you want the faces that are on the top, click the Top radio
button.
5. If you want the faces that are on the bottom, click the Bottom
radio button.
6. If you want the core surfaces, the surfaces that are neither on the
top nor on the bottom, click the Other button.
7. If you want to include the vertical surfaces, click the Include
vertical surfaces radio button.
8. If there are surfaces you would like to explicitly exclude, click the
Pick surface
button and select the surfaces or select the name
of the surface in the drop-down list and click the Add
button.
9. If you would like to split the surfaces at the silhouette curve, check
Auto split and leave the Parting surface field set to
**Automatic.
10.If you would like to split the surfaces at a parting line check Auto
split and set the Parting surface field to the name of the parting
surface.
12.The appropriate surfaces are now selected so that you can easily
create 3D surface milling features.
Creating a solid form core or cavity faces of a solid

select Select Core/Cavity from the Manufacturing category or
click the Select Core/Cavity
graphics window.
4. If you want the faces that are on the top, click the Top radio
button.
5. If you want the faces that are on the bottom, click the Bottom
radio button.
6. If you want the core surfaces, the surfaces that are neither on the
top nor on the bottom, click the Other button.
7. If you want to include the vertical surfaces, click the Include

vertical surfaces radio button.
8. If there are surfaces you would like to explicitly exclude, click the
button and select the surfaces or select the name
Pick surface
of the surface in the drop-down list and click the Add
button.
9. If you would like to split the surfaces at the silhouette curve, check
Auto split and leave the Parting surface field set to **Automatic.
10.If you would like to split the surfaces at a parting line check Auto
split and set the Parting surface field to the name of the parting
surface.
12.The surfaces are selected and then stitched together into a solid.
Split face
The split face operator takes a curve or list of curves, projects them onto
the selected face and splits the face into multiple faces using the projected
curves as the boundaries.
To create a solid lofted design feature:
1. Select Split face from the Solid wizard or the Solid toolbar.
2. Select a face name in the Face drop down list or click the Pick
surface
button and select the face in the graphics window.
3. Select the curve name in the Curve drop down list and click the
button, or click the Pick Curve
Add
curves in the graphics window.
4. Repeat step 3 if you want to use more than one curve to split the
face.
5. Click the Preview button to confirm that the surface is correct.
Deleting faces
If you have a solid that you designed in FeatureCAM, you can easily
delete a design feature (see page 234). If you delete an extrude feature,
that cut a slot in a part, the slot is removed and the material is filled back
in that region. If you have a solid model that you imported or stitched, it
is difficult to remove a design feature since you do not have the design
features that were used to create the part, so you must use delete faces to
remove the feature and heal the model back together.
The example shown below was an imported surface model that was
stitched into a solid. The left-hand figure is the original solid and the
right-hand figure shows the same model with the faces that represent the
three holes deleted.
Most of the regions that you will want to remove are the equivalent of
2.5D features in your solid. This includes extruded holes, pockets or
bosses. It is important that you select all surfaces that represent the
feature in the solid. For example for a blind hole, the walls and bottom
must be removed. If you only select the walls to be removed, the bottom
would be left floating in space and cannot be healed back into the model.
To delete faces from your solid:
1. Select Delete face from the Solid wizard or the Solid toolbar.
2. If you want to create a new solid with the faces removed, click
Create New Solid and enter the name of the new solid.
3. If you want to modify an existing solid, click Modify Existing
Solid.
4. Select the faces by either:
a. Selecting the surface name and clicking the "+" button.
b. Picking the surfaces in the graphics window and clicking the
"+" button.
c. Clicking the Pick Surface button and picking the surfaces in
the graphics window.
5. If you want the gaps left by the deleted surfaces to be filled in,
check Heal Remaining Faces.
6. Click the Preview button.
7. If you get an error message, it is probably because you left out
some of the surfaces that need to be removed. Add the other
surfaces and try Preview again.
8. Click Finish.
Explode solid
This constructor copies the faces of a solid into surfaces.
To explode a solid:
1. Select Explode from the Solid wizard or the Solid toolbar.
graphics window.
3. If you only want to copy the selected faces, click the Selected
Faces only check-box.
Parting surface
This function, takes a curve and creates a parting surface.
The Parting surface constructor does not part the model. Use Cut solid
with parting surface or Select core/cavity for that functionality. The curve
can be a 2D or 3D curve. The curve can be obtained any many ways
including Silhouette Curves (see page 255) , Surface Edges, Curve
projected onto a surface The Z axis of the UCS indicates the parting
direction of the mold. For 3D curves the curve is divided at any corners.
To create a parting surface:
1. Select Parting surface from the Solid wizard or the Solid
toolbar.
2. Specify the name of the surface, if desired.

3. Specify the Land Width. This is the width of your parting surface.
4. Specify the UCS you would like to use. The Z axis of this UCS
will be used as the parting direction.
5. Select the Parting curve by name and click the Add
button
button to select the curve in the graphics
or use the Pick curve
window.
6. If your curve is 3D, it will be broken, subdivided at sharp corners,
into a number of curves. Each of these names will be listed under
your curve name.
7. Click the Preview button to see your surface.
8. If a section of your curve seems to be oriented incorrectly follow
this procedure (see page 264).
Changing the direction of a segment of

a parting surface
1. Click the names in the curve list until the desired segment is
highlighted.
2. The direction that this segment is extruded will be displayed in the
Extrude direction field.
3. To change this direction, enter a new vector in the form - (X,Y,Z).
You must enter the parenthesis and the commas. For example
(1,0,0) is the X direction.
4. Click the Set button.
5. Click the Preview button to see the results.
Draft a Face
Many of the solid design features allow you to include a draft angle, but
they require that all faces be drafted the same amount. Draft a face
allows you to set a draft angle on one or more faces individually.
To draft a face properly, the fixed reference surface determines how

the face is rotated. When a face is drafted, the surface must be rotated
around a particular axis. This axis is determined by the intersection of the
face and the fixed reference surface. By default a face is rotated around
its intersection with the XY plane of the current UCS. This means that for
a face that intersects the XY plane, a positive angle keeps the top of the
face fixed and rotates the bottom of the face in, as shown below. The
same result is calculated if a surface connected to the top edge of the face
is selected as the fixed reference face.
If the surface connected to the bottom edge of the face is selected as the
fixed reference, the bottom of the face stays fixed and the top edge of the
face is moved out.
To draft a face:
1. Select Draft a face from the Solid wizard or the Solid toolbar.
2. Enter the draft angle in degrees.
3. Select the faces to draft by:
a. Selecting the surface name and clicking the Add
button.
b. Picking the surfaces in the graphics window and clicking the

button.
Add
c. Clicking the Pick Surface button and picking the surfaces in
the graphics window.
4. To keep the top of the face fixed, select the Fixed Reference
Surface by clicking the Pick Surface button and picking a
surface connected to the top of the face.
5. To keep the bottom of the face fixed, select the Fixed Reference
Surface by clicking the Pick Surface button and picking a
surface connected to the bottom of the face.
6. Click the Preview button to review the results.

3D surface
manufacturing (3D)
Overview of 3D surface manufacturing

To mill 3D surfaces you must create a surface milling feature. A surface
milling feature allows you to generate toolpaths for multiple surfaces
using a number of 3D toolpath techniques.
How to create a surface milling feature (see page 269)
Dimensions tab (see page 276)
Tabs of 3D properties dialog box and tree view for surface milling
features (see page 275)
See also 3D Milling methods, Recommended Machining Strategies
Roughing
Semi-finishing and finishing strategies
Finishing models with few surfaces
Finishing walls of pocket or boss shapes with a 3D floor
3D Milling methods
You have a number of options for milling a 3D feature. The object is to
select a method that is efficient for your feature's shape and that also
gives an acceptable finish.
3D surface manufacturing (3D) 267
Projection milling methods

Z level rough (see page 339)
Z level finishing (see page 350)
Isoline milling (see page 358)
Pencil milling (see page 365)
Remachining (see page 375)
Recommended Machining Strategies
Roughing
Overview of surface manufacturing

To mill 3D surfaces you must create a surface milling feature from the
surfaces. A 3D surface milling feature is made up of one or more 3D
milling operations. For example a single feature may both rough and
finish the part surfaces. The New Feature (see page 269) wizard helps
you create a feature and its initial operation. Once the initial feature is
created, you can edit the feature to further control how it is manufactured,
or to add additional operations (see page 269).
3D Milling methods
268 3D surface manufacturing (3D)
Roughing
How to create a surface milling feature

To create a surface milling feature:
1. Click the New Feature button, select Surface milling and click
Next. (If you graphically select your surfaces first, they are
automatically classified as part surfaces.)
2. The Feature wizard then steps you through the process of creating
your feature by displaying the New feature new strategy (see page
277) page.
3. The middle button in the wizard is a menu with the options Finish
and Finish and edit properties.
4. If you want to create a feature with only one operation, click
Finish.
5. If you want to add other operations, click Finish and edit
properties. The Feature properties dialog comes up. See Tree
view for surface milling features (see page 275) for information
about this dialog.
See also How to add an operation to an existing surface milling feature
(see page 269).
How to add an operation to an existing

surface milling feature
1. Select the Surface Milling Feature in the graphics window and
click the Properties
button. The Surface Milling
Properties dialog comes up.
2. Click the Process tab.
3. Click the Add New Operation
button.
4. Follow the steps of the wizard.
Types of surface milling operations

Parallel (see page 323) - creates a raster
pattern within a boundary and projects it
onto the model.
Z level finish (see page 350) - creates a

toolpath by slicing the model at specific Z
heights.
2D Spiral (see page 328) - creates a

toolpath from offsets of a pattern and
projecting it onto the model.

toolpath by offsetting the model and block.
This technique is best suited to machining
areas which require a constant stepover and
works well on near vertical surfaces.
Isoline milling (see page 358) uses the
isoline curves of a surface to mill the
surface. These curves can be in the row
direction or column direction.
Radial (see page 339) - creates a radial

onto the model.
Flowline (see page 361) - drive surface

machining. Creates a pattern from the
flowline surface and projects it onto the
model.
Between 2 curves (see page 364) -limits

machining to be between two curves.
Direction of toolpath can be set to be along
or across.
Pencil (see page 365) - creates a single

trace corner toolpath.
Z level roughing (see page 339) - Clears an

area with contours generated by repeatedly
offsetting the initial slice until no further
offset is possible.
Plunge roughing (see page 368) - A

specialized cutting tool is used to remove
large amounts of material through a series
of vertical plunging movements.
Corner (see page 373) remachining creates a multiple trace corner toolpath with
Across or Along options.
Horizontal + Vertical (see page 367)

remachining - This strategy combines two
different toolpath operations, one for
finishing shallow portions of the part and a
Z-level for finishing the steep regions.
5-Axis Trim (see page 387) - creates a
toolpath along the edges of a surface set
either offset or inset.
Swarf (see page 380) - creates toolpaths

which cut with the side of the tool. This
technique only works on developable
surfaces as the tool needs to be in contact
with the surface for the whole cutting
depth.
Four-axis (see page 369) Rotary - creates a
toolpath by rotating the model around the
index axis, with linear motion provided by
the non-index axis coordinate pairs.
Tool selection for 3D milling features

FeatureMILL3D selects a default tool for all finish operations. On the
tool selection page, there is a check-box to use the part's curvature to
select the default tool. Selecting this analyses all included surfaces and
find the smallest concave radius of curvature. A ball-end tool closest to
that radius is selected. Note that tool selection looks at the side of the
surfaces you are machining. If you flip to the other side, a different tool
might be selected.
Properties dialog for 3D milling
The 3D Surface Milling Properties dialog uses a tree view. The tabs
displayed in the dialog change depending on which level in the tree view
you select.
- Feature
- Operation information
- Operation
The top level of the tree view is the Feature level. The tabs available at
this level are:
Dimensions (see page 276) - specify the part and check surfaces
Location - reposition the feature reletive to the surface
Process (see page 277) - create, delete and reorder the operations of the
feature
Machining Side (see page 279) - control which side of surfaces to
machine
Misc (see page 281) - a variety of feature-level attributes
The next level is the Operation information level. The tabs available at
this level are:
Strategy (see page 283) - rough/finish classification, edge protection
and re-machining
Edges - choose how the tool behaves at the limits of the part surfaces as
seen from the top view.
The Edges tab is not available for Z-level roughing or Swarf
finishing operations.
Stock - choose the clipping curves for the material to be removed
Slopes (see page 304) - slope angle limits for restricting toolpaths
The Slopes tab is not available for Z-level roughing, Plunge
roughing, Isoline finishing, Flowline finishing, Horizontal +
Vertical and Swarf strategies.
Surface Control (see page 307) - exclude feature surfaces for specific
operations
The third level is the Operation level. The tabs available are:
Tools (see page 309) - view selected tool or change to a different one
F/S (see page 309) - view automatically calculated feed or speed or
change feed or speeds
Milling (see page 314) - operation level attributes
Leads (see page 310) - control leads and ramps
Tree view for surface milling features

The tabs displayed in the dialog change depending on what level in the
tree view you have selected.
- Feature
- Operation Information
- Operation
The top level of the tree view is the Feature level. The tabs available at
this level are:
Dimensions (see page 276) - specify the part and check surfaces
Process (see page 277) - create, delete and reorder the operations of the
feature
Machining Side (see page 279) - control which side of surfaces to
machine
Misc. (see page 281) - a variety of feature-level attributes
The next level is the Operation Info. level. The tabs available at this level
are:
Strategy (see page 283) - rough/finish classification, edge protection and
re-machining
Boundaries - boundary curves (formerly known as stock curves) for all
operations
Slopes (see page 304) - slope angle limits for restricting toolpaths
Surface Control (see page 307) - exclude feature surfaces for specific
operations
The third level is the Operation level. The tabs available are:
Tools (see page 309) - view selected tool or change to a different one
F/S (see page 309) - view automatically calculated feed or speed or
change feed or speeds
Milling (see page 314) - operation level attributes
Leads (see page 310) - control leads and ramps
Dimensions tab (3D)

The Dimensions tab has two buttons that open dialogs where you select
surfaces to manufacture, and surfaces to use as protected areas where the
tool must not go.
Part surfaces (see page 276)
Check surfaces (see page 277)
See also Surface manufacturing (see page 267).
Part surfaces
Use this dialog to pick surfaces you want to include in your 3D part
feature.
1. Select the surface(s) in the list box or click Pick and select a
surface with the mouse. To pick additional surfaces, click Pick
again before selecting each additional surface.
2. Click OK to return to the 3D Feature Properties dialog.
3. Click OK and Apply to return to the 3D Feature Properties
dialog and apply your surface selection to the feature.
You need to consider the following when specifying part surfaces:
You cannot manufacture undercut surfaces using 3-axis machining,
so it is a good idea to use only surfaces in the feature that can be
cut from the setup.
Some surfaces may be cut from multiple setups to manufacture all
parts of the surface. In such situations, a Stock Curve is helpful
in limiting the machining area to just those spots that need it.
Check surfaces
Use this dialog to select surfaces you want to use to limit machining in a
3D feature. Check surfaces are surfaces that denote area that will not be
milled away. You should select surfaces that are more horizontal than
vertical. The check surface acts as a boundary up to which milling occurs.
With vertical check surfaces the milling will stop there, but may resume
on the other side of the check surface if the surface to be milled extends
beyond the check surface.
1. Select the surface(s) in the list box or click Pick and select a
surface with the mouse. To pick additional surfaces, click Pick
again before selecting each additional surface.
2. Click OK to return to the 3D Feature Properties dialog.
3. Click OK and Apply to return to the 3D Feature Properties
dialog and apply your surface selection to the feature.
Process tab
The Process tab shows the operations that are included for milling.
These feature are selected in the operations list. You can turn off
operations by unchecking them. This allows you to customize operations
and then turn them off to reduce screen clutter when working on
subsequent operations.
The buttons on the right have these functions:
New
operation (see
page 277)
Move
operation up (on
page 279)
Delete (see
"Delete
operation" on
page 279)
Move operation
down (on page
279)
See also 3D Milling methods and surface manufacturing (see page 267).
Cutting strategy for new features
This page allows you to select the cutting strategy you want to use for
your feature. You can only specify one strategy in the New Feature
wizard. The strategy choices are grouped by finishing, roughing and
specialized strategies. The strategy choices are:
Finishing Strategies
Parallel (see page 323) - toolpaths that are parallel to the X or Y
axes.
Z level finish (see page 350) - toolpaths that are parallel to the XY
plane.
Isoline milling (see page 358) - toolpaths that follow the rows or
columns of individual surfaces.
2D spiral (see page 328) - Toolpaths that move in a spiral toward
or away from the center of the part. Stepover is constant from the
top view.
or away from the center of the part. Stepover is constant in 3D.
Radial milling (see page 339) - toolpaths that move out radially
from the center of the feature.
Flowline milling (see page 361) - toolpaths that follow the rows or
columns of a flowline surface which are then projected onto the
part.
Between 2 curves (see page 364) - toolpaths that are created
between two specified curves.
Roughing Strategies
Z level rough (see page 339) - toolpaths that are parallel to the XY
plane.
Plunge roughing (see page 368) - toolpaths which remove large
amounts of material from a component through a series of vertical
plunging movements.
axes.
Specialized Strategies
Horizontal + Vertical (see page 367) - machine steep and shallow
regions using different techniques.
Corner Remachining (see page 373) - A remachining technique
used to clean up corners that occur between non-tangential
surfaces.
Pencil milling (see page 365) - a single clean-up pass for corners.
4-Axis (see page 369) Rotary - used in turnmill to machine round
surfaces with an X tool.
Swarf (see page 380) - toolpaths are cut using the side of the tool.
The tool is in constant contact with the surface.
5-Axis Trim (see page 387) - toolpaths that are along the edges of
surfaces. There is the option to cut on the inside or outside edge of
the surface.
For more details on these options, see operations overview (see page
270).
1. Select the desired strategy.
2. Click the Next button.
3. If you are creating a new feature, the New feature part
surfaces dialog is displayed.
4. If you are adding a new operation to an existing feature, the New
feature strategy (see page 283) dialog is displayed.
Delete operation
Delete operation discards an operation from the feature. You can disable
an operation instead by unchecking the operation. The check box, when
set, includes that operation in the feature.
Move operation up
Move operation up changes the order of operations in the milling feature
by moving the selected operation up one place in the feature.
Move operation down
Move operation down changes the order of operations in the feature by
moving the selected operation down one place in the feature.
Machining Side tab (3D)

FeatureCAM attempts to cut on the appropriate side (see page 280, see
page 281) of a surface based on the surface normals, but occasionally you
will need to explicitly orient a surface. This will mainly be for the isoline
(see page 358), Z level rough (see page 339) or Z level finish (see page
350) techniques.
If you click a surface name, an arrow is shown that indicates which side
of the surface will be cut. If you want to reverse the side:
1. Select the name of the surface in the list. If you do not know the
button and select
name of the surface, click the Pick surface
the surface in the graphics window. The name of the surface is then
highlighted in the list.
2. Click the Switch Machining Side
button.
If you want to return the machining side of all surfaces to the

FeatureCAM defaults, click the Reset Normals button.
Automatic flipping
Vertical surfaces are usually the only surfaces that will need to be
manually oriented. FeatureCAM tries to automatically flip surface
normals so that they are consistent. For this automatic flipping to work on
vertical surfaces, there must be some non-vertical surfaces nearby. For
parts that have only vertical surfaces, FeatureCAM does not
automatically flip any normals. That means that you will have to ensure
that all surface normals point either in or out by manually flipping the
normals to ensure a consistent cutting side.
For open surfaces with a floor, the normals will be flipped to create a
pocket shape and the insides will be milled. For open surfaces with a top,
they will be treated as a boss shape and the outsides of the surfaces will
be milled.
Misc tab
Each manufacturing attribute on the Misc tab is described in detail
below.
Plunge clearance (see page 281)
Base Priority (see page 281)
Feed override % (see page 282)
Maximum spindle RPM (see page 282)
Min corner radius and deburr radius
Plunge feed override % (see page 282)
Spindle RPM override % (see page 282)
Spline tolerance (see page 282)
Tool % of arc radius (see page 282)
Z rapid plane (see page 283)
See also Surface manufacturing (see page 267)
Plunge clearance
Plunge clearance is the distance above a feature at which the tool starts to
feed. In the case of deep hole drilling, the drill will retract to this distance
between pecks. Compare with Z Rapid Plane (see page 283).
Priority attributes (3D)
If you want to ensure that an individual feature is cut before anything
else, you can set its Priority attribute in the Misc. tab. All features have
a Priority manufacturing attribute. By default, the value is 10. To make
sure that a feature is manufactured first, set its priority to a lower value.
To make a feature last, set its priority to a higher value. For example, if
you set the Priority of a pocket to 8, its roughing pass is the first
operation performed, its finish pass is second, and the rest of the
operations are ordered according to the scheme described above.
While you can specify the exact order of every feature by priority,
you shouldn't do so casually because you lose the automatic
optimization sequences built into FeatureMILL. It's harder to
maintain or change the part too.
Feed override %
Feed override % is a scaling factor for the feed rates generated by the
system. A value less than 100 reduces the calculated feed rates. A value
more than 100 increases the rates.
Max. spindle RPM
Max. spindle RPM is the maximum spindle speed (in RPM) that
FeatureMILL will calculate.
Plunge feed override %
Plunge feed override % gives the scaling value for the feed rate used
during the initial plunge into the material for milling operations.
Spindle RPM override % (3D)
Spindle RPM override % scales the system-generated speed rates for a
particular operation, enter the percentage change as the Spindle RPM
override % attribute. A value of 100 leaves the speed rate unchanged. A
value of less than 100 will reduce the speed rate, and a value of greater
than 100 increases the speed.
Spline tolerance
Spline tolerance approximates the profile with arcs and lines if a
profile is defined as a spline. The smaller the value of the parameter, the
smoother the profile.
Tool % of arc radius
Tool % of arc radius controls the size of the tool that FeatureMILL
automatically selects.
In earlier program versions this attribute was called Default tool
%.
If Tool % of arc radius is set to 100 then a tool equal to the smallest
corner radius is selected for a feature such as a pocket. With Tool % of
arc radius set to 100 the tool dwells in the corners as it changes
direction. This can sometimes nick the part. To avoid this problem, set
Tool % of arc radius to a slightly smaller number, such as 98.
Z rapid plane
Z rapid plane is the minimum safe distance in Z above your part. This
attribute can be set as a default, or it can be set on a feature.
Before performing a rapid move away from a feature, the tool is retracted
to the Z rapid plane setting for that feature. The rapid move to the next
feature will change in Z height, that is, will change Z coordinates, if the
next feature has a different Z rapid plane setting. So that when it arrives at
the next feature it will be at the Z rapid plane for that next feature.
This value is relative to the top of your stock in the current user
coordinate system. Compare with Plunge clearance (see page 281).
Strategy tab
This page allows you to fine tune your cutting strategy.
1. For Z level, you may click Rough for a roughing pass, or Finish
for a finishing pass.
2. The following options are available for certain types of operations
a. For 2D spiral milling, select Spiral in to spiral from the edge in
toward the center. Select Spiral out to spiral away from the
center. See Horizontal + vertical strategy (see page 367) if using
that specialized technique.
b. For 3D spiral milling, see step 3 below.
c. For parallel milling, select X parallel to cut parallel to the X
axis, Y parallel to cut parallel to the Y axis. Also specify an
Angle (measured in degrees in the counter clock-wise direction)
to rotate the toolpaths off of the principal axis. You may also
choose to add a perpendicular, remachining pass by selecting
Add Perp. Remach. Pass. As an example, this setting will
add a Y parallel pass to a X parallel operation. To use this
option you also must specify the Steep Slope Angle. The
perpendicular pass will only be applied to regions that exceed
this slope limit. See H (see page 367)orizontal + vertical
strategy if using that specialized technique.
d. For plunge roughing, select X parallel to arrange the drilling

operations parallel to the X axis, Y parallel to arrange parallel
to the Y axis. Also specify an Angle (measured in degrees in
the counter clock-wise direction) to rotate the holes off of the
principal axis. Also decide on whether you want to use a
honeycomb pattern (see page 285).
e. For Z level roughing, specify the style of toolpath: offsets or
zig-zag (X-parallel like). If zig-zag is chosen, this will rough the
part raster-style with an optional profile around each Z-slice (if
desired, check the Profile Contour check-box). Classify the
slices (see page 285) and set Multiple roughing diameters to
generate Z-level semi finish passes.
f. For Z level finishing, use the interleave option (see page 351) if
you want to finish the entire part with a minimum amount of
tool retraction.
g. For corner remachining, choose Along (which will create
toolpaths parallel to the sharp corner edges), Across (which
will create toolpaths across the corner edges), or a combination
of the two (Across in steep areas and Along in shallow areas).
Detection Limit - only corners below the angle specified will be
found.
h. For four-axis rotary, you may choose the type of pattern to cut:
Circle, Line, or Spiral. For more information see Overview
(see page 369).
i. For between 2 curves, select the Start Curve and End Curve
to machine between. Select Along Curves to create toolpaths
parallel to the curves radiating out from the start curve towards
the end curve. Select Across Curves to create toolpaths that
begin at the start curve and move across to the end curve. Tool
Center limits the toolpath based on the center of the tool.
Contact Point limits the toolpath based on last point of
contact between the tool and the surface.
j. For 5-Axis trim, select Inside Edge to create toolpaths on the
inside edge of the surface. Select Outside Edge to create
toolpaths on the outside edge of the surface.
k. Isoline, flowline, radial, 3D spiral, pencil milling and swarf
have no options.
3. If you wish to use this operation to clean up areas that were missed
by previous toolpaths, check the Remachining (see page 378)
check-box.
4. Click Next to display the Stock (see page 288) tab.

Honeycomb pattern (3D)
Plunge roughing is performed in either a straight rectangular pattern, as
shown below,
or a honeycomb pattern in which each row is offset horizontally by half

the rough pass stepover amount.
The honeycomb pattern is usually preferable. The Honeycomb Pattern

Strategy attribute controls the pattern type.
Z level slice classification
You can tell FeatureCAM to rough your part as a 3D boss, or as a 3D
pocket. If you select 3D Pocket, the tool will plunge or ramp onto the part
and will be cut from the inside of the part out toward the boundary of the
part. A 3D boss will typically plunge off of the part and cut from the
outside toward the center.
Even if the surfaces of your part create a boss shape (meaning it protrudes
rather than being a cavity), you can still select 3D Pocket. The two figures
shown below show the slices of a part being cut as a boss, in the first
figure, and as a pocket in the second figure. Notice that the slides of the
boss go all the way around the part at each slice, but the pocket example
has slices that just cut a region of the part.
Edges tab (3D)

Edges for surface milling
This page gives you options to set how the toolpaths are generated near
surface edges.
Cut to bottom: Roll over top edge and cut to bottom of
stock/part limits
Does not set any boundary. In this case, FeatureCAM will only use the
boundary specified by the curve options in the Stock tab (see page 288).
Cut top edge: Just roll over the top edge
Sets a pocket-like curve boundary to the silhouette of the part offset by a
tool radius. The tool will roll over the edges by a tool radius as shown
below. In PowerMILL this is known as a silhouette boundary. Edge
boundary all is using a silhouette boundary of the part, but it uses the top
(highest) Z values where the silhouettes are at a vertical surface.
Don't roll over the edge at all

Sets a pocket-like curve boundary to the silhouette of the part. The tool
will contact the surface boundary as shown in the Z-level and parallel
toolpaths below. In PowerMILL this is known as a contact point
boundary. This will prevent any cutting of sharp corners at the external
edges of the part. If the part has a vertical surface at the outside of the part
AND has a sharp corner at the top of the vertical surface, it will prevent
cutting of the vertical surface since it is coincident with the sharp corner
at the top.
Advanced options on the part boundary can be set by clicking the
Advanced (see page 408) button.
If you have a vertical surface and you want to cut to the bottom, check the
Cut to bottom of vertical walls check-box.
Cut selected surfaces: Only cut selected part surfaces

FeatureCAM will only machine the selected surfaces and will not cut any
of the neighboring or unselected surfaces. If there are no neighboring
surfaces, the tool will roll over the edges by a tool radius.
Cut to bottom of vertical walls check box.
Stock tab
This page controls the boundaries of the toolpaths.
Use part surface dimensions - creates toolpaths on the surfaces
regardless of the location of the stock. If you are using a spiral toolpath,
this option automatically calculates the silhouette curve of the feature and
uses this curve as the shape of the spiral. This generally has the best shape
for spiral toolpaths.
Use stock dimensions restricts the toolpaths to the portions of the

surface feature that are within the stock. If you are using a spiral toolpath,
this option uses the outline of the stock as the shape of the spiral. You can
set what percentage of the tool approaches or passes beyond the stock
boundary in the Overcut % (see page 332) option.
Use solid model (Z-level roughing only) - restricts toolpaths to be
within the solid model that you choose. Optionally add an Allowance.
Select curves for boundaries uses curve(s) to restrict the toolpath
boundaries or to affect the shape of a spiral toolpath. Additional options
are displayed for 2D spiral toolpaths (see page 329), 3D spiral toolpaths
(see page 335) or all other techniques (see page 333).
The Show Combined Boundary button will display the effective
boundary for the operation. This is a combination of the edge boundary,
the stock curve boundary, and the slope limit. In some cases, this may
take some time to compute, but it will be computed and stored with the
operation, that is, only computed once.
5-Axis tab
For a turn/mill document with a B-axis enabled post (.cnc file) or a 5-axis
positioned document, some surface milling operations will have a 5-Axis
tab. The set of operations is restricted to parallel, z-level finish, isoline,
3D spiral, flowline finish, 5-axis trim, and swarf.
This tab lets you set three different things: Tool Axis, Tilt Axis for
Gouge Avoidance, and Tool Axis Limits. The first two sections of
the dialog can be confusing because they both control the tilt of the tool
axis. The first section, Tool Axis, can be thought of as a first level of
tool tilting, controlled in a manual way. And then you can add extra
tilting in order to avoid gouges with the tool holder by using Tilt Axis
for Gouge Avoidance.
You can use these two sections of the dialog box independently, one
without the other, meaning that you can use the second section
without having specified any tilting in the first section.
The Tool Axis will let you define the tool orientation. The default value
is Vertical which is used for standard 3-axis machining. However, it can
also be a continuously changing orientation for so-called 5-axis
simultaneous machining.
Vertical (Z) - The tool remains aligned with the Z-axis of the
active setup. This is the default value and is the value used for
standard 3-axis machining.
Use Lead and Lean - The tool is at a fixed angle relative to the
direction of the toolpath.
Lead Angle - the tool angle in the feed rate direction.
Lean Angle - the tool angle perpendicular to the feed rate
direction.
For more information, see Lead/Lean (see page 291).
Other Toward Point - The tool tip always tries to point towards the
fixed point. The angle of the tool is constantly changing. For
more information see Continuously Changing Orientation (see
page 293).
From Point - The tool tip always tries to point away from the
fixed point. The angle of the tool is constantly changing. For
page 293).
Towards Line - The tool tip always tries to point towards the
fixed line. The angle of the tool is constantly changing. For
page 293).
From Line - The tool tip always tries to point away from the
fixed line. The angle of the tool is constantly changing. For
page 293).
Automatic - The swarf operation will have an automatic option
(instead of the above Other option). The automatic option will tilt
the tool to keep the side of the tool in contact with the surface(s)
being cut.
The Retract to Cylinder (see page 303) check-box - defines the safe
area of the operation to be an infinitely long cylinder.
Tool Axis Limits (see page 298) - enable you to define limits on the
direction of the tool axis whilst cutting a multi-axis toolpath.
Tool Axis Tilt For Gouge Avoidance (see page 295) - Allows you to
tilt the tool in order to avoid gouging the model with the holder in a user
defined way.
Lead/Lean
The tool is at a fixed angle relative to the direction of the toolpath. You
can specify two different angles - Lead and Lean. If you specify a Lead
and a Lean angle the Lead Angle is applied first in the direction of the
move, and then the Lean Angle from this rotated position towards a
vector perpendicular to the move.
Lead Angle - defines a rotation of the tool axis in the direction of travel.
It is measured from the perpendicular to the direction of travel; 0 is
vertical. Typically this is used to avoid cutting at the center of a ball
nosed tool on flattish areas. The diagram below has a lead of 30 degrees.
Lean Angle - defines a rotation of the tool axis at right angles to the
direction of travel; 0 is vertical. The diagram below has a lean of 30
degrees. Typically this is used to avoid collisions (such as a step). Or this
can be used when machining up to a step to allow you to use a smaller
tool.
Continuously Changing Tool Axis

The top of the tool always tries to point towards/from a fixed point/line.
The angle of the tool is constantly changing.
Towards Point - The head of the machine tool will move significantly
whilst the tip of the tool remains relatively still. This option orientates the
tip of the tool towards a point.
From Point - The tip of the tool will move significantly whilst the head
of the machine tool remains relatively still. This option orientates the tip
of the tool away from a point.
Towards Line - The head of the machine tool will move significantly
whilst the tip of the tool remains relatively still. This option orientates the
tip of the tool towards a line.
From Line - The tip of the tool will move significantly whilst the head
of the machine tool remains relatively still. This option orientates the tip
of the tool away from a line.
In general, the tool axis, when viewed as an infinite line, will not pass
through the given entity (i.e., will not pass through the point when using
X-parallel, towards point). This is because the tool paths are laid out on
what we call the frame and the tool axes are computed in the frame. For
example, for an X-parallel with a .05" stepover, lines (toolpaths) are
computed on the front (or top) of the stock spaced at .05". The tool axes
are calculated for each of these lines/toolpath points and then the
projection (to the part surfaces) maintains that tool axis vector all the way
to the point of contact that will become the toolpath point. Some options
such as tool axis limits and automatic collision avoidance alter the final
tool axis as well.
Tool Axis Tilt
This area of the dialog automatically tilts the tool axis, in a user defined
way, to avoid collisions between the shank/holder of the tool assembly
and the model.
Tilt Axis for Gouge Avoidance - specifies how the tool will move to
avoid any collisions.
The default of No tilting - means that the holder and shank are not gouge
checked.
Lean - if a collision is detected, the tool axis will move from the
original axis in the Lean direction until the collision is avoided.
Lead - if a collision is detected, the tool axis will move from the
original axis in the Lead direction until the collision is avoided.
To Point - if a collision is detected, the tool axis will move from
the original axis, in the direction of the Point, until the collision is
avoided, to become a Toward Point Tool Axis.
From Point - if a collision is detected, the tool axis will move
from the original axis, in the direction of the Point, until the
collision is avoided, to become a From Point Tool Axis.
To Line - if a collision is detected, the tool axis will move from
the original axis, in the direction of the Line, until the collision is
avoided, to become a Toward Line Tool Axis.
From Line - if a collision is detected, the tool axis will move from
the original axis, in the direction of the Line, until the collision is
avoided, to become a From Line Tool Axis.
Towards the Surface Normal - if a collision is detected, the
tool axis will move from the original axis and move towards the
Surface Normal direction until the collision is avoided.
This simple example uses a X-parallel toolpath over a step to show the
effect of Collision Avoidance. If you create a simple parallel toolpath
over this, you will get collisions of the shank as it climbs or descends the
step:
One way around this is to increase the length of the tool. Another way is
to change the toolpath strategy. The third way is to use Collision
Avoidance. In this case, the initial Tool Axis is Vertical. Select a Tilt
Axis for Gouge Avoidance of Lead.
Create a new parallel toolpath. You can see that the toolpath now tilts on
the steep portions to avoid the tool holder colliding:
However, the toolpath is still 3-axis on the flat portions where the tool
holder doesn't collide:
In summary, the tool tries to respect the original Tool Axis Definition
for as much of the toolpath as possible. Only when this isn't possible does
the tool axis change, in the direction specified in the Tool Tilt Axis
field, until the tool assembly no longer collides.
Linearization
5-Axis machine tools do not guarantee (and frequently don't use) a
straight line move from one point to another in multi-axis. This means
that you cannot necessarily guess where the tool might move to between
two points. The machine tool will move all of its axes at once - it doesn't
just move in X and then rotate the head. It will do both together so that
both movements are carried out at the same time. This is not a big issue
if the points are close together. However, if the points are far apart, the
machine tool (which may be rotating the tool tip between two points) can
cause gouges when the part is cut on the actual machine.
Consider moving between two points. Although the move looks like a
straight line, it won't necessarily be a line on the machine tool.
Arc swept by machine tool.

FeatureCAM does attempt to linearize moves by dividing the curves into
smaller straight line moves, based on the Wrapping Tolerance (see page
151) found under Manufacturing Attributes (milling/misc.).
A very small wrapping tolerance will tend to make 3D and machine

simulation rather slow. For this reason, the simulation has its own
wrapping tolerance which may be set to a larger number than that of
manufacturing. That is, the simulation will use its wrapping tolerance
(which can be set under Options/Simulation/2D3D Shaded) for
linearization, and the posting process will use the wrapping tolerance
found under Manufacturing Attributes.
Tool Axis Limits
This area of the dialog controls angular limitations of the machine
toolpath which therefore limits the angle at which a tool can be positioned
while cutting a multi-axis toolpath.
When the angular limits are met or exceeded, there are two options:
Remove Toolpaths - removes the toolpath outside the angular
limit.
Leave Tool At Limit - keeps the tool axis at the machine limit on
reaching an angular limit.
Azimuth Angle - defines the angular limits of the machine tool in the
XY plane; 0 is along the X axis; 90 is along the Y axis.
Elevation Angle - defines the angular limits of the machine tool above
the XY plane; 0 is in the XY Plane; 90 is along the Z axis.
Project to XY Plane - this is the same as setting the elevation angle to
zero. Since the elevation angle is fixed, this constitutes 4-axis machining.
It is not always immediately obvious how to translate the machine tool
angular limits with FeatureCAM's Azimuth and Elevation angles. This
looks at a couple of machine configurations with different angular limits.
The configuration of the rotary axes varies widely. However, the
differences between many of these are relatively minor, and there are
really only three fundamentally different machine configurations:
Table - Table
Both rotary axes move the table.
With table - table machine tools, typical angular limits are:

X 30
Y 360
The machine tool Y limits are equivalent to the Azimuth Angle or the
angular limits in the XY plane. The Y limit of 360 translates to
Azimuth Angle limits of 0 to 360.
The machine tool X limits are equivalent to the angle above the XY
plane. However, they are not the same angle. This is best described using
the diagram below. The machine tool measures the angular range relative
to the Z axis and FeatureCAM measures it relative to the XY plane. So,
the angle required for the limit is the complementary angle to the one
given for the machine tool.
If you select a Mode of Remove Toolpath this will machine a sphere

to the following extent:
Head - Head
Both rotary axes move the head.
With head - head machine tools, typical angular limits are:

X 60
Z 360
The machine tool Z limits are equivalent to the Azimuth Angle or the
angular limits in the XY plane. The Z limit of 360 translates to
Azimuth Angle limits of 0 to 360 .
The machine tool X limits are equivalent to the angle above the XY
plane. The machine tool measures the angular range relative to the Z axis
and FeatureCAM measures it relative to the XY plane. So, the angle
required for the limit is the complementary angle to the one given for the
machine tool. This is described in more detail in Table - Table. The X
limit of 60 translates to Elevation Angle limits of 30 to 90 .
If you select a Mode of Remove Toolpath this will machine a sphere

to the following extent:
Alternative typical Head - Head machine tool angular limits are:

X -50 to +60
Z 360
This translates to Azimuth Angle limits of 0 to 360 and to Elevation
Angle limits of 30 to 90 . In this case, although the machine tool limits
appear to be different to those in the first Head - Head example, the
FeatureCAM angular limits are in fact the same. This happens because
rotating the head 180 about Z then gives you the complete range.
Head - Table
One rotary axis moves the head; the other moves the table. This is the
case for lathes with a B-axis head.
Azimuth Angle - defines the angular limits of the machine tool in the
XY plane. 0 is along the X axis; 90 is along the Y axis. Can range from 0
to 360.
Elevation Angle - defines the angular limits of the machine tool above
the XY plane. 0 is in the XY Plane; 90 is along the Z axis, -90 is along
the -Z axis. Can range from -90 to 90.
That is, the elevation angle limits the angle in the XZ plane. Angle 0 is
the X tool, 90 is the Z tool, so a minimum elevation 0 to max elevation 90
cuts the complete right half of a sphere (flowline) given no
min_azimuth/max_azimuth. (Think of it as latitudes and longitudes that
are reachable. The longitude (circles parallel to XZ plane for millturn) is
controlled by elevation angles).
The latitude (think of a tool axis in the XY plane for millturn) is
controlled by azimuth angles. I.e. -90 to 90 would cut the entire top half
of a sphere if given no elevation limits... (X axis is 0 azimuth angle).
However, the allowable range is 0 to 360, so setting minimum to 270 and
maximum to 90 is acceptable (the limit is set going clockwise around
positive Z axis from minimum to maximum).
The example below shows you how to transpose the angular limits on the
machine tool to the Azimuth and Elevation limits on the Limits tab on
the Tool Axis Direction dialog. These examples all use a sphere with
an Isoline or Flowline Projection toolpath. If no tool axis limits are
imposed, you will see the following toolpath:
Retract to cylinder
On the 5-axis tab, there is a Retract to Cylinder check box. This will
affect the approaches, plunges, and retracts of a 5-axis simultaneous
operation. With Retract to Cylinder selected, the safe area of the
operation will be defined as an infinitely long cylinder. The radius of this
cylinder is calculated as the maximum distance of the stock's bounding
box from the cylinder's axis plus the Z rapid plane distance. For instance,
with a round stock (along the Z), the blue square is calculated as the
bounding box of the stock. An additional Z-rapid (1.0 " in this example)
is added to this radius to define the safe area as the black 'cylinder'. All
retracts and rapids will essentially go to or from this radius. All plunges
will begin a distance of plunge clearance (0.1 " in this example) away
from the stock's bounding cylinder (at the black dot).
Notice that retracting to cylinder is not desirable in this case. (The tool
axis is fairly close to the vertical (Z-axis) tool. In this case, the tool must
begin at a very large Z value in order to start on the 'safe area cylinder'
(the black circle above). Here is the same tool position, but no longer in
the top view. 'Retracting to cylinder' will result in large Z-values in the Gcode (+30 ") in this case.
Contrast this to Retract to Cylinder deselected. In this case, the safe

area is defined as a plane, a distance of Z-rapid plane (1 " in this case)
above the top of the stock. All plunges will begin a distance of 'plunge
clearance' away from the top of the stock (at Z = 0.1 " in this example).
Slopes tab (3D)

Many of the 3D toolpath techniques can be limited to regions of the part
by angles. These controls are located on the Slopes tab. The options are:
None - All regions of the surfaces of the model will be included
regardless of slope
Horizontal only - Limit cutting to regions with a slope less than

Maximum surface slope (see page 305)
Vertical only - Limit cutting to steep regions with slope greater than
Minimum surface slope (see page 306)
If you are using a spiral operation that is limited by slope, then
checking the Horizontal only option will generate spiral
operations based on the outlines of the slope-based regions.

Maximum surface slope
Maximum surface slope limits the toolpaths to portions of surfaces with a
slope less than that angle. This is a good way to limit milling to the
"flatter" portions of your model. This attribute applies to most finishing
types of toolpaths (for example Parallel, Radial and so on). The figure
below shows an example of limiting X parallel toolpaths to the bottom of
the mold by setting Maximum slope angle to 45 degrees.
The toolpaths do not climb up steep walls.
See also Minimum surface slope (see page 306).

Minimum surface slope
Minimum surface slope limits toolpaths to surface portions that have a
slope greater than that angle. It works well to limit toolpaths to the
"steeper" portions of the model. The figure below shows an example of
using Minimum surface slope to limit the finishing passes to the walls.
The bottom of the mold not machined.
See also Maximum surface slope (see page 305).
Surface control tab (3D)

The Surface Control tab is active for isoline milling or Z-level
finishing. On this page you can change the side of the surface that is
milled. All surfaces are listed as a row in the table. If the row has a check
next to it, the surface is included in the current operation. Deselect it to
remove the surface from the operation. If you select a row in the table, the
surface is highlighted in the graphics window. Use the Pick surface
button on the right to select a surface graphically and select the
appropriate row in the table. FeatureCAM attempts to mill the correct
side of each surface. The Machining Side column will be set to Auto
to indicate this.
Each feature has a set of surfaces, but individual operations of a feature
may want to exclude certain surface. All surfaces with a check next to its
name is included in the feature.
To include/exclude a surface:
1. If you know the name of the surface, toggle the check box next to
the name.
2. If you do not know the name of the surface, click the Pick
surface
button and select the surface in the graphics window.
The name of the surface is then highlighted in the list. You can
then toggle the check box next to the name.
Isoline milling only
The order that the surfaces appear, is the order that the surfaces will be
milled. The Up and Down arrows on the right side will move the
operations accordingly. When a surface is selected in the table, an arrow
indicating the starting corner and isoline direction is displayed along the
surface normal direction as shown below.
When a surface is selected, two arrows are displayed. One arrow is

normal to the surface. This indicates the side that will be
machined.
If the wrong side is selected, click the Switch Machining Side
button or go to the Machining Side tab to change this. The arrow that is
tangent to the surface indicates the starting corner and direction of the
first isoline toolpath.
The Start Curve column indicates whether you are going to start milling
at the First row, Last row, First Column or Last Column. If you
want to change start curve of the isoline paths, click the Set Isoline
Row Column
button until the arrow in the graphics window is
aligned with the correct row or column of the surface. The Cut
Direction column of the table indicates the direction of the toolpaths.
button to toggle the direction along the row
Click the Cut direction
or column.
Flowline Guide Surface
If you select a flowline guide surface (see page 361), the isolines of
another surface are projected onto all the surfaces of the feature.
F/S tab
The F/S tab lets you view and edit feed and speed settings for the
operation selected in the tree view.
Speed
The Speed section is for setting how fast the tool spins. The default units
are RPM (revolutions per minute). Optionally select Use SFM (surface
feet per minute) to change the units. FeatureCAM uses the
Recommended speed value by default. You can optionally enter a
different value and the override option is automatically selected. If want
to revert back to the recommended value, deselect override.
Feed
The Feed section is for setting how fast the tool moves through the
stock. The default units are IPM (inches per minute). Optionally select
Use IPR (inches per revolution) to change the units.
You can set the Use IPR attribute globally on the Misc. tab of
Machining Attributes.
FeatureCAM uses the Recommended feed value by default. You can
optionally enter a different value and the override option is
automatically selected. If want to revert back to the recommended value,
deselect override.
Coolant
The Coolant section is for setting the type of coolant to use for the
selected operation. The default coolant is Flood. You can select a
different coolant from the list and the override option is automatically
selected. To revert back to the default coolant, deselect override.
You can change the default Coolant type on the Misc. tab of
Machining Attributes.
Reset All clears any overrides you made to the feeds and speeds and
returns the settings to the default value for tool attributes listed on that
page.
See also Feeds and speeds (see page 117).
Leads tab (3D)

The Leads tab controls how the tool moves on and off the surface
milling feature (lead in/out) and how the tool moves between toolpaths
(stepovers).
Ramping
If Ramp to Depth is not checked, the tool will plunge to depth. If
Ramp to Depth is checked and Helical is not checked, the tool will
zig-zag into the material. The angle of the zig-zag passes is controlled by
Ramp angle. If Helical is checked, the tool will spiral into the material.
See Helical ramping for more information.
Lead Moves
The Use lead in/out (see page 311) controls when lead in/out moves are
applied. If Normal to Surface is selected, the lead in/out moves are
performed with respect to the surface normal. If it is not checked, the
moves are performed in the plane of the toolpath. The Lead in/out plane
(see page 312) controls how the arcs and ramps are measured.
Lead moves are either performed as arcs or linear moves by selecting one
of the following categories:
Use arc ramp in/out (see page 313)
Use linear lead in/out (see page 313)
The moves between toolpaths are controlled by the Stepover type (see
page 315).
See also Overview of surface manufacturing (see page 268), surface
milling feature dimensions tab (see page 276), 3D Milling methods,
strategy tab (see page 277), Feed and speed tab (see page 309), milling
tab (see page 314)
3D Milling methods
Roughing
Use lead in/out

The Use lead in/out drop-down list controls when lead moves will be
applied. The options are:
Never: Do not use lead moves on this feature.
On all plunges/retract: Apply the leads on all plunge and retract
moves.
On first plunge/retract: Apply on the first plunge and first
retract move only.
On all toolpaths: Apply the leads on every toolpath.
Lead in/out plane

The arcs and ramps are measured relative to one of the following options:
Normal: Lead in/out moves are relative to the surface normal.
Horizontal: Moves are relative to a horizontal plane. Directions of the
ramp could be right or left.
Horizontal left: This setting is most useful for uni-directional paths. It
ensures a consistent left ramping.
Horizontal Right: This setting is most useful for uni-directional paths.

It ensures a consistent right ramping.
Vertical: Moves are relative to a vertical plane.

Default: The default for z level finish is Horizontal, and Vertical for
all others.
Use arc ramp in/out

If Use arc ramp in/out is selected, the following parameters are used
to control the ramping on and off the part feature:
Ramp diameter: The diameter of the ramp move.
Ramp in angle: The angle of the ramp in move.
Ramp out angle: The angle of the ramp out move.
Use linear lead in/out

If Use linear lead in/out is clicked, then the following parameters
controls the move off the feature:
Lead-in angle: Angle measured away from the toolpath for the
lead-in move. Note this angle can be negative.
Lead-out angle: Angle measured away from the toolpath for the
lead-out move. This angle can be negative.
Lead-in length: Length of the linear lead-in length.
Lead-out angle: Length of the linear lead-out length.
Arc ramp parameters
3D Milling tab and Manufacturing attributes

When you click the Milling tab for a feature's operation, you see the
attributes available for 3D milling. These attributes control how the
manufacturing takes place. You can override any attribute you wish for
the kind of manufacturing you desire. The check boxes (see page 388)
and attributes (see page 399) are discussed separately.
Stepover type
The Stepover type controls the type of transition move that is inserted
between toolpaths. The choices are:
Direct: The tool moves straight over to the next position. The tool
can move in all 3 axes. This figure shows a direct stepover move
on a flat surface feature.
Arc: For Z-roughing only, the tool attempts to connect to the next
position with an arc. (If that is not possible, an arc and several
tangential lines are used). For Z-roughing, only Direct and Arc
apply.
Stair step: The tool moves up in Z and then over in X and Y. This
figure shows a stair step transition move on a spherical surface.
This figure shows the same surface feature using a direct stepover.
Loop: The tool makes an arc move out of one toolpath and an arc
move into the next toolpath. These transitions are actually
programmed from linear moves and may move all three axes. This
figure shows a loop move on a flat surface feature.
3D Z rough leads/step tab

The Leads tab controls how the tool moves on and off the surface
milling feature (lead in/out) and how the tool moves between toolpaths
(stepovers).
Ramping
There are three choices for the Z-roughing ramp style. You may Plunge
To Depth, Ramp To Depth, or Plunge To A Predrill Location.
If Ramp To Depth is not selected, the tool will plunge to depth. If
Ramp To Depth is checked and Helical is not checked, the tool will
zig-zag into the material. The angle of the zig-zag passes is controlled by
Ramp angle. If Helical is checked, the tool will spiral into the material.
See Helical ramping for more information.
Selecting Plunge To Predrill Location(s) will create a predrill

operation(s) in the feature if appropriate (there may only be one predrill
operation per feature). You must set the Predrill Diameter which will
attempt to select a drill of that particular diameter. Be advised to select a
drill smaller than (or equal to) the diameter of the tool used for the Zroughing. (A bigger tool may gouge). FeatureCAM will automatically
calculate (perhaps multiple) predrill locations based upon the regions
where it needs to plunge interior to the stock boundary.
If Approach Outside Where Possible is checked, the approach
moves will include a small horizontal move so the tool plunges off the
stock.
The moves between toolpaths are controlled by the Stepover type (see
page 315).
See also Overview of surface manufacturing (see page 268), surface
milling feature dimensions tab (see page 276), 3D Milling methods,
strategy tab (see page 277), Feed and Speed tab (see page 309), milling
tab (see page 314)
3D Milling methods
Roughing
Z level slice classification

You can tell FeatureCAM to rough your part as a 3D boss, or as a 3D
pocket. If you select 3D Pocket, the tool will plunge or ramp onto the part
and will be cut from the inside of the part out toward the boundary of the
part. A 3D boss will typically plunge off of the part and cut from the
outside toward the center.
Even if the surfaces of your part create a boss shape (meaning it protrudes
rather than being a cavity), you can still select 3D Pocket. The two figures
shown below show the slices of a part being cut as a boss, in the first
figure, and as a pocket in the second figure. Notice that the slides of the
boss go all the way around the part at each slice, but the pocket example
has slices that just cut a region of the part.
3D milling strategies
Types of surface milling operations
Parallel (see page 323) - creates a raster
onto the model.
Z level finish (see page 350) - creates a

toolpath by slicing the model at specific Z
heights.

toolpath from offsets of a pattern and
projecting it onto the model.

toolpath by offsetting the model and block.
This technique is best suited to machining
areas which require a constant stepover and
works well on near vertical surfaces.
Isoline milling (see page 358) uses the
isoline curves of a surface to mill the
surface. These curves can be in the row
direction or column direction.
Radial (see page 339) - creates a radial
onto the model.
Flowline (see page 361) - drive surface

machining. Creates a pattern from the
flowline surface and projects it onto the
model.
Between 2 curves (see page 364) -limits

machining to be between two curves.
Direction of toolpath can be set to be along
or across.
Pencil (see page 365) - creates a single

trace corner toolpath.
Z level roughing (see page 339) - Clears an

area with contours generated by repeatedly
offsetting the initial slice until no further
offset is possible.
Plunge roughing (see page 368) - A

specialized cutting tool is used to remove
large amounts of material through a series
of vertical plunging movements.
Corner (see page 373) remachining creates a multiple trace corner toolpath with
Across or Along options.
Horizontal + Vertical (see page 367)

remachining - This strategy combines two
different toolpath operations, one for
finishing shallow portions of the part and a
Z-level for finishing the steep regions.
5-Axis Trim (see page 387) - creates a

toolpath along the edges of a surface set
either offset or inset.
Swarf (see page 380) - creates toolpaths

which cut with the side of the tool. This
technique only works on developable
surfaces as the tool needs to be in contact
with the surface for the whole cutting
depth.
Four-axis (see page 369) Rotary - creates a
toolpath by rotating the model around the
index axis, with linear motion provided by
the non-index axis coordinate pairs.
Cutting strategy for new features

This page allows you to select the cutting strategy you want to use for
your feature. You can only specify one strategy in the New Feature
wizard. The strategy choices are grouped by finishing, roughing and
specialized strategies. The strategy choices are:
Finishing Strategies
axes.
Z level finish (see page 350) - toolpaths that are parallel to the XY
plane.
Isoline milling (see page 358) - toolpaths that follow the rows or
columns of individual surfaces.
or away from the center of the part. Stepover is constant from the
top view.
or away from the center of the part. Stepover is constant in 3D.
Radial milling (see page 339) - toolpaths that move out radially
from the center of the feature.
Flowline milling (see page 361) - toolpaths that follow the rows or
columns of a flowline surface which are then projected onto the
part.
Between 2 curves (see page 364) - toolpaths that are created
between two specified curves.
Roughing Strategies
Z level rough (see page 339) - toolpaths that are parallel to the XY
plane.
Plunge roughing (see page 368) - toolpaths which remove large
amounts of material from a component through a series of vertical
plunging movements.
axes.
Specialized Strategies
Horizontal + Vertical (see page 367) - machine steep and shallow
regions using different techniques.
Corner Remachining (see page 373) - A remachining technique
used to clean up corners that occur between non-tangential
surfaces.
Pencil milling (see page 365) - a single clean-up pass for corners.
4-Axis (see page 369) Rotary - used in turnmill to machine round
surfaces with an X tool.
Swarf (see page 380) - toolpaths are cut using the side of the tool.
The tool is in constant contact with the surface.
5-Axis Trim (see page 387) - toolpaths that are along the edges of
surfaces. There is the option to cut on the inside or outside edge of
the surface.
For more details on these options, see operations overview (see page
270).
1. Select the desired strategy.
2. Click the Next button.
3. If you are creating a new feature, the New feature part
surfaces dialog is displayed.
4. If you are adding a new operation to an existing feature, the New

feature strategy (see page 283) dialog is displayed.
Parallel milling
Overview of projection milling methods
Projection milling techniques are a robust and easily understood method
of generating 3D toolpaths. They work by taking a pattern of curves and
projecting points from these curves onto the surfaces of the part.
Advantages
Robust
Handles overlapping surfaces well.
Good for multiple surface manufacturing.
Allows specifying planar stepover distances or scallop heights for
finishing.
Surface normals are not considered for the manufacturing
computation
Disadvantages
Poor handling of nearly vertical surfaces
Does not handle vertical surfaces since they are invisible from
above.
See Restrictions of projection milling techniques (see page 325) for
more details.
Parallel toolpaths
Parallel toolpaths are parallel to the X axis or Y axis of the current setup.
To slant the toolpaths relative to the axis, set the Parallel angle (see page
324) attribute on the Strategy tab.
This figure shows X parallel toolpaths.
Y parallel toolpaths are shown here.
This method mills only the area above and down to the surface(s) in the
feature. If part of the stock does not have a feature surface in it, that area
wont be milled away, except perhaps incidentally to the manufacturing
of another surface feature.
For information about 3D Manufacturing attributes, refer to 3D Milling
tab and Manufacturing attributes (see page 314).
Parallel angle
Parallel angle is available only in X and Y parallel roughing and sets
what angle the roughing passes occur in reference to the X or Y axis. This
value can be anywhere from -360 to 360 degrees. A positive value rotates
counter-clockwise from the Z axis, and a negative value rotates clockwise
from the axis. Examples of using Parallel angle are:
1. Setting the angle to 90 on an X-parallel operation causes it to
effectively become a Y-parallel operation.
2. Setting the angle to 180 causes the toolpaths to be cut from the
opposite side of the part. For example, an X-parallel operation with
the angle set to 0 starts at the minimum Y coordinate. With the
angle set to 180, the toolpaths start at the maximum Y coordinate.
Restrictions of projection milling techniques

Vertical surfaces are almost invisible to projected manufacturing methods
because the vertically projected lines may not detect the vertical surface.
The top edge of such a surface is protected, but the actual surface may not
be milled. Surfaces that are exactly and completely vertical must be
machined with another technique. Vertical surfaces might be better
candidates for a Side feature instead of a surface.
Troubleshooting projection milling methods
1. Bad surface finish on nearly vertical walls. If you are finishing
across a nearly vertical surface, portions of a surface have larger
scallops than other parts of the surface. Possible solutions include:
Use scallop height (see page 391) instead of fixed planar
distance stepovers. This gives a constant scallop height over
surfaces of the model. See item 3 below.
Finishing the surface with isoline milling (see page 358)
Finishing the surface in another direction with a projection
technique. Finish going up the steep slope rather than across.
Use a stock curve (see page 419) if you only want to mill a
small portion of the surface milling feature.
Finishing the surface again with the same technique using a
much smaller stepover (see page 418) value.
2. The toolpaths extend beyond the edge of the surface. See Stock
curve (3D) (see page 419)or Edge Rollover (see page 286)
3. Bad finishing of vertical walls. Projection techniques do not finish
vertical walls. Finish vertical walls with Isoline milling (see page
358) or Z level finishing (see page 350).
Add perpendicular pass
Add Perpendicular Pass - Defines a second parallel pass
perpendicular to the first one.
Shallow Angle - allows you to create a perpendicular pass only where
necessary - rather than over the whole model.
An example: Add Perpendicular Pass deselected.
Perpendicular Pass, Shallow Angle 0

Add Perpendicular Pass selected, and Angle = 0, adds a Y-parallel
over the entire part.
Add Perpendicular Pass - selected, Angle = 5
One raster pass over the entire model. A second pass, perpendicular to the
first, that only machines the areas of the model that are steeper than the
Angle.
2D Spiral milling
2D Spiral toolpaths
2D Spiral toolpaths mill a feature in a continuous spiral either towards the
feature center or away from the feature center. Spiral is only a general
description of the actual path as not all feature shapes lend themselves to
a truly spiral pattern. The pattern is obtained by taking the stock
boundary, the feature boundary or the curve specified in the Stock tab
(see page 288) and offsetting this curve toward the center of the part. The
steps between the passes is calculated in 2D. For spiral toolpaths that use
a 3D stepover use the 3D spiral technique (see page 335). To use the
stock boundary, click Use stock dimensions on the Stock tab. This
results in a square shape to the toolpaths.
To automatically calculate the silhouette boundary of the surfaces of your

feature, click Use part surface dimensions. This toolpath mimics the
boundary of your feature.
If you want to use a different curve as your toolpath shape, Click Select
curves for boundaries on the Stock tab. The options for using a curve are
different for spiral milling (see page 329) and other techniques (see page
333).

tab and Manufacturing attributes (see page 314). See also
Troubleshooting projection milling methods (see page 325).
Spiral toolpath example
Boundaries for 2D spiral toolpaths

The shape spiral toolpaths (see page 328) are determined by the boundary
and island curves and the classifications of 3D pocket (see page 330), 3D
boss (see page 330), 3D side (see page 331), or Wall only (see page 331)
Multiple boundary curves can be specified, but these curves must not
touch. If none is specified, then the stock boundary is used.
Curve allowance (see page 332) - The distance to stay away from the
boundary or island curves.
For Wall only profile types, click the Other side button to offset
the other direction. For bosses, use stock overcut % (see page 332)
to control how close you come to approaching the stock boundary.
Total offset - This is the total distance away from the boundary curve to
cut for boss or side profile types.
See also How to create a surface milling feature (see page 269), Spiral
toolpaths (see page 328) and How to create a 3D boss from font curves
(see page 334)
3D pocket
The 3D pocket projects the boundary curve onto the surface and spirals
inside of this closed curve as shown in this figure.
If an island curve is specified, that region is avoided.

3D boss
The 3D boss setting cuts between the stock boundary and the boundary
curve by projecting the boundary curve onto the surface, for example:
3D side
The 3D side setting projects the boundary curve onto the surface and then
cuts on one side or the other as shown in this figure.
Wall only
The Wall only setting traces along the curve, for example:
Boundary Curve allowance
Spiral boss feature with curve allowance. Notice the gap between the
bosses and the toolpaths.
Stock overcut % (3D)
Stock curve overcut % applies to three types of surface milling
features, spiral toolpaths designated as a boss on the stock page, features
cut with projection milling technique that do not have an explicit
boundary curve and select Z level rough passes. In the boss case this
attribute applies only to how the toolpaths behave around the stock
boundary. For other 3D surface milling features use the cut allowance
feature described on the stock page (see page 288). The stock overcut
% only applies if Use stock dimensions is selected on the feature's
Stock tab (see page 288).
Stock overcut specifies what percentage of the tool approaches or
passes beyond the stock boundary.
It can have a value between -100 and 100 with the following meanings:
0 puts the centerline of the tool on the stock curve.
100 overcuts the region by a tool radius.
-100 stops one tool radius short of the stock curve.
For Z level rough, this attribute applies to all features except pocket
features without stock curves. This attribute controls the outer extend of
boss features and the amount that pocket feature cuts beyond its
boundary. The default value is 100% which puts the edge of the tool on
the boundary. A number greater than 100 extends the toolpaths beyond
the boundary. A number less than 100 essentially offsets the outer
boundary and clips the toolpaths against this closer boundary.
Boundaries for technique other than spiral
You are given a choice of:
3D pocket - The toolpaths are restricted to the regions inside of the
curves specified as the boundaries.
Island curves can also be specified for 3D pockets. The toolpaths are
generated outside of the island curves, but inside the boundary curves.
The island curves must be inside of the boundaries and must not touch the
boundaries.
3D boss - The toolpaths are restricted to the regions outside of the

curves specified as the boundaries.
Boundary curves may extend beyond the stock or beyond the surfaces of
the feature. Regardless of the curves that are specified, toolpaths do not
extend beyond the surfaces of a feature.
Curve allowance (see page 332) - The distance to stay away from the
boundary or island curves. This must be a positive number and is an
absolute distance.
How to create a 3D boss from font curves
1. Create the surface or surfaces you want to use as the floor of your
feature.
2. Create your text.
3. Use Extract font curve and extract the outer boundaries of the text.
4. Use Extract font curve again and extract the islands.
5. Create a spiral out 3D boss operation (see page 269) for the floor
surfaces using the outer boundary curves as the boundaries.
6. Set the curve allowance to the tool radius.
7. Create another spiral out 3D pocket operation for the floor surfaces
using the island surfaces as the boundaries.
8. Again, set the curve allowance for this operation to the tool radius.
3D spiral
This finishing technique is best suited to machining areas, which require a
constant stepover and works well on near-vertical faces.
Spiral toolpaths mill a feature in a series of offsets towards the feature
center. The initial pattern is specified by taking the stock boundary, the
feature boundary or the curve (see page 288) specified in the Stock
tab. To use the stock boundary, click Use stock dimensions on the
Stock tab. This results in an initial square shape to the toolpaths. The
next and subsequent toolpaths are obtained by offsetting the initial shape
in 3D (along the surfaces being cut). This differs from 2D spiral
operations (see page 328) which offset the initial shape in 2D and then
project this shape onto the surfaces. Also, there is no spiral-out with a 3D
spiral operation.
Select Use part surface Dimensions in order to use the silhouette of
the part surfaces as the initial boundary shape as shown in the simple
figure on the left. The figure on the right shows the toolpaths that would
result if Use stock dimensions was used instead.
The Spiral option on the milling attributes page eliminates the stepover
between the offsets, and morph the pattern into a continuous spiral. With
the Spiral option checked, you get the result shown below. You can see
that this minimizes the number of tool retracts and converts the original
closed contours into one long spiral.
With the Spiral option deselected you get the following result. Notice
that there is a retract between each contour.
Boundary curves can also be used to control the shape of the spiral. All of
these options are accessed by clicking the Curve options button on the
Stock tab. By specifying a boundary curve, this shape is used as the
initial contour of the spiral.
The boundary curve is clipped against part surfaces as shown in the figure
below. If the curve is entirely outside of the stock, the silhouette of the
surfaces is used as the boundary curve.
If the operation is specified as a boss, then boundary curves determine

regions that are avoided.
If the operation is specified as a pocket, then the boundary curves

represent the shape of each region. Any island curves are avoided. In the
example below, the operation is specified as a pocket with three boundary
curves. The lower left region also has a circular island region.
Details of 3D spiral milling

The Z height of any boundary curve is ignored. This means that the
curve can be above, below or even inside of the part.
The Total Offset option of the Boundary curve dialog (see page
329) is disabled for 3D spiral milling.
Curve Allowance is the same as described for 2D spiral milling
(see page 329).
Radial toolpaths
Radial toolpaths are created from the center of the part toward the
boundary. This figure shows a radial toolpath example.
The center of the pattern is automatically calculated unless the Center

point (see page 339) milling attribute is set. Not all feature shapes lend
themselves to this manufacturing style. Features long in one direction and
skinny in the other probably aren't best milled in this way. The radial term
is only a rough description of the actual path as not all feature shapes lend
themselves to a truly radial pattern.
tab and Manufacturing attributes (see page 314) or 3D leads/step tab (see
page 310).
Center point
The Center point attribute applies to Radial toolpaths (see page 339).
This point is projected down onto the surface to become the center of the
radial pattern.
Z-level roughing
The Z-level roughing method slices the feature at various depths and
mills the corresponding 2.5D contours as a pocket or boss shape at each
depth.
Methods of Z-level roughing (see page 341)

Z-level roughing with multiple tools
How to create a Z level roughing operation (see page 349)
High speed Z roughing
Reordering (see page 345)
Troubleshooting (see page 350)
See also Surface manufacturing (see page 267), Recommended
Machining Strategies, 3D Milling tab and Manufacturing attributes (see
page 314) and 3D leads/step tab (see page 310).
Roughing
Overview of Z-level roughing

Z-level roughing slices the model at various depths to obtain planar
contour curves. It then uses these curves to rough the model using a
pocketing or boss toolpath generation technique. For a generalized boss,
FeatureMILL3D uses the stock boundary or stock curve (see page 419) as
the outer boundary of the boss.
There are two different methods of Z-level roughing (see page 341).
Methods of Z-level roughing

Zig-zag - more like an X parallel rough. Roughs each Z level raster-style
with an optional profile pass around each slice.
Offsets - each slice is offset repeatedly to form the toolpaths.
Flat surface support

With Flat surface support as Off, the Z levels are calculated at a constant
Z increment. With Flat surface support as Level or Area, extra levels are
inserted above each flat surface in the model. This ensures that the finish
allowance is accurately left on all flat surfaces.
There are three options available for flat surface support:
Level - machines whole flat Z levels.
Area - machines flat areas only (rather than the whole level).
Off - flat areas are not considered.
The images below illustrate the differences in the slicing. The second
picture shows the slices without Flat surface support. The bottom picture
shows the additional slices that are added with the level option invoked.
Here is another example.
Looking at a different angle you can see that three complete levels are
machined.
Area- machines flat areas only (rather than the whole level).
Looking at a different angle you can see that only the flat areas are
machined in the first level.
Reorder for Z rough

Selecting the Reorder milling attribute for Z level rough creates a depth
first strategy. Without Reorder checked, each Z level is roughed
completely before moving to a lower depth.
With Reorder selected, paths are created that machine vertical regions as
shown below.
High speed roughing

Corner radius %
Slices in Z-level (both rough and finish) can be arc fitted to avoid sharp
changes in direction. For Z roughing, only the toolpath closest to the part
is rounded. Corner radius % defines the radius that is inserted in to the
toolpaths.
The radius of internal corners is defined as a proportion of the tool
diameter. The default value is 5% for a finish pass and 0% for a roughing
pass. So if you have a tool of diameter 10 mm then the arc radius is 0.5
mm. The Corner radius % can have a value between 0 and 100.
Arc fitting is of particular importance when high speed machining as it
eliminates sudden changes in tool direction.
Toolpath corner %
Effective only during Z-level rough, a non-zero Toolpath corner %
replaces sharp corners with rounded corners. Defines the maximum
deviation from the sharp corner. The maximum this can be set to is 40%
of stepover. This means that if you have a 10mm stepover the maximum
deviation from the sharp to the rounded corner is 4mm.
Using the Toolpath Corner % produces a toolpath with fewer small

arcs which makes the toolpath more suitable for high speed machining.
The original profile has the same number of points in it, it is just the
offset passes that have a reduction in the number of points.
Trochoidal Cut - Z rough

Checking the Trochoidal cut check box essentially turns on the ability
to detect and avoid tool overload. As the tool gets towards an overload
situation then FeatureCAM automatically puts in a trochoidal path to take
away the overload. This happens in corners, in narrow channels, slots and
the first cut of an offset toolpath which is, in effect, a narrow channel.
Since some tool overload may be acceptable, it can be controlled by the
Avoid tool overload attribute. This is the allowable overload percentage
of the existing stepover. So, if you use a stepover of 10 mm and an
allowable overload of 10%, trochoidal moves don't start appearing until
an overload condition of 10% (or 1 mm) is exceeded.
Looking in detail at a typical toolpath:
Looking in at a corner in even more detail you can see the trochoidal
paths more easily:
Reorder
The Reorder attribute tells FeatureCAM to re-sequence the toolpaths to
minimize retractions while trying to avoid full width cuts. Use Reorder
when you have a part where several separate regions are cut. If you want
the toolpaths to move directly across a surface without worrying about
retractions, deselect Reorder.
For Z-level operations (rough or finish), the Reorder attribute enables

zone machining, where the toolpaths descends in the Z (or -Z) direction if
that is more efficient than cutting the entire part in complete Z levels. The
phone handset example below shows that the toolpaths cut the top of the
part in complete Z levels and then cut one side and the other.
How to create a Z level roughing operation

To create a Z level roughing operation:
1. Create a surface milling feature. (see page 269)
2. Specify Z level rough as the Strategy on the New Strategy page
(see page 277).
3. If your shape is a 3D boss, choose the Boss option. If your shape
is a cavity, click the Pocket button.
4. At the conclusion of the wizard, click the Finish and Edit
properties button. If this button is not displayed, hold down the
triangle on the right side of the Finish button and select Finish
and edit properties from the menu.
5. Click the Milling tab (see page 314).
6. Select the Z-level roughing method (see page 341).
7. Click the Leads tab (see page 316) and set the options for the
moves between toolpaths.
8. Click OK.
9. Generate toolpaths. If you receive an error, see Troubleshooting Z
level roughing (see page 350) for more information.
The toolpaths for Z level rough always use both linear and circular
interpolation where appropriate. While Arc/line approximation (see
page 391) is an option for other types of 3D toolpaths, it is always
used for Z level rough.
Troubleshooting Z level roughing

FeatureCAM has different methods of Z level roughing (see page 341).
1. Mills the wrong side of the surfaces.
Toggle the Boss attribute (see page 285) on the milling tab.
If the Boss attribute is set correctly, make sure that the
normals of the vertical surfaces are pointing out. Use the
Surface Control tab to reverse the surfaces.
2. Slices are very coarse. Decrease the tolerance attribute (see page
421) on the milling tab.
3. The slices look strange around holes or passages in the walls of the
feature. Use a cap surface to plug holes, (or surface untrim), or use
a larger diameter tool.
Z-level finishing
The Z-level finishing method slices the feature at various depths and then
mills each slice. This technique works well for steep sloped walls.
Z-level interleave (see page 351)
machining strategies, 3D Milling tab and Manufacturing attributes (see
Roughing
Overview of Z-level finishing

Z-level finishing is a good technique for finishing steep walls or when
you require a consistent depth of cut. This technique is sometimes called
waterline milling. Just like Z-level rough (see page 339), it starts with
slicing the model and then creating toolpaths from the slices.
The figure below shows an example of Z-level finishing.
Z level interleave option

The interleave option of Z level finishing (see page 350) inserts toolpaths
in the shallow regions between the slices. This option attempts to finish
the entire part with a minimum number of retracts. The example below
shows coarse interleaved toolpaths.
Interleaved toolpaths are enabled by checking the interleave spiral paths

check-box on the strategy tab (see page 283). Interleaved toolpaths are
controlled by the Spiral max slope parameter. This parameter controls
the slope below which the zig-zag toolpaths are inserted. A higher setting
of Spiral max slope increases the size of the zig-zag or spiral region. In
general, this parameter should be set to a value less than 40, since the zigzag toolpaths should be limited to surfaces with slight slopes. When using
the Interleaved technique, Z level toolpaths are always calculated using
the desired scallop height (see page 392), rather than an explicit Z
increment. How accurately the toolpaths fit the surfaces is controlled by
the tolerance (see page 421) parameter. To minimize retracts, you may
also have to adjust the stepover rapid distance (see page 418). Arcline
approximation applies for the z level portion of interleaved toolpath.
There are four different styles of toolpaths that can be created for the
shallow regions. If you check Closed spirals on the Strategy tab, but
deselect the Spiral Milling attribute, offset toolpaths are generated.
If you check Closed spirals on the Strategy tab and check the Spiral
Milling attribute, continuous spiral toolpaths are generated.
If you deselect Closed spirals on the Strategy tab and select bidirectional as the cut direction (see page 404), zig-zag toolpaths are
created.
If you deselect Closed spirals on the Strategy tab and select Uni- d
(see page 404)irectional as the cut direction, you can create toolpaths
that cut in a single direction.
In addition to the style of cut on the shallow regions, you can also change
the toolpaths with the Remove shallow slices Strategy attribute. The
figure below shows an example of Z finish toolpaths.
Without Remove shallow slices checked, toolpaths are inserted

between each slice. This results in the shallow regions being relatively
flat.
With Remove shallow slices checked, the slices in the flatter regions
are removed. This results in the removal of some possibly unnecessary
slices, but shallow regions tend to be larger and the shallow toolpaths
tend to vary more in the Z direction.
Troubleshooting Z level finishing

Problem: Z level finish cuts both sides of part.
Solution: Use a boundary curve to limit cutting to the inside or select the
internal only edge boundary.
Corner correction
Corner correction defines the type of corner correction that you want to
apply to all internal corners of a Z-level finish toolpath. The types are
available from a pull-down list and three options are available:
None - no sharpening or arc fitting is carried out.
Arc Fitted - arcs are created and rounded in all internal corners.
The yellow toolpath shows the Arc Fitted toolpath and the green
toolpath shows the Normal toolpath.
Arc fitting is of particular importance when high speed machining, as it
Corner Radius %
This defines the radius used if you select a Type of Arc Fitted. The
radius is defined as a proportion of the tool diameter. For a Z finish pass
the default value is 5%. So, if you have a tool of diameter 10mm (radius
5mm) then the arc radius is 0.5mm. The Corner Radius% can have a
value between 0 and 100.
Spiral Z level
The standard Z level finishing toolpaths creates paths with a constant Z
height as shown below. The tool either retracts or feeds along the surface
between Z levels.
With the Spiral milling attribute checked, the toolpaths change into a
continuous spiral. The toolpaths no longer have a constant Z height.
Isoline milling
Isoline manufacturing follows the isolines of the surface being
manufactured. It is a good technique for finishing surfaces.

Flowline guide surface
Roughing
Overview of isoline milling

Isoline milling uses the isoline curves of a surface to mill the surface.
These curves can be in the row direction or column direction. This figure
shows an example of isoline toolpaths on a single surface.
Advantages
Uniform finish with scallop height control. The toolpaths are
spaced based on the distance along the surface.
Nearly-vertical walls handled well. Since this is not a projection
technique, nearly vertical walls are cut correctly.
Disadvantages
Toolpaths generated on a surface by surface basis.
Restrictions of isoline milling

Isoline milling works on a surface by surface basis. This can result in
numerous retracts.
The orientation of the surfaces matters. Toolpaths are generated for
surfaces whose normals point up. Surfaces are "auto flipped" where
possible, but for vertical and some other cases, the machining side must
be specified. Select the surface in the list box and click Switch
machining side. Isoline milling may mill on the wrong side of the
surface or if certain flags are set, it may skip the surface.
See Troubleshooting isoline milling (see page 360)
Troubleshooting isoline milling
1. The toolpaths are on the wrong side of the surface. Select the operation
in the features tree view. Go to the Surface control tab. Change the
button.
machining side to Reverse using the
2. Toolpaths should go the other direction or start at the other end of the
surface. In the Isoline control tab the Start curve has the options of
first row, last row, first col, last col. Select the surface in the table and
button. An icon appears on the screen
toggle the Start curve using the
that indicates the start point and the direction of the first toolpath.
3. Performance is slow. If you dont need the Avoid self-gouging
milling option, turn it off.
4. Surfaces are cut in the wrong order. Select the operation in the
features tree view. Go to the isoline control tab. Use the arrow keys to
rearrange the order of the toolpaths.
5. Toolpaths for a surface are begin reorder strangely. Select the operation
in the features tree view. Go to the Milling tab. Turnoff the Reorder
option.
Flowline
The Flowline technique projects the isolines from one surface onto the
surfaces of the feature. The isolines are projected in the direction of the
surface normal. In the example below, the isolines of a flat surface are
projected onto the part. By using a side mill cutter, flowline machining
can be used to machine undercut regions.
A flowline milling operation is created using the following steps:

1. Click the Features step.
2. Click Surface Milling. Click Next.
3. Select the part surfaces and click the plus button.
4. Click Choose a single operation and click Next.
5. Click Flowline and click Finish.
6. Double-click the feature to edit it.
Click the word, Flowline, in the tree view and click the Surface
Control tab.
1. Click the Pick surface
surface.
button and select the flowline guide
.
2. The normal of the flowline guide surface must point toward the
surfaces of the part. When you click the surface control tab, two
arrows are displayed on the flowline guide surface. In the figure
below, the normal correctly points toward the part surfaces. If the
normal needs to be reversed, click the Switch machining side
button .
The arrows also indicate the starting point of the surface isolines and their
direction. In the picture above, the toolpaths that is projected starts in the
lower left and follows the rows of the surface. Use the Set isoline
button to change the starting point of the pattern and use the
row/col
Cut direction button to change the direction of the cuts.
Machining under cut regions
Undercut regions can be cut with either a Isoline (see page 358) operation
or a Flowline (see page 361) operation.
To machine undercut regions you must.

1. Create an Isoline or Flowline operation.
2. Select an appropriate side mill cutter. FeatureCAM does not
automatically select side mill cutters.
3. Specify a Horizontal lead-in/out plane on the leads tab (see page

310). You may also have to experiment to determine an appropriate
Ramp diameter to prevent gouging.
Between Two Curves

Between two curves calculates toolpaths that are bounded by two curves.
This finishing operation is used to control the shape of the toolpath over
multiple surfaces by restricting the machining of the surface to be
between the two specified curves.
The toolpaths mill a feature in a series of offsets starting from the first or
start curve towards the second or end curve. The toolpaths can be
generated to run in two directions. Across curves, the toolpath goes
from a point on the start curve to one on the second curve. Along
curves, the toolpath is similar to an offset toolpath radiating out from the
start curve to the end curve.
Along curves:
Equation
1: Along
curves
Across curves:
Equation
2: Across
Curves
You can limit the pattern by selecting Tool Center to generate the
pattern based on the center of the tool. Select Contact point to generate
the toolpath based on last point of contact between the tool and the
surface.
In the Milling tab, you can set Edge tolerance which is the trimming
tolerance used to reduce the noise of resulting toolpath near the start and
end curves. The Stepover attribute is by default blank and the value is
automatically determined based on the tool radius and tolerance.
However, if you want to override the automatically generated stepover,
you can set "stepover" to a particular value. If the automatically generated
stepover is too large, you can restrict it by specifying a Max stepover.
Pencil milling
Pencil milling is used to clean up corners or fillets of a part.
How to create a pencil mill operation (see page 366)
Roughing
Overview of pencil milling

Pencil milling operations automatically detect corners less than or equal
to the specified radius (including sharp corners) and then creates a single
toolpath to clean out these corners. Applications of pencil milling include:
Finishing fillets in a part with a single toolpath
Cleaning up sharp concave corners
Pre-relieving corners before high-speed finishing the part with a
small tool
Roughing fillets by using the finish allowance.
The first step is to determine the regions that contain the corners as shown
on the left. Depending on the number of surfaces in the model, this step
may take a little time. After the regions are detected, a single toolpath is
created that cleans out the corners regardless of the number of surfaces
contained in the region.
How to create a pencil mill operation

1. Create a surface milling feature (see page 269)
2. Click New
button on strategy page
3. Select Pencil milling and finish as the operation and click OK.
4. Click the Leads/steps tab (see page 310) and set the options for the
moves between toolpaths.
5. Click OK.
6. Generate toolpaths. If you receive an error, see Trouble shooting
pencil milling (see page 367).
Troubleshooting pencil milling

1. Calculating the regions takes too long. Use a stock boundary on the
Remachine tab to limit the search for remachining regions or
create a separate feature with only the surfaces of interest.
2. Some fillets/corners are not being detected. Decrease the tolerance.
Horizontal + vertical strategy

This strategy combines two different toolpath operations, one for
finishing shallow portions of the part and one for finishing the steep
regions. An X parallel or spiral toolpath is applied to the shallow regions,
while a Z level finishing operation cuts the steep regions. The Slope
boundary on the Strategy page indicates the angle that divides the two
regions. Portions of the surfaces with slopes less than this angle are
machined with the parallel toolpaths, and the steeper slopes are machined
by the Z level. The Slope overlap indicates how much the two regions
overlap. An overlap of 0 means that the two regions are distinct. A value
of 10 means that the two passes overlap by 10 degrees. The parallel pass
is parallel to the X axis unless the Parallel angle is set. Set the Parallel
angle to 90 to be parallel to the Y axis. If you are using a spiral in or
spiral out toolpath for the shallow regions, the shape of those regions is
automatically calculated based on the slope region boundaries.
Combo strategy with parallel (see page 367)
Combo example with spiral (see page 368)
Horizontal + vertical with parallel on shallow
Horizontal + vertical with spiral on shallow
Plunge roughing
Overview of plunge roughing (see page 368)
Restrictions of plunge roughing (see page 369)
Overview of plunge roughing
Plunge roughing provides an alternative form of roughing. With this
technique, roughing is performed with a series of overlapping holes. The
advantage of this technique is parts can be roughed quickly since the
force of the operation is directly up the spindle.
This figure shows a sphere that is being plunge roughed with a flat end
tool.
The pattern of the drilling operations are parallel to the X or Y axes just
like parallel milling (see page 323). Neighboring rows of the pattern can
be offset horizontally (see page 285) to better cover the part.
Rough pass stepover for plunge roughing

This attribute controls how far the holes in the same row are spaced. It is
specified as a percentage of the tool's diameter.
Restrictions of plunge roughing

1. The initial implementation of plunge roughing is limited to center
cutting tools. While you could use non-center cutting tools, nothing
is done to specifically accommodate the use of such tools.
2. There is no control of the retract distance. Retracts are performed
in the Z-direction.
3. There is no pecking. Each plunge is performed as a straight linear
move.
4. The uphill only and downhill only settings do not apply.
Four Axis Rotary

Overview of Rotary
Creates a toolpath by rotating the job around the index axis. This axis is
often the Z-axis in a millturn document and often the X-axis in a milling
document. Rotary milling creates toolpaths that cut surfaces without the
need for wrapping (see page 150). In a millturn document, the feature
must have the Cut with X-tool check box selected in the Feature
Location (see page 480) tab before you can create a rotary operation.
The angle of the X-tool must also be 0 .
There are three options, circular, line or spiral, for the cutting style found
on the Strategy page.
Circle Rotary Milling

In circular milling the job rotates with the tool at a fixed position,
effectively machining a circle. The tool then steps over the required
amount and machines the next circle.
Line Rotary Milling

Linear rotary milling causes the tool to traverse along the index axis in
straight lines, with the rotary axis only used at the end of each pass to
reposition the job.
Spiral Rotary Milling

A continuous spiral is cut along the length of the job when spiral milling
is used. To ensure a clean finish a full circle is cut at the two ends. Since
rotation is continuous, only Climb and Conventional milling are
available (so, you must have a rotary head that can make an unlimited
number of rotations).
See also Options for Rotary (see page 371)

Options for rotary milling
Strategy tab attributes
Y-Offset is a distance to avoid cutting on the center of the tool. This
view along the index axis shows how an offset tool approaches a
cylindrical shape.
Milling tab attributes

Angle Start and Angle End limits define the angular positions at
which machining will Start and End. It is only applicable to Circle or
Line milling. The Start field defines the angular position at which
machining is to start, and the End field defines the end angle. The
angular limits are measure in an anti-clockwise direction when viewed
along the positive Z axis. The area machined is between the start and end
angles.
To limit the cutting area along the index axis, set Index Start Coord
and Index End Coord. For a turn/mill document these parameters
control the extend of the toolpaths along the Z axis. For a 4-axis milling
document, they are values along the index axis.
Stepover controls the distance between circular cuts for circle milling or
the distance the tool travels in a full revolution along the index axis for
spiral milling.
A stepover angle is presented for the Line type. This angle controls the
distance between the linear cuts.
Overview of Corner Remachining

Remachining is used to automatically mill regions that were not cut by
previous operations. You provide the diameter of the previous tool that
was used to cut the part and FeatureCAM automatically determines the
uncut regions and applies a toolpath to them.
Corner remachining is used to clean up corners that occur between nontangential surfaces. Each corner edge is called a trace line. By using the
options on the strategy page, you may cut in various directions relative to
the trace lines.
Corner remachining is available in four different styles: along, across,
combo along and across and Multi pencil.
Along
This style of remachining creates a corner toolpath which follows the
trace lines.
Across
Across remachining creates corner toolpaths that zig-zag across the trace
lines.
Combo Along and Across

The combo corner toolpath creates a corner toolpath which produces
Across toolpaths on the steep areas of the trace line and Along
toolpaths on the shallow areas of the trace line.
Multi-pencil
Creates a corner toolpath which follows 'along' the trace lines. This is
basically a different ordering of the Along tool path.
The slope boundaries (see page 304) tab is available, so that a
horizontal-only corner operation is possible.
Detection Limit - only corners below the angle specified are found.
The tool used for the corner remachining must be smaller than the
Previous tool diameter.
Overview of remachining
previous operations. Remachining can be performed with or with a
parallel (see page 323), Z finish (see page 350) or 3D spiral toolpath (see
page 335). There is also a separate type of toolpath that is strictly for
remachining called corner remachining (see page 373).
How to create a remachining operation (see page 378)
Remachining settings (see page 378)
Limitations (see page 379)
page 314), Pencil milling (see page 365) and 3D leads/step tab (see page
310).
Roughing
Overview of planar remachining

previous operations. You provide the diameter of the previous tool that
was used to cut the part and FeatureCAM automatically determines the
uncut regions and applies a toolpath to them. In the example below, the
trough region is automatically calculated and the parallel toolpath is
limited to this region.
Remachining applies to parallel, z-level and 3D spiral . For parallel and Z

level remachining, the previous tool diameter is used to calculate the
uncut region and the toolpath is clipped to that region as shown in the
figures below.
For 3D spiral remachining, the outer boundary of the uncut region is

automatically calculated from the previous tool diameter. A toolpath is
then created that spirals inward from the boundary. 3D spiral remachining
creates a toolpath that is similar to corner remachining (see page 373), but
in some cases, the 3D spiral has fewer retracts.
Uses of remachining include:

1. Remove material that could not be reached with a larger tool for
both finishing and roughing.
2. Pre-relieve corners roughed with a larger tool for high speed
finishing with a smaller tool.
How to create a remachining operation
To create a remachining operation:
1. Create an X-parallel, Y-parallel milling operation a Z-level finish
(see page 350) or a 3D spiral (see page 335) operation using the
Features step. Alternatively, a corner remachining (see page 373)
operation may be created.
2. On the Strategy page (see page 283), click Remachining and
enter the Previous tool diameter. This diameter is used to
calculate the region for remachining.
3. Click Finish.
4. If the toolpaths do not look correct see Troubleshooting
remachining (see page 379) for hints.
Remachining settings
Remachining is controlled by the following Strategy tab settings:
Previous tool diameter

Overcut percent
Minimum rest material
Additional remachining information
Example of connection between minimum rest material and overcut
See also Remachining overview (see page 375).
Limitations of planar remachining
1. Parallel and Remachining operations use projection toolpath
techniques and have the same limitations (see page 325) as those
techniques.
2. Z-level finishing Remachining has the same limitations Z-level
finishing (see page 350).
Troubleshooting planar remachining
Remachining is not generating toolpaths. Examine your part and
make sure there are really regions where the previous tool diameter
would not fit. Remember that fillets are specified by their radii and
tools are specified by their diameters.
Calculating the regions takes too long. Use a stock boundary on the
Remachine tab to limit the search for remachining regions or
create a separate feature with only the surfaces of interest.
Regions that are exactly the same diameter as the previous tool are
being ignored. If there is a region that you would like to remachine
that the previous tool exactly fits into it is best to slightly overstate
the Previous tool diameter to ensure that the region is properly
remachined. For example if you have a pocket with a 0.25 radius
corner fillet, you should set the Previous tool diameter to 0.51
inches. The region is larger than necessary, but the remachining
boundaries are more predictable. Increasing the overcut percentage
can also help with this issue.
Swarf milling
Swarf machining
Swarf cutting calculates toolpaths which cut with the side of the tool and
only works on developable surfaces as the tool needs to be in contact with
the surface for the whole cutting depth.
For a tool to swarf cut, it has to be able to have contact with the surface at
all points along the cutting edge of the tool. For non-developable surface,
FeatureCAM always leaves material on or produce fragmented toolpaths
(rather than gouge). This means that you need to look at parts carefully
before trying to swarf cut them. It may be that rotating the part (cutting
from the side rather than the top of an aerofoil blade) may produce the
desired result. Swarf machining makes every attempt to machine the
selected surfaces but you may have to consider running more commands
including ones with different options for swarf milling to obtain the best
machining results.
It is possible to identify approximately whether a surface is developable
and ruled by shading and also displaying its wire frame geometry within
FeatureCAM. You can then orientate the view to be roughly down the
expected tool axis vector. If the surface top edge and the surface bottom
edge appear to be parallel at all points on both edges and no shaded
elements are visible then the surface is roughly developable and ruled.
Use the Surface Control tab to determine whether you swarf cut on the
inside,
or outside of the surface.
On the Milling - tab you can set :
Axial Offset - offsets the lowest position of the toolpath along the
tool axis.
Leave Allowance - specifies the amount of stock material to

leave after the cut. In PowerMILL this attribute corresponds to
Radial Offset.
Multiple Cuts - allows multiple toolpaths with a z-increment

setting.
Restrictions of swarf milling

In a non-indexed milling document, swarf machining is limited to vertical
toolaxis.
The orientation of the surfaces is quite important in swarf machining.
Toolpaths are generated on the outer side of surfaces, i.e., on the side of
the positive surface normal. Stand-alone surfaces are not auto flipped
(because FeatureCAM cannot compute which side is desired), whereas
faces in a solid should have outward pointing normals. In most cases of
swarf milling stand-alone surfaces, the machining side must be specified
manually.
Swarf machining makes every attempt to machine the part surfaces, even
though the part surfaces may not be entirely ruled or developable. This
may lead to wild toolpaths - paths that retract a lot and cut in unintended
places. For this reason, it is recommended that you include only the ruled
surfaces in the feature's part surfaces. Other, non-developable surfaces
may be included as check surfaces.
Swarf milling works best with ruled surfaces where the parameterization
of the surfaces is well-behaved.
Although this appears to be a ruled, developable surface, the isolines are

curved. This may lead to strange looking toolpaths, because FeatureCAM
tries very hard to keep the entire side of the tool in contact with the
surface, in other words, the tool axis may vary radically. The
parameterization below produces toolpaths that are closer to the expected
results:
Troubleshooting Swarf
Swarf is a very powerful technique. Unfortunately, in a five-axis
simultaneous situation, there are, perhaps, many different correct answers
to the swarf problem. FeatureCAM attempts to pick an intelligent answer,
but sometimes picks a different answer than what you had in mind. For
instance, a single plane can be swarfed in the U direction or the V
direction. In the picture below, the feature consists of the two magenta
surfaces and the red surface. The swarf correctly cuts the desired edge of
the magenta surfaces, and then (mathematically, correctly) cuts an
undesired edge of the red surface. There are several things you can try :
Break the feature into many features (at the limit, you might have
one swarf feature per surface). In this case, you may end up with
three features.
In a turnmill document, you may sometimes get the desired answer

by choosing to cut the feature with an X tool. This is the case for a
single planar surface that cuts the U direction instead of the V
direction.
Construct a ruled surface and use it as the part surface(s).
Additional surfaces can sometimes provide FeatureCAM with a

hint as to what is desired. In this picture, the previous hint was also
used (the green ruled surface replaced the three faces of the solid).
Eliminate any fillets in the model, and use a ball-end of the

appropriate size.
Decrease or increase the tolerance. Since the surface(s) in between

its edge curves may not be perfectly ruled, swarf is very dependent
on the tolerance setting.
Frequently, the tool is upside down of the desired toolpath. Open
the Strategy tab, and select Reverse tool axis.
In cases like the above, the floor of the swarf must not be
touched. This is very difficult to do especially with a flat-end
tool. The floor may be included as a check surface, but then most
likely, you will not get the complete toolpath. In this situation, you
can get close by using multiple cuts and a fairly small Zincrement. You may also use a slightly negative check allowance.
Increase the Degouge tolerance. The regular tolerance controls
the accuracy of the tessellation. That is, curved surfaces are first
flattened out to triangles, and it's the triangles that are machined.
The Degouge tolerance, on the other hand, tells FeatureCAM
that, in order to get a better, smoother toolpath, it's ok to gouge the
triangles by up to that much.
5-Axis Trim
This technique allows you to profile (or trim) around the outside of a set
of surfaces. This technique only works on surface models (not triangle
models). On the strategy page of the trim operation, you may choose
whether to profile on the Inside Edge of the surface set:
or the Outside Edge of the surface set:
The trim operation only computes toolpaths for unconnected edges

in the feature's surface set. For instance, if all six faces of a cube
are part surfaces in a shell milling feature, the trim operation does
not generate any toolpaths (since all edges are connected to other
edges in the feature). That is, to trim the top face of a cube, select
only the top face for the feature, i.e., the feature should consist of
one part surface.
3D machining attributes
3D Milling tab and Manufacturing attributes
When you click the Milling tab for a feature's operation, you see the
attributes available for 3D milling. These attributes control how the
manufacturing takes place. You can override any attribute you wish for
the kind of manufacturing you desire. The check boxes (see page 388)
and attributes (see page 399) are discussed separately.
Switch settings
Check boxes
Not all check boxes are available for all operation types.
Bi-directional - sets the operation to mill in each direction. You can

combine this setting with Climb Mill to force the first pass to be a climb
mill cut.
Climb Mill - sets the operation to use climb milling. When set in
conjunction with Bi-directional milling, it ensures that the first pass will
climb mill.
Arc/line approx. (see page 391)
Scallop height checkbox (see page 391)
Flat surface support (see page 341)
Reorder (see page 348)
Corner Correction (see page 357)
Spiral (see page 358)
Trochoidal Cut (see page 347)
Fan at ends - for swarf operation
Multiple cuts - for swarf operation
Improved - for plunge operation. Uses extra calculations for high
accuracy.
Corner Correction - for Z-level finish operation
Add perpendicular pass
Add Perpendicular Pass - Defines a second parallel pass
perpendicular to the first one.
Shallow Angle - allows you to create a perpendicular pass only where
necessary - rather than over the whole model.
An example: Add Perpendicular Pass deselected.
Perpendicular Pass, Shallow Angle 0

Add Perpendicular Pass selected, and Angle = 0, adds a Y-parallel
over the entire part.
Add Perpendicular Pass - selected, Angle = 5
One raster pass over the entire model. A second pass, perpendicular to the
first, that only machines the areas of the model that are steeper than the
Angle.
Arc/line approx.
Select this check box to create an arc line approximation for toolpaths
that are contained in the XY, YZ and XZ planes. This allows 3D
programs to be smaller and to result in smoother surface finishes for
certain types of parts.
Arc/line approximation applies to the following 3D techniques
X-parallel and Y-parallel roughing or finishing with Parallel
Angle set to 0
Z-level roughing and finishing
Isoline finishing where the toolpaths line in a plane
Scallop height checkbox
This check-box is available on the Milling page of certain finish
operations. For projection milling methods, it toggles the way that you
specify how far the tool moves over between passes. With Scallop
height unchecked, you specify the stepover (see page 418). With it
checked, you specify the scallop height (see page 392).
For Z-level finish operations it toggles how you specify how the tools
moves down in Z. With Scallop height unchecked, you specify the Zincrement (see page 424). With it checked, you specify the scallop height
(see page 392).
With scallop height checked, spacing of the toolpaths are calculated along
the surfaces to provide a uniform surface finish. These figures show
surfaces cut without using scallop height:
This figure shows the same surfaces cut with scallop height:
Scallop height
Absolute scallop height between passes for isoline milling, projection
milling finishing passes and Z-level finishing. This distance is measured
along the surface and represents the maximum cusp height between
neighboring passes as shown here.
This attribute only applies if the scallop height checkbox (see page 391)
is selected.
Flat surface support
With Flat surface support as Off, the Z levels are calculated at a constant
Z increment. With Flat surface support as Level or Area, extra levels are
inserted above each flat surface in the model. This ensures that the finish
allowance is accurately left on all flat surfaces.
There are three options available for flat surface support:
Area - machines flat areas only (rather than the whole level).
The images below illustrate the differences in the slicing. The second
picture shows the slices without Flat surface support. The bottom picture
shows the additional slices that are added with the level option invoked.
Here is another example.
Looking at a different angle you can see that three complete levels are
machined.
Area- machines flat areas only (rather than the whole level).
Looking at a different angle you can see that only the flat areas are
machined in the first level.
Reorder
Spiral Z level
The standard Z level finishing toolpaths creates paths with a constant Z
height as shown below. The tool either retracts or feeds along the surface
between Z levels.
With the Spiral milling attribute checked, the toolpaths change into a
continuous spiral. The toolpaths no longer have a constant Z height.
Trochoidal Cut - Z rough

Checking the Trochoidal cut check box essentially turns on the ability
to detect and avoid tool overload. As the tool gets towards an overload
situation then FeatureCAM automatically puts in a trochoidal path to take
away the overload. This happens in corners, in narrow channels, slots and
the first cut of an offset toolpath which is, in effect, a narrow channel.
Since some tool overload may be acceptable, it can be controlled by the
Avoid tool overload attribute. This is the allowable overload percentage
of the existing stepover. So, if you use a stepover of 10 mm and an
allowable overload of 10%, trochoidal moves don't start appearing until
an overload condition of 10% (or 1 mm) is exceeded.
Looking in detail at a typical toolpath:
Looking in at a corner in even more detail you can see the trochoidal
paths more easily:
Attributes
3D attributes
Attributes specific to 3D milling are described here. For information on
other attributes shared with 2.5D milling, refer to Manufacturing attribute
descriptions.
Add perp. pass (see page 325)
Angular start and end (see page 415)
Arc/line approx. (see page 391)

Axial offset (see page 401)
Axial tolerance (see page 401)
Center point (see page 339)
Check allowance (see page 402)
Corner radius (see page 346)
Corner correction (see page 357)
Cut direction (see page 404)
Degouge tolerance (see page 405)
Fan at end (see page 411)
Leave allowance (see page 412)
Minimum fanning (see page 413)
Minimum Z increment (see page 413)
Next row stepover (see page 414)
Parallel angle (see page 324)
Radial offset (see page 414)
Radius start and end (see page 415)
Reorder (see page 348)
Stepover (see page 418)
Scallop height (see page 392)
Start points (see page 417)
Stepover rapid distance (see page 418)
Stock curve (3D) (see page 419)
Stock curve overcut % (3D) (see page 332)
Surface join tolerance (see page 421)
Tolerance (see page 421)
Toolpath start and end
Toolpath corner % (see page 346)
Up/down axis smoothing (see page 422)
Upper offset (see page 424)
Z end (see page 424)
Z increment
Z start
Arc/line approx.
Select this check box to create an arc line approximation for toolpaths
that are contained in the XY, YZ and XZ planes. This allows 3D
programs to be smaller and to result in smoother surface finishes for
certain types of parts.
Arc/line approximation applies to the following 3D techniques
X-parallel and Y-parallel roughing or finishing with Parallel
Angle set to 0
Z-level roughing and finishing
Isoline finishing where the toolpaths line in a plane
Axial offset
For swarf finishing, this attribute offsets the lowest position of the
toolpath along the tool axis. Positive numbers offset the toolpath towards
the tool holder, negative numbers away.
A swarf with a positive offset:
Axial tolerance
This is only relevant to swarf finishing.
For a relatively rare number of geometries, the tool axis can waver
slightly as it positions accurately on the surfaces to be machined. This can
be due to small but significant changes in the geometry as the tool moves
from one position to another. To allow a degree of latitude for the
command, this tolerance can be set to a value larger than the machining
tolerance to allow the tool axis to be stabilized as it moves across this
geometrically varying region. As a result excess material may be left on
the surface involved but the load on the tool may be reduced.
No axial tolerance set:
Axial tolerance set to 0.5 (mm):
Check allowance
Check allowance sets the distance that the tools will approach, but not
pass closer than for a check surface. If Check allowance is set to a
specific value, that value is used for both rough and finish passes. If it is
left blank then if behaves differently for roughing and finishing. If left
blank for a roughing pass then check allowance is set to finish allowance
+ leave allowance. If left blank for a finishing pass then check allowance
is set to leave allowance.
More information about check surfaces (see page 277).

Center point
The Center point attribute applies to Radial toolpaths (see page 339).
This point is projected down onto the surface to become the center of the
radial pattern.
Corner correction
Corner correction defines the type of corner correction that you want to
apply to all internal corners of a Z-level finish toolpath. The types are
available from a pull-down list and three options are available:
None - no sharpening or arc fitting is carried out.
Arc Fitted - arcs are created and rounded in all internal corners.
The yellow toolpath shows the Arc Fitted toolpath and the green
toolpath shows the Normal toolpath.
Arc fitting is of particular importance when high speed machining, as it
Corner Radius %
This defines the radius used if you select a Type of Arc Fitted. The
radius is defined as a proportion of the tool diameter. For a Z finish pass
the default value is 5%. So, if you have a tool of diameter 10mm (radius
5mm) then the arc radius is 0.5mm. The Corner Radius% can have a
value between 0 and 100.
Corner radius %
Slices in Z-level (both rough and finish) can be arc fitted to avoid sharp
changes in direction. For Z roughing, only the toolpath closest to the part
is rounded. Corner radius % defines the radius that is inserted in to the
toolpaths.
The radius of internal corners is defined as a proportion of the tool
diameter. The default value is 5% for a finish pass and 0% for a roughing
pass. So if you have a tool of diameter 10 mm then the arc radius is 0.5
mm. The Corner radius % can have a value between 0 and 100.
Arc fitting is of particular importance when high speed machining as it
Cut direction
This dialog provides controls for the direction the tool will cut. Different
options are available for certain toolpath techniques.
Style Options
Unidirectional - Toolpaths will only go in one direction. For Zlevel toolpaths, the conventional/climb mill parameters control the
direction. For other toolpaths, the decreasing/increasing controls
the direction.
Bidirectional - If active, the decreasing or increasing parameters
control the initial cuts direction.
Uphill only - Breaks toolpaths up into segments that increase in Z.

If this option is checked all direction parameters are dimmed since
Up hill only fully determines the cut direction.
Downhill only - Breaks toolpaths up into segments that decrease
in Z. If this option is checked all direction parameters are dimmed
since Down-hill only fully determines the cut direction.
Direction
Conventional - Only applies to Z level with unidirectional set.
The tool rotates against the direction of the cut.
Climb mill - Only applies to Z level with unidirectional. If Climb
mill is set the tool will rotate in the direction of the cut.
Decreasing - Forces the cut to decrease in its principal direction.
For X-parallel operations, the tool will start at the maximum X
value and cut in the negative direction.
Increasing - Forces the cut to increase in its principal direction.
For X-parallel operations, the tool will start at the minimum X
value (or Y value for Y-parallel) and cut in the positive direction.
If unidirectional is set, the Increase and Decrease options only affects
the direction of the initial cut. For spiral milling use
Decrease/Increase to toggle the clockwise/counter-clockwise nature
of the paths. For pencil milling Decreasing/Increasing options toggle
the direction of cut. For radial milling, use Decrease/Increase to
toggle the clock-wise and counter-clockwise ordering of each radial pass
around the center. For parallel milling set Parallel angle (see page 324) to
180 to cut from the opposite end of the part.
Start corner
Choose the starting point for the parallel pass from among lower left,
lower right, upper left, lower right. These terms are relative to a top
view of the part.
Degouge tolerance
For swarf finishing, this attribute is the maximum distance (in addition to
radial offset) that is used to push the tool away from the surfaces to avoid
gouges. It defines the upper acceptable bound for this intermediate form
of gouge avoidance. If gouges greater than this value are detected then the
tool will be lifted axially to avoid the gouge.
This value can therefore be used to control the location and amount of
material left on non-swarfable surfaces. For example, if material on a
surface can mostly be machined by swarf machining, but there is a region
where 3 mm of material could be left, then you can either:
choose a Radial offset of 3 mm to leave 3 mm of material on the
whole of the surface; or
set a Radial offset of 0 mm and a Degouge tolerance of 3
mm. In this case, the surface will be completely machined where
possible, but some material of up to 3 mm will be left on a part of
the surface.
Degouge tolerance remains in effect even if Gouge check is
not selected.
Edges for surface milling
This page gives you options to set how the toolpaths are generated near
surface edges.
Cut to bottom: Roll over top edge and cut to bottom of
stock/part limits
Does not set any boundary. In this case, FeatureCAM will only use the
boundary specified by the curve options in the Stock tab (see page 288).
Cut top edge: Just roll over the top edge
Sets a pocket-like curve boundary to the silhouette of the part offset by a
tool radius. The tool will roll over the edges by a tool radius as shown
below. In PowerMILL this is known as a silhouette boundary. Edge
boundary all is using a silhouette boundary of the part, but it uses the top
(highest) Z values where the silhouettes are at a vertical surface.
Don't roll over the edge at all

Sets a pocket-like curve boundary to the silhouette of the part. The tool
will contact the surface boundary as shown in the Z-level and parallel
toolpaths below. In PowerMILL this is known as a contact point
boundary. This will prevent any cutting of sharp corners at the external
edges of the part. If the part has a vertical surface at the outside of the part
AND has a sharp corner at the top of the vertical surface, it will prevent
cutting of the vertical surface since it is coincident with the sharp corner
at the top.
Advanced options on the part boundary can be set by clicking the Adva
(see page 408)nced button.
Cut to bottom of vertical walls check-box.
Cut selected surfaces: Only cut selected part surfaces

FeatureCAM will only machine the selected surfaces and will not cut any
of the neighboring or unselected surfaces. If there are no neighboring
surfaces, the tool will roll over the edges by a tool radius.
Cut to bottom of vertical walls check box.
Advanced part boundary options
This page gives you advanced settings for the Don't roll over the edge
at all option.
There are two types of curves used by the Don't roll option. One type is
a curve on the surfaces of the feature. This is called a part boundary and
the points are the contact points where the tool will stop at the edge of the
feature. These curves do not depend on the tool. The second type of curve
is a tool center (offset) curve. A tool center curve is a part boundary curve
that has been offset by the tool edge radius. The Show combined
boundary button on the Stock page gives a preview of all the part
boundary and tool center curves.
Boundary tolerance: controls the accuracy of the part boundaries. The
default value is automatically computed. Smaller values give better
results but take longer to compute. To reset to the default value, set the
value to 0, click OK and Apply on the Edge page.
Use separate wall tolerance: The part boundaries use a tolerance to
check for vertical surfaces (walls). By default it uses the boundary
tolerance (above). Selecting this option lets you enter a separate tolerance
value for vertical walls. You may need to use this setting if you use the
Cut to bottom of vertical walls option on the Edges page. If you
preview the part boundaries and they are not consistently at the bottom of
vertical walls, select Use separate wall tolerance and enter a larger
tolerance than the boundary tolerance above.
Edge tolerance: specifies the tolerance between the part boundaries
and the surfaces. The default value of 0 means this tolerance is set
automatically based on the boundary tolerance above. If the tool center
curve is rolling over the edges of the feature you may need to set a larger
edge tolerance (relative to the boundary tolerance).
Milling tolerance: Note that the tolerance setting on the Milling tab of
the surface milling operation is used for the tolerance of the tool center
curves. You may need to use a smaller milling tolerance to get smooth
tool center curves.
Advanced part boundary examples
The Show combined boundary preview shows both the part
boundary (blue) and the tool center (red) curves;
In the following example, the part boundary (red) is smooth, but the tool
offset (blue) is rough. Decrease the Milling tolerance for a smoother
tool offset:
This shows a smoother tool offset (blue) with decreased Milling

tolerance:
In the following example, the part boundary (red) is not consistent along a
vertical wall. First try reducing the Boundary tolerance. If that does
not solve the problem, try using a separate (larger) Wall tolerance.
By using a reduced Boundary tolerance, a smoother part boundary is

produced along the top of a vertical wall:
Using the Rollover option, the tool offset (red) (and toolpath) rolls over
the part boundary (blue):
Using an Edge tolerance larger than the Boundary tolerance

eliminates the rollover. Reducing the Boundary tolerance may also
eliminate the rollover without setting the Edge tolerance:
Fan at ends
This is relevant to swarf finishing.
As the toolpath moves from one surface to another there can be a change
in ruling direction. This is called 'fanning'. When Fan at end on
planes is selected, fanning will happen only in the end region of a plane.
When Fan at ends is not selected, fanning is allowed to happen
anywhere 'across' the plane.
In the example, when Fan at ends is selected, the tool axis will change
primarily in regions labelled
constant in the region labelled
in region
and
. The tool axis will be relatively
. Conversely, the tool axis may change
if Fan at ends is not selected.
First feed override %

The initial pass of many 3D toolpaths are slotting cuts or cuts with
increased tool load. This attribute slows the feed rate for these initial pass
as a percentage. This percentage is applied to the operation's feed rate to
determine the feed rate for the initial pass. This attribute applies to all 3D
toolpaths except Z level roughing.
See also Feed optimization (see page 130)
Leave allowance
The amount of material to leave after a 3D finish pass. If unset leave
allowance defaults to 0. This number can be set to a negative number (up
to - tool radius) to allow for shrinkage or spark gaps. If set to a negative
number, the part will be machined into the part surfaces by the negative
amount specified.
Minimum fanning
In a swarf toolpath, as the toolpath moves from one surface to another
there can be a change in the ruling direction. Since the tool aligns itself
with the ruling direction, you have to specify the distance over which the
tool can change from one ruling direction to the next. The fanning
distance is measured as the smallest movement on either surface edge (or
the distance the closest part of the tool is to the opposite part of the
surface before fanning starts). The actual fanning distance may be larger
than the Minimum fanning value specified, to prevent the toolpath
from gouging.
and
: ruling direction
: fanning distance
Min Z increment
Is used with scallop-height Z-level finish. There is a scallop height
attribute which specifies the stepdown such that the height of the material
left between Z heights does not exceed the scallop height. However, if the
calculated value is smaller than the Min. Z increment, it is set to Min.
Z increment.
Next row stepover

Next row stepover controls the distance between rows of a plunge
roughing operation.
Number of first feed paths

If you set the First feed override % (see page 412) on a parallel operation,
the Number of first feed paths attribute controls the number of passes to
apply this feed rate to.
See also Feed optimization (see page 130)
Parallel angle
Parallel angle is available only in X and Y parallel roughing and sets
what angle the roughing passes occur in reference to the X or Y axis. This
value can be anywhere from -360 to 360 degrees. A positive value rotates
counter-clockwise from the Z axis, and a negative value rotates clockwise
from the axis. Examples of using Parallel angle are:
1. Setting the angle to 90 on an X-parallel operation causes it to
effectively become a Y-parallel operation.
2. Setting the angle to 180 causes the toolpaths to be cut from the
opposite side of the part. For example, an X-parallel operation with
the angle set to 0 starts at the minimum Y coordinate. With the
angle set to 180, the toolpaths start at the maximum Y coordinate.
Radial offset
Radial offset is applicable to swarf and trim.
The distance which the toolpath is offset in a direction perpendicular to

the tool axis. This defaults to zero.
: Trim with no radial offset

: Trim with 5 mm offset
Radius start and end
Is only available for the radial operation. These control the dimensions of
the pattern along with angle start and end. This is illustrated in the
diagram below:
Start Angle and End Angle - determine over what portion of a full
circle the picture is generated, and whether the tool travels in a clockwise
or anticlockwise direction:
Start Angle > End Angle - tool travels clockwise.
End Angle > Start Angle - tool travels anticlockwise.
These two alternatives are illustrated in the diagram below:
If you want to machine an area counter-clockwise starting at 350 and

ending at 10 you need to think about the values you enter. If you enter a
Start Angle of 350 and an End Angle of 10 then FeatureCAM will
travel clockwise and machine the opposite of what you want. So you must
enter a Start Angle of 350 and an End Angle of 370 to get the
desired result.
Reorder
Scallop height
Absolute scallop height between passes for isoline milling, projection
milling finishing passes and Z-level finishing. This distance is measured
along the surface and represents the maximum cusp height between
neighboring passes as shown here.
This attribute only applies if the scallop height checkbox (see page 391)
is selected.
Start point(s)
The Start point(s) attribute controls the initial points for Z-level finish
(see page 350) toolpaths.
It only works for toolpaths that are closed loops. Start point(s) can
either be a single point or a curve made from a connected line. The
closest point on the toolpath loop relative to the start point is found
and that point is used as the starting point for the loop.
In this figure a spherical surface feature is viewed from the top.
The blue start point controls the location of the start of each toolpath.
See also 3D leads/step tab (see page 310) for information on transitions
between toolpaths.
Stepover
Planar stepover distance for finishing with projection techniques. This is
the distance between toolpath center lines as shown here. This distance is
measured in the XY plane and then the toolpaths are projected onto the
surfaces of your feature. This attribute only applies if the scallop height
check box (see page 391) is deselected.
Stepover rapid distance
Stepover retract distance is used just to determine when to feed vs.
rapid to the next toolpath.
This only applies to stepovers between toolpaths.
Use Retract gap distance to prevent retracting over a gap in a
toolpath. Stepover retract distance is a 3D distance. If not explicitly
set, the stepover threshold is the tool diameter plus twice the allowance.
For a rough operation, allowance in this context is the Finish allowance.
For finish operation it is Leave allowance.
The practical use of this attribute is to prevent stepovers from climbing up

or down a big wall. This image shows toolpaths before increasing
Stepover retract distance.
This figure shows how the tool stays on the metal with an increase in
Stepover retract distance.
Stock curve (3D)

Stock curve applies only to Z level rough operations. It applies to features
that are designated as bosses or pockets on the Strategy page. For boss
features, the stock curve sets the outer boundary of the boss feature. For
pockets, it creates the toolpaths in a subregion.
Stock curves are selected in the using the select curve dialog. See
Methods of selecting curves in the select curve dialog box for further
information.
The figure on the left shows a feature cut without a stock curve. Notice
that the toolpaths extend to the stock boundaries. In the figure on the left
a circular stock curve is used.
Stock overcut % (3D)

Stock curve overcut % applies to three types of surface milling
features, spiral toolpaths designated as a boss on the stock page, features
cut with projection milling technique that do not have an explicit
boundary curve and select Z level rough passes. In the boss case this
attribute applies only to how the toolpaths behave around the stock
boundary. For other 3D surface milling features use the cut allowance
feature described on the stock page (see page 288). The stock overcut
% only applies if Use stock dimensions is selected on the feature's
Stock tab (see page 288).
Stock overcut specifies what percentage of the tool approaches or
passes beyond the stock boundary.
It can have a value between -100 and 100 with the following meanings:
0 puts the centerline of the tool on the stock curve.
100 overcuts the region by a tool radius.
-100 stops one tool radius short of the stock curve.
For Z level rough, this attribute applies to all features except pocket
features without stock curves. This attribute controls the outer extend of
boss features and the amount that pocket feature cuts beyond its
boundary. The default value is 100% which puts the edge of the tool on
the boundary. A number greater than 100 extends the toolpaths beyond
the boundary. A number less than 100 essentially offsets the outer
boundary and clips the toolpaths against this closer boundary.
Surface join tolerance
This is relevant to swarf and trim.
This value may be used to disassociate the machining tolerance from the
tolerance used to define what is a gap between surfaces. Occasionally a
machining tolerance will be chosen that is smaller than the gap between
surfaces. When this occurs, two segments of toolpath will be created. To
ensure one continuous toolpath across a gap, you may use a larger surface
joining tolerance.
Tolerance (3D)
Tolerance sets how close the milling will be to the mathematically ideal
surface. This does not guarantee that your feature is machined to this
tolerance in all locations if the tool you select is incapable of cutting
within that tolerance in constrained areas. If your part shows a faceted
appearance, set the tolerance to a lower value.
Set this attribute separately for roughing and finishing passes.
Toolpath corner %
Effective only during Z-level rough, a non-zero Toolpath corner %
replaces sharp corners with rounded corners. Defines the maximum
deviation from the sharp corner. The maximum this can be set to is 40%
of stepover. This means that if you have a 10mm stepover the maximum
deviation from the sharp to the rounded corner is 4mm.
Using the Toolpath Corner % produces a toolpath with fewer small

arcs which makes the toolpath more suitable for high speed machining.
The original profile has the same number of points in it, it is just the
offset passes that have a reduction in the number of points.
Up/down axis smoothing

This is relevant to swarf finishing.
Allows the command to smooth out regions of toolpath within the

supplied tolerance. This is a percentage of the tool diameter.
Occasionally, the swarf toolpath must move up and down in order to
avoid gouging. The default is 15%:
A larger smoothing tolerance will reduce this 'spike' in the toolpath, but
will affect more of the toolpath near the area:
Upper offset
With a multiple cut, swarf operation, the Upper offset attribute is used
to start the toolpath above the upper edge of the part. This example shows
an upper offset of 10 mm:
: bottom edge
Z end
Z end sets the distance along the Z axis below which the operation will
not mill. You may want to use Z end on an earlier operation then follow
it with an operation using the Z start attribute so you control the
toolpaths efficiently.
Z increment (3D)
Z increment sets the distance the tool moves down in the Z axis with
each pass.
Default 3D attributes
Surface mill attributes
Click the attribute for further explanation:
Tolerance (see "Tolerance (default attribute)" on page 425)
Parallel angle (see "Parallel angle (default attribute)" on page 425)
Tool diameter (on page 425)
Tool end radius (on page 425)
Scallop height (see "Scallop height (default attribute)" on page 425)
Check allowance (see "Check allowance (default attribute)" on page 425)
Slope limitation angles (see page 304)
Finish allowance (see page 425)
Scallop height stepovers (see page 426)

Tolerance (default attribute)
Sets the default tolerance used to mill all surface milling features unless
you override the value on a given feature. It can be overridden on
individual features as needed.
Parallel angle (default attribute)
Sets the angle used by default for X parallel, or Y parallel milling.
Defaults to 0.0. You can override it on individual features as needed.
Tool diameter
Tool diameter sets the default tool diameter for 3D surface milling
features.
Tool end radius
Tool end radius is set with radio buttons.
Ball end sets the default tool to a ball end tool with a radius equal to half
that of the tool diameter setting.
Flat sets the default tool to a flat endmill.
You can override it on individual features as needed.
Scallop height (default attribute)
Sets the default scallop height allowed for surface milling features. You
can override it on individual features.
Check allowance (default attribute)
Sets the check allowance used by default in surface milling features. By
default, it has no value associated with it. You can override it on
individual features as needed.
Finish allowance
Finish allowance is the amount of material left after a 3D roughing
pass.
Scallop height stepovers

Select this attribute to set the default stepover type for projection milling
finishing and Z-level finishing to be specified by scallop height instead of
a linear stepover distance.
See the Scallop height checkbox (see page 391) for more information.
Troubleshooting 3D toolpaths
Troubleshooting Z level roughing (see page 350)
Troubleshooting isoline milling (see page 360)
Troubleshooting projection milling methods (see page 325)
Troubleshooting Z level finishing (see page 356)
Extending
FeatureCAM
FeatureCAM add-ins
FeatureCAM can be extended using its application programming
interface (API). Detailed information on this interface is available in the
FeatureCAM API help file, available under the FeatureCAM Help menu.
But a few topics are available in the online help:
Loading the example add-ins that were installed with FeatureCAM (see
page 428)
Running the API examples provided with FeatureCAM (see page 429)
Installing new add-ins (see page 427)
Creating toolbar buttons for macros (see page 430)
Assigning a macro to a toolbar button (see page 431)
User-defined features (UDFs)
Installing new add-ins

In order to install an add-in that you've downloaded from the
FeatureCAM website, www.support/addins or that you wrote yourself,
use the following procedure.
1. Select Options > Add-ins from the menu.
2. If you see your file listed, select the check-box next to the file
name.
Extending FeatureCAM 427
3. If you don't see your file listed, click the

button. This will allow
you to browse your hard drive in order to find the add-in that you
downloaded. If you do not remember where you put the file, then
download it again paying special attention to where you are putting
the file so that you can find it later when you visit the Add-ins
dialog.
4. Click OK.
Loading the example add-ins that were

installed with FeatureCAM
The first step to understanding FeatureCAM's programming ability is to
successfully use the programming examples that ship with
FeatureCAM. Make sure that you install the latest version of
FeatureCAM. You'll get a folder called Addins in your <C:\Program
Files\FeatureCAM> folder.
Choose the Add-Ins menu item in the Options menu. This brings up the
Add-ins dialog that lists the add-ins available to you.
As an example let's load MakeStockGeometry.bas and run it:
1. Select the check box next to MakeStockGeometry.bas in order
to load it into FeatureCAM.
2. Click OK on this dialog to close it. Then look around your screen
for a new floating toolbar that looks like
created when the add-in was loaded.
. This button was
3. Press the new button to create lines that matches the outline of your
stock.
4. You are done. You've loaded and used an add-in.
Not all add-ins create buttons. See Creating Toolbar Buttons for
Macros (see page 430) for information on creating buttons.
428 Extending FeatureCAM
Running the API examples provided

with FeatureCAM
The best way to get started with the FeatureCAM API is to just try and
run some of the simple examples that others have written for you. This
will give you an easy introduction to the FeatureCAM programming
environment. The following sections will show you how to load and run
the programming examples that ship with FeatureCAM on the CD-ROM.
Example add-ins installed with FeatureCAM
The following examples are installed along with FeatureCAM in the addins folder (in Program Files\FeatureCAM\addins). You will find
additional documentation about each example if you open the .bas file
using Notepad.
CenterIndexedStock.bas - center the stock about the stock axis
for purpose of indexing.
HoleRecog.bas - event handlers for hole recognition that support
colored surfaces.
MakeStockGeometry.bas - make geometry (lines) that
coincide with the stock. Pictured above.
MoveSetupToUL.bas - move the setup to the upper left corner
of the stock (against the hard jaw).
SelectHeight.bas - select surfaces and faces at a height that
matches a selected object.
NewDocumentLayers.bas - automate shop practice by
initializing a new document with particular layers.
MakeHexagon.bas - make lines that form a hexagon around the
selected arc or circle.
Creating toolbar buttons for macros
Neither the SelectHeight.bas nor HoleRecog.bas create buttons for

you. It is the responsibility of the add-in author to create these buttons,
but it is not mandatory. For the SelectHeight add-in, the add-in author
declined to create a toolbar button for whatever reason. So in order to use
SelectHeight.bas, you need to create a button yourself. Here's how:
1. First, make sure that SelectHeight.bas is loaded by using the
Add-ins dialog.
2. Click OK on the Add-ins dialog to close it.
3. Make a new toolbar using the Toolbars tab of the Customize
Toolbars dialog.
4. Make a new toolbar button using the Commands tab of the
Customize Toolbars dialog.
430 Extending FeatureCAM
Assigning a macro to a toolbar button
The first time you click your new button, it will ask you for the name of
the macro to run. Enter SelectHeight and click OK.
You may return to this dialog at any time to reassign any custom toolbar
button (the hammer) to a different macro by right-clicking on the button
after it has been placed into a toolbar.
Now, whenever you click the toolbar button, the SelectHeight macro will
be executed. If a message comes up saying that the macro doesn't exist,
then either you spelled it incorrectly, or you failed to load the
SelectHeight.bas add-in.
Even if you loaded the add-in and spelled the macro name correctly,
clicking the button will probably cause some type of error that comes
from the SelectHeight macro itself. This is because you don't know how
to use the SelectHeight macro yet. What does the SelectHeight macro
do? You can open the macro in the Sax Basic IDE to find out.
Feature Recognition
(RECOG or 3D)
Feature recognition is the process of creating manufacturing features
directly from solid or surface models. Feature recognition requires the
FeatureRECOGNITION option (formerly SolidM) for FeatureMILL2.5D.
It is included in FeatureMILL3D.
Overview of feature recognition (see page 433)
Types of features that can be recognized (see page 434)
Methods of feature recognition (see page 442)
How to recognize features from surfaces (see page 449)
How to recognize features from surfaces using curve chaining (see page
452)
How to recognize all holes in a setup (see page 451)
How to recognize pockets and bosses from top or bottom surfaces (see
page 453)
How to recognize drafted features (see page 454)
Hole recognition (see page 436)
Slot recognition (see page 438)
Boss recognition (see page 439)
Pocket recognition (see page 441)
Side recognition (see page 441)
432 Feature Recognition (RECOG or 3D)
Overview of feature recognition

When you create models from scratch in FeatureCAM, you use the set of
manufacturing features that the program provides. While this process
results in a 3D representation of the feature on the screen, the type of
feature and dimensional information you enter provides information that
is crucial to the efficient manufacture of the part. For example, knowing
that a hole is a counter bored hole, aids in deciding on the appropriate
operations for manufacturing the feature. The dimensions are also helpful
in determining the dimensions of the resulting operations.
With the popularity of solid modeling, more and more surface/solid
models are being created that contain 2.5D features (like holes, pockets,
or slots). While they look the same as a FeatureCAM feature-based
model, they are actually only surfaces.
The cylindrical voids are only surfaces, not holes. What looks like a
FeatureCAM pocket feature is actually only a collection of surfaces.
While it has been possible to extract edges from the solid model and join
them into curves for features, this process can be time consuming.
Feature Recognition (RECOG or 3D) 433
FeatureCAM now provides the ability to create features directly from

solid (*.sat or *.xmt files) or surface models (*.iges files). With this
process you classify surfaces in the model as a FeatureCAM
manufacturing feature.
The features that you recognize from a solid model are the same as any
that you create from scratch. The same feature-based automation applies
so that you can quickly and easily create part programs.
Types of features that can be

recognized
FeatureCAM can recognize the following feature types:
Holes (see page 436)
Slots (see page 438)
Bosses (see page 439)
Pockets (see page 441)
Sides (see page 441)
Only these feature types will activate the Extract feature from solid
model button in the Feature wizard.
This set of features should cover the features contained in most parts. If
you need to extract other features from a solid or surface model, you
should use the curve from surface tools and then create your features
from this geometry.
Feature recognition examples
Hole recognition
Four types of holes can be recognized.
Hole type Surfaces recognized from
Plain
Cylindrical surfaces with an optional 45

degree chamfer surface.
Counter
bore
Two cylinders (larger diameter on top) with

an optional 45 degree chamfer on the top.
Counter
sink
A cylinder with a cone on top that is not 45

degrees.
Counter
drill
A cylinder on top of a cone, on top of another

cylindrical surface. A 45 degree chamfer is
optional on top.
Example hole surfaces are shown below.
Note that the cylinders can be comprised of one or more surfaces.

Holes are recognized automatically using either the Automatic Feature
Recognition (see page 445) wizard (AFR wizard) or invoking the
Automatic option of the New Feature (see page 445) wizard. The
same holes should be created regardless of the method used, but using the
AFR wizard will recognize holes along with other features, while using
the Automatic option of the New Feature wizard will only recognize
holes. Holes can be recognized from surface or solid models.
Follow the steps listed here (see page 449) to use the Automatic option
of the New Feature wizard.
See Hole features for complete details on all hole types; How to
recognize features from surfaces (see page 449) for a description of the
overall process; and Feature recognition surface requirements (see page
451) for information on how surfaces are used in feature recognition.
Slot recognition
Only straight slots can be recognized. They are recognized from straight,
parallel side surfaces. You must select surfaces on both sides of the slot.
In the example below, the shaded surfaces are the selected surfaces. The
extent of the slot is defined by these surfaces. Note that the flat bottom
surface is ignored.
For interrupted slots, select surfaces on each end. In the picture below, the
slot is interrupted, but can be created by selecting the wall surfaces at
either end.
If the feature you are trying to recognize is a straight cut that extends off
the side of the part, as in the yellow region of the part shown below, use a
side feature (see page 441). You cannot recognize such a feature as a slot,
since there aren't two opposing side walls.
Note that chamfers, draft angles and bottom radii cannot be recognized,
but you can add these parameters to the slot in the Dimensions page of
the New Feature wizard. See Slot feature for more general information
on slots. See How to recognize features from surfaces (see page 449) for
a description of the overall process. See Feature recognition surface
requirements (see page 451) for further information on how surfaces are
used in feature recognition.
Boss recognition
Bosses are features that must be closed. This means that the cross-section
of the feature must form a loop.
Bosses can be created by recognizing features directly from surfaces (see
page 449) by using curve chaining from the solid model (see page 452) or
automatically (see page 445).
If you are recognizing the feature directly from surface data keep in mind:
It is often easiest to select the surfaces from the top view after
clicking Hide All Nonvertical Surfaces from the Hide menu.
Bosses require a closed curve. Once you select your surfaces, view
them from the top. The selected surfaces should form a loop as
shown in this example.
If you don't see a loop as in the following example, you must select
additional surfaces to fully define the pocket.
Chamfers, draft angles and bottom radii cannot be recognized, but

you can add these parameters to the feature in the Dimensions
page of the New Feature wizard.
If the part has multiple bosses at the same height, you should select
all the surfaces of each boss and create a single boss feature. The
collection of features is then milled at one z-level at a time. If you
accidentally create more than one boss at the same height, the first
boss will cut away the second boss.
You can recognize drafted bosses. See How to recognize drafted
features (see page 454) for more information.
See also Boss feature and Feature recognition surface requirements (see
page 451)
Pocket recognition
Pockets are features that must be closed. This means that the crosssection of the feature must form a loop.
Pockets can be recognized using one of these four methods:
1. Pockets with bottoms and walls all around can be automatically
recognized (see page 446) from solid models. This is the only
method that can recognize islands and bottom radii.
2. Recognition from selected bottom surfaces (see page 453).
3. Recognition from selected side surfaces (see page 449).
4. By extracting feature geometry and chaining curves (see page 452).
This is the only method that can be used to recognize drafted
pockets (see page 454).
See also Pocket feature and Feature recognition surface requirements (see
page 451).
Side recognition
Side features can be created using the Automatic (see page 448)
method, or from side surfaces.
Use a boss (see page 439) or pocket (see page 441) for closed features.
If you are recognizing the feature directly from the side surfaces, keep in
mind:
clicking Hide All Nonvertical Surfaces from the Hide menu.
Chamfers, draft angles and bottom radii cannot be recognized, but
you can add these parameters to the feature in the Dimensions
page of the New Feature wizard.
See also Boss feature and Feature recognition surface requirements (see
page 451).
Face feature recognition

Milling face features can be created from flat faces of a solid or flat
surfaces using the feature recognition (see page 432) wizard. It works
best on solid models since the other faces of the model are avoided when
the toolpaths are created. An example of face feature recognition from a
solid model is shown below. Face features created from surfaces do not
take other surfaces into account.
Methods of feature recognition

FeatureCAM provides three different methods of feature recognition:
1. Recognition from surfaces. With this method, a feature's shape and
depth are determined solely from selected surfaces. For holes and
slots this is the only applicable method. See How to recognize (see
page 449) features from surfaces.
2. Recognition using curve chaining. For milled features that require
curves (bosses, pockets and sides) the shape of the features can be
determined by chaining the curves in the plane of the current UCS.
Use this technique for features that are made up of too many
surfaces to conveniently pick. See How to recognize features from
surfaces using curve chaining (see page 452)
3. Automatic feature recognition (see page 443)
Styles of automatic feature recognition

There are three styles of automatic feature recognition available in
FeatureCAM.
1. Automatic Feature Recognition (see page 445) wizard - The
Automatic Feature Recognition (AFR) wizard attempts to
create all features for milling a part. It creates features by dividing
the model into horizontal slices. All features of the model are
recognized at once. It creates plain, counter drilled, counter bored
and counter sunk holes and all milling features are created as side
features. It will often create a set of features that will completely
cut your solid, but it may create more features that you might
create if you modeled the features yourself.
2. Automatic option of the New feature wizard (see page 445) - The
Automatic option of the New Feature wizard is applicable to
holes, pockets, bosses and side features. It is more limited to how
much of the part can be automatically recognized and you must
recognize each type of feature with separate runs of the wizard.
3. Automatic recognition of turned features - This option is only
available through the Import wizard.
The following example shows the milling features that are extracted using
each method. The figure below shows the three side features created by
the automatic feature recognition wizard. The model has the advantage
that the two slots are cut by the top feature. It has the disadvantage that
top circular pocket is not represented by a single pocket.
The image below is the result of automatically recognizing the pockets in

the model using the Automatic option of the New Feature wizard.
Each pocket is represented by a separate pocket, but the two slots are
ignored.
Invoking the automatic feature

recognition wizard
1. Click the AFR
2. Follow the wizard.
Automatic feature recognition error

The type of automatic feature recognition performed by the AFR wizard
provides a solution for many types of models, but it is not the best method
for every model. In the event the AFR wizard fails for your model, try
other automatic feature recognition methods (see page 443) or try
Interactive Feature Recognition provided by the New Feature
wizard.
Invoking the automatic option of new

feature wizard
1. Select the Feature step from the Steps toolbox.
2. Select either the Hole, Boss, Pocket, or Side radio button.
3. Check the Extract with FeatureRECOGNITION check box and
click Next.
4. Select the Automatic Recognition radio button and follow the
rest of the wizard.
You must have a solid model to use this feature recognition method.
Automatic boss recognition on solid

models
If you are working with a solid model, you can recognize a limited set of
boss features automatically. In general, it is recommended that you use
the AFR (see page 445) wizard for parts with boss features. For a set of
faces to be recognized as a boss automatically, the following conditions
must be met:
1. The boss must have a flat top.
2. The boss must have walls all the way around it.
3. If the part has multiple bosses at the same Z height, they must be
included in a single boss feature. (If they are not, each boss will cut
away the other). The surface of each individual boss must be the
same for them to be included as a single feature.
Bottom radii are recognized. Chamfers are not recognized, but can be
interactively added to a feature (see page 446). Drafted bosses cannot be
recognized automatically. You must use Chain feature curves option (see
page 454)to recognize drafted features.
Interactively extracting chamfers from

a solid or surface model
1. Turn off shading.
2. Make sure Snap to Object is set in Snap Mode dialog box.
3. Use Interrogation to extract the Z-distance from a line at the top
of the pocket and a line at the bottom of the chamfer.
4. Enter this value as the Chamfer Dimension of the part.
5. Add the Chamfer Value to the Feature Depth.
6. Add the Chamfer Value to the Z coordinate of the feature
location.
Automatic pocket recognition on solid

models
If you are working with a solid model, you can recognize blind pockets
automatically. For a cavity to be recognized as a pocket automatically, the
following conditions must be met:
The pocket must have a flat floor. A cavity that passes all the way
through the stock cannot be recognized. Through cavities can only
be recognized as side features.
The pocket must have walls all the way around it.
For cavities that meet these conditions the automatic recognition will
find:
The pocket boundary and the island boundaries. Note that the
islands must be distinct from the boundary, but they can be of
different heights. The island of this solid will automatically be
recognized.
This island will not be automatically recognized.
The pocket depth is determined by the tallest pocket wall. If you

want to force all the features you are recognizing to start at the
same Z coordinate, then click Force same Z height and then
enter an elevation. If the pockets you are trying to recognize, share
a wall with a boss, you will want to control the depth in this way.
This figure shows the pocket that is automatically recognized.
This figure shows the pocket that is recognized if an elevation is set to the
bottom of the boss.
If the pocket has a consistent bottom radius, it will be automatically

recognized.
Chamfers are not recognized, but can be interactively added to a feature
(see page 446). Drafted pockets cannot be recognized automatically. You
must use Chain feature curves option (see page 454)to recognize drafted
features.
Automatic side recognition on solid

models
Some side features can be recognized using the Automatic Feature
Recognition option of the New Feature wizard. In general, the AFR
(see page 445) wizard is better at recognizing side features.
The type of side features that are recognized using this method fall into
three categories:
1. Through cavities - Pockets that go all the way through the part are
recognized as side features. The light blue region of the figure
below is an illustration.
2. Open side features that are on the border of the part. The yellow
region of the image below is such a feature.
3. Outer boundaries. The material from the stock boundary to the part
boundary is removed using a side feature. Note that if your stock
boundary and part boundary are the same, a side feature will still
be recognized, but no toolpaths will be generated.
Blind pockets and bosses that formed from closed curves not recognized
as side features. They should instead be recognized as pockets and bosses.
How to recognize features from

surfaces
1. Import your solid model or IGES file.
2. If necessary, transform the part so that the surfaces that represent
the features are facing toward the Z axis.
3. Click the Features
4. Select your feature type. Remember, only holes, slots, pockets,

bosses and sides can be recognized.
5. Select Extract with FeatureRECOGNITION and click Next.

6. If you are extracting a single hole or hole pattern, click Extract a
single hole or pattern or holes and click Next.
7. If you want to recognize all holes in your part, see How to
recognize all holes in a setup (see page 451).
8. If you are creating a pocket, boss or side, you are presented with a
choice of methods. Click Select surfaces and click Next.
9. Select the surfaces and click Next. For more information see
Feature recognition - surface selection.
For advanced users only: at this point you may click the Preview
button to see the feature that will be created. If it looks acceptable
you may click Finish.
10.If you are making a feature other than a hole, the top and bottom
page is displayed. The top and bottom surfaces are extracted from
the surfaces so you will probably not have to adjust the top and
bottom values. Just click Next. For more information see Feature
recognition - top & bottom.
11.Confirm the extracted dimensions of the feature. Modify the
features dimensions if desired and click Next.
12.The Strategies page is displayed. Click the desired attributes
depending on your manufacturing preferences. Click Next. See
Strategy tab for information on the specific attributes.
13.The Operations page is displayed. This page displays the
operations that will be used to manufacture the feature along with
the names of the selected tools and calculated feed and speed
values. If these values are acceptable, click Finish. If you want to
change the tooling or feeds and speeds click Next and follow the
instructions on the screen.
Some additional things to keep in mind are:
clicking Hide all nonvertical surfaces from the Hide menu.
Pockets require a closed curve. After you select your surfaces, view
them from the top. The selected surfaces should form a loop as
shown in this example. If you dont see a loop as in this example,
you must select additional surfaces to fully define the pocket.
For pockets there is no automatic island detection. Do not include

island surfaces in your selection. Instead create your pocket
without the island and then add the island separately by modifying
the feature.
Chamfers and draft angles, but you can add these parameters to the
feature in the Dimensions page of the New Feature wizard. See
Interactively extracting chamfers from a solid or surface model
(see page 446).
If you select surfaces that define more than one cavity, a single
pocket feature is created that contains multiple pocket cavities. The
collection of features is then milled one z-level at a time.
Feature recognition surface

requirements
The following requirements apply for the recognition of surfaces for
milling features:
1. Only straight walled-surfaces are recognized. If a single surface
also contains the bottom radius or a chamfer it will not be
recognized.
2. Tapered surfaces are not recognized.
3. The current setup must be oriented so that the vertical walls of
feature surfaces are parallel to the Z-axis.
4. You can include surfaces other than straight walls and they will be
used to calculate the depth of the feature. These surfaces will not
be used in determining the feature shape.
How to recognize all holes in a setup

1. Import your solid model or *.iges file.
4. Select the Hole feature type.

5. Select Extract with FeatureRECOGNITION and click Next.
Select Recognize and construct multiple holes and click

Next.
6. See New Feature - Hole recognition options for information on
completing this process.

surfaces using curve chaining
4. Select your feature type. Remember only pockets, bosses and sides
can be recognized using curve chaining.
5. Click Extract feature from solid model and click Next.
6. Click Chain curves and click Next.
7. The geometry for the features is projected onto the plane of the
UCS. Chain the appropriate geometry. See Feature recognition chaining for more information.
8. The top and bottom page is displayed. Enter the top and bottom
values or click the Pick buttons and graphically pick the locations.
Click Next. For more information see Feature recognition - top &
bottom.
9. Confirm the extracted dimensions of the feature. Modify the
feature's dimensions if desired and click Next.
How to recognize pockets and bosses

from top or bottom surfaces
1. Import your solid model or IGES file.
4. Select a Boss or Pocket feature type. Click Extract with

FeatureRECOGNITION and click Next.
5. Click Use horizontal surface and click Next.
6. For a boss, select the flat top surface of the boss, for a pocket,
select the flat bottom surface. Click here to see examples of these
surfaces. For more information see Feature recognition - surface
selection. Click Next.
7. The top and bottom page is displayed. Enter the top and bottom
bottom.
9. The Strategies page is displayed. Click the desired attributes
How to recognize pockets

automatically from solids
1. Import your solid model. Pockets can only be recognized from
solids.

4. Select a Pocket feature type. Click Extract with

5. Click Automatic and click Next.
6. The pockets are then found and highlighted and the Pocket
recognition options dialog box (see page 454) is displayed.
7. After completing this dialog, click Finish.
New feature - pocket recognition

options
All pockets that are recognized are displayed and you have the following
options:
Exclude pockets smaller than - Click this option so that small
cavities are not recognized. This option is mainly used to ignore
blind holes that you would rather drill. All cavities whose
maximum dimension is smaller than the distance you specify are
automatically ignored.
Merge pockets of same height into a single pocket - This
option will combine pockets that are located at the same height and
that have the same depth into a single pocket feature.
Add all new pockets into a group if there is more than
one - This option will place all pockets into a single group.
You must then select the pockets you want to keep. Use the Select All
button to keep them all. You can also pick individual pockets with the
mouse. Click a selected pocket to unselect it.
After you have selected all the pockets you want to keep, click the
Finish button.
How to recognize drafted features

4. Select your feature type. Remember only pockets, bosses and sides
can be recognized using curve chaining.
5. Click Extract with FeatureRECOGNITION and click Next.
6. Click Chain curves. Wall angle and elevation values are shown.
7. If you know the angle, enter it. If not, click the Draft Angle label.
The dialog will warp out of the way. Click two points on the same
vertical isoline as shown below. The dialog returns.
8. For the Elevation enter the Z coordinate of the top of the feature
or click the Elevation label and click the top of a wall of the
drafted surface. Click Next.
9. The geometry for the features is projected onto the plane of the
UCS. Chain the appropriate geometry. See Feature recognition chaining for more information.
10.The top and bottom page is displayed. Enter the top and bottom
bottom.
11.Confirm the extracted dimensions of the feature. Modify the
The Operations page is displayed. This page displays the operations
that will be used to manufacture the feature along with the names of the
selected tools and calculated feed and speed values. If these values are
acceptable, click Finish. If you want to change the tooling or feeds and
speeds click Next and follow the instructions on the screen.
How to recognize face features from

flat surfaces
2. If necessary, transform the part, so that the surfaces that represent
3. Click the Feature step from the Steps toolbar or the
Advanced toolbar.
4. Select your Face feature type. Click Extract with
5. Select a flat surface. Currently face features must be created one at
a time. For more information see Feature recognition - surface
selection. Click Next.
features dimensions if desired and click Next, otherwise click
Finish.
See also Face feature recognition (see page 442) and Feature Recognition
(see page 432)
Rerecognition wizard
The Rerecognition wizard compares a new solid model with an
existing set of features. It is assumed that you have imported a new solid
model that is a variation on the initial model. If are trying to recognize the
initial features from a part model use automatic feature recognition (see
page 443).
If you are going to rerecognize a model, you should make sure that you
use the same alignment.
The Rerecognition wizard automatically recognizes features from the
new solid and then compares the new features to the existing features and
classifies the new features into the categories of unchanged (see page
457), new (see page 457), modified (see page 457) and deleted (see page
457).
FeatureCAM attempts to rerecognize both individual features and
patterns of features.
Unchanged features
These features are identical to existing features. They will be ignored in
the rerecognition process.
New features
These features are not part of the existing features and therefore are
assumed to be new. The Rerecognition wizard will offer you the
opportunity to add these features to your part.
Modified features
These features have the same shape or size as existing features, but
parameters like depth, bottom radius or chamfer distance have been
modified. The Rerecognition wizard will ask you if want to replace the
existing features with their modified versions.
Deleted features
These features exist in the current set of part features, but were not found
in the new model. You are offered by the Rerecognition wizard the
option of deleting these features. There are many possible reasons that
this feature is in your existing set of features but was not automatically
recognized, so you should be careful about deleting these features. If the
feature has clearly been deleted, you can comfortably remove it. If the
feature was created through interactive methods, you probably want to
keep this feature. If you are uncertain, you should preview each feature
and decide on an individual basis.
Tombstone machining
(TOMB)
If your milling machine is equipped with a tombstone, FeatureCAM
makes it easy to take advantage of this high production feature.
You must license the Tombstone machining option to use tombstone
machining.
Overview of tombstone machining (see page 459)
Specifying tombstone dimensions (see page 459)
Creating global fixture coordinate systems from setups on placed parts
(see page 460)
Creating global fixture coordinate systems on the tombstone (see page
461)
Creating a tombstone machined part (see page 462)
Adding a part to the tombstone (see page 462)
Specifying ordering of tombstone operations (see page 462)
Saving and opening tombstone parts (see page 463)
Edit button (see page 463)
Delete button (see page 463)
Reload button (see page 464)
458 Tombstone machining (TOMB)
Overview of tombstone machining

The tombstone fixture document helps you arrange various FeatureCAM
milling parts on a tombstone for production manufacturing. Your first
step is to describe your tombstone. Tombstones for vertical and horizontal
milling machines are both supported. Input the number of faces and the
dimensions of a face and these dimensions are remembered for future
parts. Next use the tombstone wizard to open FeatureCAM parts and
locate them on the tombstone. You can cut multiple copies of a single
part or mix different parts on the tombstone. You can automatically order
the operations to minimize tool changes across all setups or to cut each
setup completely before rotating.
Example of four parts on a two face horizontal tombstone
Example of twelve parts on a six face horizontal tombstone
Example of four parts on a four face vertical tombstone.
Specifying tombstone dimensions

It is important to accurately reflect the dimensions of the tombstone
because these dimensions are used for simulating toolpaths and to
calculate the required retract distances.
The tombstone dimension dialog comes up automatically the first time
you open a tombstone part. It is assumed that you will not have to change
these dimensions again. If you need to alter the dimensions, click the
Tombstone step in the Steps toolbox.
To set the dimensions of the tombstone:
1. Select the tombstone axis of rotation. For horizontal machining
centers, this is normally the Y-axis. For vertical machining centers,
this is normally the X-axis.
2. Specify the number of faces of the tombstone.
3. Specify the Axis Length. This is the dimension of the tombstone
parallel with the tombstone axis.
4. Specify the Width of a Face. This is the dimension that is
perpendicular to the Axis Length.
Tombstone machining (TOMB) 459
5. Specify the final dimension, the Tombstone Thickness. For a

tombstone with an even number of faces, this is the distance
between parallel faces. For a tombstone with an odd number of
faces it is the perpendicular distance from a face to the joint of
faces on the opposite side of the tombstone.
6. Click OK when finished.
See also Handling multiple tombstones.
Creating global fixture coordinate

systems from setups on placed parts
If you want to use a setup of a part that you have placed on the tombstone
to locate other part setups, use the following procedure:
1. Open the tombstone dialog by clicking on the Properties button
or clicking the Parts icon in the Steps toolbox.
2. Click the Fixtures button. The Fixture Offset Locations
dialog opens.
3. Click the Add button. The Fixture Location dialog opens.
4. Select Create the fixture zero at the origin of a setup... and
click Next.
5. The Select fixture setup dialog comes up. Select the setup whose
origin you want to use and click Next.
6. The Fixture ID dialog comes up. Specify the Fixture ID to use
for the first face. You will probably not have to change the default
value since it was set when you placed the first part.
7. If you want to set the origin of each face at the same point, click
Use this fixture ID on each face.
8. Click Increment the fixture ID for each face if you want to
use a different origin for each face.
9. Click the Finish button.
10.The fixture offsets you create are displayed on each face of the
tombstone with the
symbol.
11.The Create fixture dialog is displayed showing the fixture IDs

you created. The faces that they apply to are shown underneath the
fixture IDs. Click OK to accept these fixture IDs.

systems on the tombstone
The first step to placing parts on the tombstone is to locate a point on the
tombstone to position the primary setups of the parts. These coordinate
systems are created relative to the tombstone and are called global fixture
coordinate systems.
1. Bring up the Tombstone process plan dialog by clicking on
the Properties button.
2. Click the Fixtures button. The Fixture offset locations
dialog opens.
3. Click the Add fixture button. The Fixture location dialog
opens.
4. Select Create the fixture zero relative to one of the faces
of the tombstone and click Next.
5. The Fixture ID dialog opens. Specify the Fixture ID to use for
the first face.
6. If you want to set the origin of each face at the same point, select
Use the same fixture ID on each orientation and click Next.
7. Select Increment the fixture ID for each orientation if you
want to use a different origin for each face and click Next.
8. The Fixture Zero Location dialog opens. Enter the offsets from
the left edge, top edge and tombstone face. Note that these values
are for simulation purposes only. When you set up the machine you
can locate the origin anywhere on the face that you want.
9. Click the Finish button.
10.The fixture offsets you create are displayed on each face of the
tombstone with the
symbol.
11.The Create fixture dialog is displayed showing the fixture IDs
you created. The faces that they apply to are shown underneath the
fixture IDs. Click OK to accept these fixture IDs.
Creating a tombstone machined part

1. Select File > New from the menu or click the New
from the Standard toolbar.
button
Select Tombstone Fixture as the type.

2. Select the system units you will use for the multiple part document.
This is the unit you will use to specify the size of the tombstone
and to position the parts on the faces of the tombstone. It specifies
the system of units for all parts that you will place on the
tombstone.
3. Click OK.
4. If it is the first time you have created a part for tombstone
machining, your next step is to specify the dimensions of the
tombstone (see page 459).
5. If it is not your first tombstone machined part, your next step is to
add parts to the tombstone (see page 462).
Adding a part to the tombstone

1. Bring up the Tombstone process plan dialog by either clicking
on the Properties button or clicking the Parts step in the Steps
toolbox.
2. Fixture IDs will be assigned to the parts beginning with the ID
contained in the Start Fixture IDs at field. If you want to use a
different fixture ID, change this value.
3. Click Add to place a part on one face of the tombstone and bring
up the select part dialog box.
4. Click Add to all to position a part on all faces of the tombstone
and bring up the select part dialog box.
See also Specifying ordering of tombstone operations (see page 462).
Specifying ordering of tombstone

operations
1. Bring up the Tombstone dialog by either clicking on the
Properties button or clicking the Parts step in the Steps
toolbox.
2. If you want the ordering of operations to minimize tool changes

across all setups, click Tool Dominant. Note that you must also
set the Minimize tool changes ordering attribute for Tool
Dominant to work correctly. See Ordering default attributes for
more information.
3. If you want the ordering of operations to complete each setup
before moving on to another setup, click Setup Dominant. The
order that operations are performed within a setup are determined
by the milling ordering attributes. Click Generate Single
Program to create a single NC program for all faces.
Saving and opening tombstone parts

Tombstone parts are saved in files with the *.ts extension. When opening
tombstone documents change the Files of type to be TSF Documents
(*.tsf) to view the tombstone documents saved on your disk.
Tombstone delete button

This button allows you to delete a face of the tombstone or delete a part
from a tombstone face.
To delete a face:
1. Click a face name. Faces have names like 0 degrees, 90
degrees.
2. Click the Delete button.
To delete a part from a face:
1. Click a part file name.
2. Click the Delete button.
Tombstone edit button

The Edit button allows you to edit Tombstone information.
To edit the location of a part on a face:
1. Select the file name.
2. Click Edit.
3. The Tombstone part location dialog box comes up for editing.
To edit a setup name or fixture ID:
1. Click a setup.
2. Click the Edit button.
3. The Tombstone setup information dialog box comes up for editing.
Tombstone reload button

This button allows you to reload a FeatureCAM file into your tombstone
document. If your initial part file has changed since you created your
tombstone part, you will want to reload the part.
To reload a part
1. Click a part file name.
2. Click the Reload button.
Overview of 5-axis
positioning (5-axis
Pos)
5-axis positioning provides a convenient method of manufacturing parts
that require milling on multiple faces by minimizing setups. The figure
below shows an example of a part that requires milling from 4 different
orientations. With 5-axis positioning, this entire part can be milled with a
single program.
FeatureCAM provides two types of 5-axis positioning NC programs. The

first method requires the operator to set only a single coordinate system.
The entire program is then generated with regard to this coordinate
system. The advantage of this method is that it minimizes the setup time.
The disadvantage is that the resulting NC programs are harder to read
since the coordinates for milling each face are rotated. See 5-axis
positioning using a single coordinate system (see page 473) for more
details.
The second method uses standard fixture offsets to determine the

coordinate system for each face. The advantage of this method is that the
code for each face is easier to read. The disadvantage is that the operator
must touch-off each face. See 5-axis positioning using fixture offsets (see
5-axis positioning example
5-axis machine types

The following 5-axis machine types are supported by FeatureCAM.
466 Overview of 5-axis positioning (5-axis Pos)
Table on table machines

Horizontal with stacked tables - These horizontal milling machines
rotate about the Y-axis, then around the X-axis. They are also called A
over B machines.
Vertical with stacked tables - These machines are vertical mills that
rotate about X-axis then around the Y-axis. These machines are also
known as B over A machines.
Machines with tilting heads
FeatureCAM supports machines with tilting heads as long as they have
the following two capabilities:
3D coordinate transforms - The control must allow programming of 2.5D
features in the X and Y planes. This means that the depth of features are
always in the Z or -Z directions.
Tool length offset - The touch-off point (or zero point) of the tool must
move with the rotated tool.
The specific machine architectures support are as follows:
C rotary table and B tilting head - These machines rotate about X and
then the head rotates around the Y-axis.
C rotary table and A tilting head - These machines rotate about Z and the
head rotates around X.
C swiveling and A tilting head - These machines rotate around Z with a

table and then the head tilts around the X axis. They are also known as
gimbal heads.
B and A tilting head - Rotates about Y using a table and then X in the
head.
A and B tilting head - Rotates about X using a table and then Y in the
head.
B and 45 Degree angled A tilting head - Rotate about Y, then rotate about
X with a head that is angled by 45 degrees. This head is also known as a
huron head.
A and 45 degree angled B tilting head - Rotate about X, then about Y

with a head that is angled by 45 degrees. Also known as a huron head.
See machine dimensions for specific machine parameters.
Use alternative 5 axis position

Depending on the type of 5-axis machine you are working with, there are
often two ways of orienting the machine axes to address a particular
face. FeatureCAM has a default orientation for each machine architecture.
By checking Use Alternative 5 axis position on the Setup definition
page, you can choose which orientation will be used for a specific setup.
As an example in the machine below, the default is to keep A in the 0 to
180 range and then find the suitable B.
With Use alternative selected, we keep A in the 0 to -180 range and

then find the suitable B.
The default and alternative orientations for each 5 axis machine type are
shown below.
Horizontal with stacked tables (rotate about Y then X)
Default is to keep B 0 to 180, then find A. Alternative is to keep B 0 to 180, then find A.
Vertical with stacked tables (rotate about X then Y)
Default is to keep A 0 to 180, then find B. Alternative is to keep A 0 to 180, then find B.
C rotary table and B tilting head
Default is to keep B 0 to 180, then find C. Alternative is to keep B 0 to 180, then find C.
C rotary table and A tilting head
Default is to keep A 0 to 180, then find C. Alternative is to keep A 0 to 180, then find C.
C swiveling and A tilting head
Default is to keep A 0 to 180, then find C. Alternative is to keep A 0 to 180, then find C.
B and A tilting head
Default is to keep B 90 to -90 if setups Z is positive and 90 to 270 if
setup's Z is negative, then find A. Alternative is to keep B 90 to 270 if
setup's Z is positive and 90 to -90 if setup's Z is negative, then find A.
A and B tilting head
Default is to keep A 90 to -90 if setup's Z is positive and 90 to 270 if
setup's Z is negative, then find B. Alternative is to keep A 90 to 270 if
setup's Z is positive and 90 to -90 if setup's Z is negative, then find B.
5-axis positioning using a single

coordinate system
This method minimizes setup time by only requiring a single touch off
point and is performed with the following steps:
1. Create a part with multiple setups and either:
Click through to the third page of the Stock wizard, the Multiaxis Positioning page. Click 5th Axis Positioning and
click Next; or
Double-click the stock and click the Indexing tab and click
5th Axis Positioning.
2. Designate one of your setups as the 5-Axis Touch-off Point.
The Z-axis of this setup must be parallel with the A-axis.
3. For the 5-Axis Touch-off Setup Offset, enter the distance, in
each coordinate system direction, from the center of the A-axis
face to the 5- Axis Touch-off Point. This distance will change for
each part. In this example, the X and Y offsets are negative and the
Z offset is positive.
4. For the B-Axis Rotational Offset, enter the angle (measured

counter-clockwise) between the spindle and the A-axis when the B
angle is set to 0. For example, the A-axis faces the spindle when B
is set to 0, then enter 0. If it faces the door when B is set to 0, as
shown in this figure, then enter -90. This offset will be set the same
for all parts machines on a specific machine.
5. If you want the ordering of operations to be tool dominant across

all setups, click Tool Dominant. Note that you must also set the
Minimize tool changes ordering attribute for Tool Dominant to
work correctly.
by the milling ordering attributes. See Ordering default attributes
for more information. Click Generate Single Program to create
a single 5-axis indexed program.
7. Click Finish in the stock wizard or OK in the Stock Properties
dialog.
8. Generate toolpaths. Don't forget to check Minimize tool
changes, if you want Tool Dominant toolpaths.
9. The simulation works for both centerline and 3D simulation. In
centerline simulation an arc is displayed for a 5-axis
reorientation. In 3D simulation the part position and orientation
stays fixed and the tool moves. The tool does not move smoothly
between setups, it simply reappears in the new setup.
10.Select a 5-axis post processor and create NC code.
11.The NC code is generated with respect to the b-axis coordinate

system. Only a single touch-off is required to locate the part.
12.The Rotary Center Offset values are contained in the post
processor files. See five axis post processing variables for more
information.
5-axis positioning using fixture offsets

1. Create a part with multiple setups and either
Click through to the third page of the Stock wizard, the Multiaxis Positioning page. Click 5th Axis Positioning and
click Next; or
Double-click the stock and click the Indexing tab and click
5th Axis Positioning.
2. Click Use Fixture Offset. The 5-Axis Touch-off Setup and 5Axis Touch-off Setup Offset do not apply to this method.
3. For the B-Axis Rotational Offset, enter the angle (measured
counter-clockwise) between the spindle and the A-axis when the B
angle is set to 0. For example, the A-axis faces the spindle when B
is set to 0, then enter 0. If it faces the door when B is set to 0, as
shown in this figure, then enter -90. This offset will be set the same
for all parts machines on a specific machine.
4. If you want the ordering of operations to be tool dominant across
all setups, click Tool Dominant.
You must also set the Minimize tool changes ordering
attribute for Tool Dominant to work correctly. See
Ordering default attributes for more information.
by the milling ordering attributes. Click Generate Single
Program to create a single 5-axis indexed program.
6. Click Finish in the stock wizard.
7. Generate toolpaths. Don't forget to check Minimize tool
changes, if you want Tool Dominant toolpaths.
8. The simulation works for both centerline and 3D simulation. In

centerline simulation an arc is displayed for a 5-axis reorientation.
In 3D simulation the part position and orientation stays fixed and
the tool moves. The tool does not move smoothly between setups,
it simply reappears in the new setup.
9. Select a post processor that supports fixture offsets and create NC
code.
10.The NC code is generated with respect to the coordinate system of
each setup. If it is desired to see the NC code for each setup
specified in machining coordinates (Y up and X to the right), then
each setup should be positioned so that the setup coordinate system
will be aligned with the machine coordinates when that face is
pointing toward the tool. The operator must touch off each setup
individually.
Rotation of primary axis

The rotation of the primary axis (the B-axis on an A over B machine) will
by default operate in the 0 - 90 and 90 - 180 quadrants. If you want to
operate in 0 - -90 and -90 - -180 quadrants then use the following steps.
1. Hold down the CTRL key and click the right mouse button on the
status bar at the bottom of the FeatureCAM screen.
2. Check the Use -90 -180 for first axis rotation.
Turn/milling
(TURN/MILL)
FeatureTURNMILL allows the combination of turning and milling
features on lathes with powered rotary tools. FeatureTURNMILL
supports the normal Z and X axes of turning combined with the C and
optional Y-axis.
The yoke shown in the left-hand figure, could be manufactured with a C
axis lathe in two setups or using a C axis lathe with a subspindle. The
right hand figure is a piece that requires a Y-axis due to the flat pockets
on the top and bottom of the piece. (If these pockets were wrapped, they
would have a curved bottom and then they could be manufactured
without a Y-axis.)
When creating features, you are given the choice of creating turning
features or turnmill features (see page 479). Turning and turnmill features
can be mixed in a single setup. Turning features are identical to those on a
2-axis lathe and milling features are created the same as for a 3-axis mill,
except that you are given new choices for positioning and orienting the
features either on the OD or on the face of the part.
Turn/milling (TURN/MILL) 477
Tool selection in FeatureTURNMILL is very similar to FeatureMILL and

FeatureTURN, except that rotary tools are automatically classified (see
page 480) as either parallel to the X-axis or Z-axis.
All forms of simulation (Centerline, 2D and 3D solid) are supported. In
3D simulation the rotation of the part is accurately simulated.
Turnmill parts require specially written posts. Two axis turning posts or
milling posts will not work correctly.
Turnmilling
Turnmill Overview (see page 477)
Beginning a turnmill part (see page 478)
Turnmill feature type dialog box (see page 479)
Features appropriate for millturn (see page 479)
Turnmill location dialog box
Tool selection for turnmill features (see page 480)
Feed rates for turnmill features (see page 481)
Polar interpolation in turn/mill (see page 481)
Beginning a turnmill part

To begin a new turnmill part:
1. Click the New button.
2. Select Turnmill as the type.
478 Turn/milling (TURN/MILL)
Turn/mill feature type dialog

Turn/mill features are classified as either Turn/Mill or pure Turning
features. Turn/mill features assume powered tools and turning features
assume that the tool does not spin. For example, you can make a hole
along the Z-axis with both feature types, but the milled one uses rotary
tools and the turned hole uses a drill that does not spin.

Select either Turn/Mill or Turning.
Click Next.
See also Features appropriate for turnmill (see page 479)
Features appropriate for turn/mill

Milling features can be performed in turnmill with the following
considerations:
Milled features on the Z face. FeatureTURNMILL can make any
feature on the face of a part by using only XZC moves, for
machines that do not have a Y-axis. If you want to use Y-axis on
the face of a feature, you must check the Cut using Y-axis
coordinates check-box on the Dimensions page of the feature's
Properties dialog.
Drilled features on the Z face or OD can be created without any
restrictions.
Unwrapped milled features on the OD. These features are output in

X, Y and Z moves. If your machine does not have a Y axis, the
only features you can cut on the OD (without wrapping) is a simple
slot whose length is aligned with the Z axis. If your machine has Yaxis capabilities, you can cut the full set of milling features on the
OD.
Wrapped features (see page 150) are supported (using a live tool),
with known limitations -- the same limitations that FeatureCAM
has with wrapped 4th- axis features (see page 159). To invoke
wrapping, you must check the Wrap feature around Z-axis checkbox on the Dimensions page of the feature's Properties dialog.
Feature location
This dialog helps you select the location point of the feature. This point
that you are specifying corresponds to the red X in the diagram.
1. If you want to type the coordinate, type the values into the X, Y
and Z locations
2. If you want to graphically pick the location, click the Pick point
button. The dialog will warp into a title bar with a single button
with a red X on it. (Click this button if you want to cancel your
selection)
3. Pick the point with the mouse. Remember that the snap modes
control what the cursor will snap to. After you pick the point, the
dialog returns to the screen.
4. If you are creating a milled feature, you can set an angle, A, that
represents a counter-clockwise rotation around the feature location.
5. Click Next.
Tool selection for turn/mill features

Turn/mill features use the same tools as the normal milling features, but
they are renamed with -rotaryX appended to the name to indicate that it
is a powered rotary tool. For example, if a tool called center_4 is
selected for a turnmill center drill operation, the tool is copied and the
copy is called center4-rotaryX.
480 Turn/milling (TURN/MILL)
Rotary tools cannot be explicitly created, but if you manually select a tool
for a turnmill operation, it is copied and the copy is designated as a rotary
tool.
Rotary tools cannot be used for turning operations.
Feed rates for turn/mill features

All feed rates are specified in inches per minute (or millimeters per
minute). The post processor then translates these rates into degrees per
minute or inverse time.
Polar interpolation in turnmill

Polar interpolation can be performed by FeatureCAM or at the machine
tool. This is controlled by the Polar interpolation done by variable in the
post processors General tab.
Generate single program for all setups

This option, located on the Indexing tab of the stock, combines the
toolpaths of all setups into a single setup. This means that when
simulating the toolpaths, the toolpaths from all setups will be displayed.
Only a single NC program will created. This option must be set if you are
using subspindle. With this option turned off each setup will create a
separate NC file.
If this option is set, then FeatureCAM will insert a stop operation between
each setup. This allows for the part to be flipped and machined on both
sides within a single NC program. For a turn or turn/mill document, the
stop operation will be created if the setups are on the same spindle and
oriented opposite to each other. For a milling document, the setups can be
in any orientation.
See also Subspindle feature.
Introduction to
FeatureWIRE for
FeatureMILL users
FeatureWIRE is structured similarly to all other FeatureCAM products
and the steps are used to walk you through the process.
A model of the stock is displayed in the graphics window.
Geometry and curves are used to describe the shape of the part.
The geometry and curves are included in features and toolpaths are
derived from these features.
Toolpaths are simulated in the graphics window using line drawings
or 3D shaded graphics. 3D simulation also allows the simulation of slug
removal (see page 483).
Toolpaths are translated into machine specific code using the
appropriate post processor.
Differences between FeatureWIRE and other FeatureCAM products
include:
1. The diameter and type of wire you are using are specified as part of
the Stock wizard instead of on individual operations.
482 Introduction to FeatureWIRE for FeatureMILL users
2. FeatureWIRE provides cutting condition tables instead of

feed/speed databases. These cutting condition tables list registers
that contain power settings, water (coolant) settings and sometimes
cutter compensation. This information is machine specific and is
supplied by the EDM machine tool vendor.
For some machine types, FeatureWIRE provides a single text file that can
control the entire process. For other controls, FeatureWIRE provides a
file that you must reference from a command file that you create at the
control.
Simulated slug removal

In FeatureWIRE, you can graphically remove a slug after the 3D
simulation is finished. The region to remove must be totally separated
from the rest of the part.
To remove the slugs:
1. Perform a 3D solid toolpath simulation.
2. Toggle the viewing mode in the viewing flyout menu to the up
position.
3. Click the slug in the graphics window. The slug is removed.
4. You can click as many slugs as you wish to remove.
5. Click the Stop button in the simulation toolbar (see page 42) to
clear the screen.
FeatureWIRE feature types

The feature types offered by FeatureWIRE are:
2-axis Die (see page 484)
Introduction to FeatureWIRE for FeatureMILL users 483
2-axis Punch (see page 485)

2-axis Side (see page 485)
4-axis Die (see page 488)
4-axis Punch (see page 489)
4-axis Side (see page 489)
The shape of the features is defined by the curve (see page 484).
These features can create a number of wire EDM operations (see page
493). The type of operations are controlled by the Strategy Tab.
Taper (see page 486).
See also:
Upper Curve, Lower curve, Match curves (see page 492), Location tab,
Strategy Tab, Start Tab, Side control Tab, Misc Tab, Simulated slug
removal for wire EDM (see page 483)
Multiple curves in a single 2-axis wire EDM feature

All wire EDM curves must lie in the XY plane or a plane parallel to the
XY plane.
A single 2-axis die, punch or side feature can contain multiple curves. In
this case you have the option of setting separate start points and variable
taper values for each curve, but all other settings apply to all of the
curves.
If the feature has multiple operations, such as a retract followed by a
cutoff, each operation is performed on each curve before moving on to
the next operation. If you wish to change this ordering, you must
manually reorder the operations in the Operations List (see page 65).
Die
The Die feature requires one or more closed curves (see page 484). It is
assumed that the region(s) outside of the curve(s) is the part that you
keep. As a consequence, the wire travels on the inside of the curve(s).
The thickness parameter is used to access the appropriate cutting data

table (see page 119).
The A parameter is used to rotate the feature around the Z-axis of the
current setup.
A 2-axis die feature can create a number of cutting operations (see page
493). These are specified on the Strategy tab.
See also Wire EDM Taper (see page 486).
Punch
The Punch feature requires one or more closed curves (see page 484).
The wire travels on the outside of the curve(s).

current setup.
A 2-axis punch feature can create a number of cutting operations (see
page 493). These are specified on the Strategy tab.
See also Wire EDM Taper (see page 486)
Side
The Side feature can use one or more closed or open curves (see page
484). The Punch or Die features provide more cutting options for closed
curves. You can optionally place the wire on either side of the curves. A
side feature must have at least three arcs or lines in it including the lead
moves.

current setup.
A 2-axis side feature can create a number of cutting operations (see page
493). These are specified on the Strategy tab.
See also Wire EDM Taper (see page 486).
Side feature restrictions

Side features must have at least three moves in it including the lead
moves. If it does not, then no feature is displayed in the start page that is
displayed in the wizard. For example, if you are creating a feature from a
single line, you must change the start point and end point so that the
feature has three moves. If you add these moves and click the Next
button in the wizard, the feature displays.
Wire EDM Taper

None - With this option, the feature has no taper.
Constant - With this option, the feature has a constant taper angle all the
way around the feature. The taper is specified by an angle, specified in
degrees, and taper type (see page 486).
Variable - If you want to specify a different taper value for each line and
arc of your curve, click the Variable radio button and then click the
Variable button to display the variable taper table (see page 488).
Types of wire EDM tapers

All left tapers are performed to the left of the curve (at the bottom of the
feature) relative to the Primary Cut Direction, and all right tapers are
performed to the right of the curve (at the bottom of the feature) relative
to the Primary Cut Direction.
Left: Sharp corners tapered into sharp corners (G29 on a
Charmilles machine) and arcs tapered into conical corners (see
page 487) (G28).
Right: Sharp corners tapered into sharp corners and arcs tapered
into co (see page 487)nical corners.
Rounded-Left: Sharp corners tapered into arcs (G28) and arcs
tapered in (see page 487)to conical corners (G28).
Rounded-Right: Sharp corners tapered into arcs and arcs tapered

into co (see page 487)nical corners.
ISO-Left: Arcs tapered into cylindrical corners (see page
487) (G29) and sharp corners tapered into sharp corners (G29).
ISO-Right: Arcs tapered into cylindrical corners (see page 487) and
sharp corners tapered into sharp corners.
ISO/Rounded-Left: Arcs tapered into cylindrical corners (see page
487) (G29) and sharp corners tapered into arcs (G28).
ISO/Rounded-Right: Arcs tapered into cylindrical corners (see
page 487) and sharp corners tapered into arcs.
Default conical corner

The normal taper has corners that are shaped like a cone. The arc of the
top curve is different from the arc of the bottom curve.
ISO cylindrical corner

An ISO taper has cylindrical corners. The arcs of the top and bottom
curves have the same radius.
Variable taper table

If the feature has multiple curves, select the appropriate curve from the
Curve drop down list. The curve is broken down into arc and line
segments and each segment is represented by a row in the table. As you
click a row of the table, the segment of the curve is highlighted in the
graphics window. If you wish to find the row of the table that corresponds
to a segment, click the Pick curve piece
segment. The row of the table is then selected.
The columns of each table are:
Status - Double-click box in the status column to display a drop down
list of Types of wire EDM tapers (see page 486).
First Angle - This is the taper angle, specified in degrees, for the first
end point of the segment.
Angle - This is the taper angle, specified in degrees, for the second end
point of the segment.
Taper reg - This is the register on the machine containing taper
information for this segment.
If you want smooth walls of your part, the angle of one segment
must match the first angle of the next segment.
4-axis Die feature (Wire)

The die feature requires two closed curves. It is assumed that the region
outside of the curve is the part that you will keep. As a consequence, the
wire travels on the inside of the curves.

current setup.
4-axis Punch feature (Wire)

The punch feature requires two closed curves. The wire travels on the
outside of the curves.

current setup.
4-axis Side feature (Wire)

The side feature can utilize a closed or open curve. The Punch or Die
feature provides more cutting options for closed curves. You can
optionally place the wire on either side of the curve. A side feature must
have at least three arcs or lines in it including the lead moves.

current setup.
Wire EDM feature recognition

There are two forms of interactive feature recognition available for wire
EDM features.
For two axis you can project the vertical surfaces from a solid model.
In the New feature dialog:
1. Select the 2 axis feature type, check Extract with

2. Select the solid and click Next.
3. Geometry is created from the vertical surfaces of the solid as
shown below. Chain the curves you want to use in the Feature
and complete the wizard.
Four axis features can be recognized from a collection of ruled surfaces.

In the New feature dialog:
1. Select the 4 axis feature type, check Extract with
2. Select the boundary curve in the Surface boundaries (see page 491)
dialog and then complete the wizard.
New feature - surface boundaries

This page is part of the new feature wizard and it assists you in creating
4-axis wire EDM features from ruled surfaces. It can be performed on
both surface and solid models. When you enter this dialog, the edges of
all ruled surfaces in the model are displayed in blue.
To complete the dialog:

1. Click the Pick Curve
bar.
button. The dialog warps into just a title
2. Select the Upper curves of the feature in order.

3. Click the Pick button in the title bar of the warped dialog to
complete the picking.
4. Click the Preview button to make sure you have selected the
correct curves.
5. Click Next and complete the wizard.
6. As you select curves, the ruled surfaces are entered into a table in
the middle of the dialog. This table lists the surface name, the
number of the boundary selected and whether or not the curve has
been reversed. There are a number of additional operations that can
be performed on a selected row of the table.
The delete button removes the boundary currently selected in the
tables.
This button moves the selected boundary up in the table.
This button moves the selected boundary down in the table.
This button selects an alternative boundary of the surface.
This button reverses the direction of the selected curve. Note that
FeatureCAM automatically sets the direction of the curves so this option
should not be necessary most of the time.
There are two additional check boxes. Use the Show lower curve
option to display the corresponding bottom curve for each curve selected.
Check Hide surfaces when finish to have the surfaces hidden after
you leave this dialog.
Alignment of 4-axis curves

Adding a single point to a 4-axis wire curve piece
1. Click the Pick curve piece then location
button.
2. Select the curve piece.

3. Slide the cursor along the pieces and click the location.
4. A new point is inserted at this location.
Adding points uniformly to a 4-axis wire curve
1. Enter the number of pieces. A piece is the segment between the
points. The number of points added is number of pieces -1.
2. Click the Pick curve piece
button.
3. Click the piece of the curve.

Removing curve pieces from a 4-axis wire curve
1. Click the Merge broken pieces
button.
2. Click the first curve piece.

3. Click the last curve piece. The portion of the curve is highlighted
as you move the cursor to preview the selected region of the curve.
4. All internal points within these pieces are removed.
You cannot remove the segment that contains the start point.
4-axis match curve
The feature should be displayed when this dialog comes up. If not click
here (see page 486).
FeatureCAM attempts to match up the points of the upper and lower

curves of a 4-axis feature. If the curves are not matched as you would
like, then you can manually match the two curves.
Before starting to manually match your points, first make sure that the
start points of each curve are close to each other when viewed from the
top. Use the start page of feature wizard or the start tab of the
Properties dialog.
To match two curves:
1. Click the pick curve point
button.
2. All of the endpoints of the two curves are displayed as green

rectangles and their connections are shown as thick green lines.
3. Click a point of the lower curve.
4. Click the corresponding point of the upper curve. These points are
connected with a green line.
5. Repeat steps 3 and 4 until you have matched all the points you
wish to change.
6. If you want to see how the feature looks with your new matches,
click the Next button. If you want to make further changes, click
the Back button and repeat steps 1-4.
If you want to connect a point on the bottom curve to multiple points on
the top curve, hold down the SHIFT key when you select the bottom
point and each top point.
You cannot change the start points of the curves by adjusting the
matching points. Use the start tab to change the start points.
Sometimes you need to insert extra points or delete points from a curve In
order to properly align the curves. click a topic below for more
information:
Adding points uniformly to a 4-axis wire curve (see page 492)
Adding a single point to a 4-axis wire curve piece (see page 492)
Removing curve pieces from a 4-axis wire curve (see page 492)
Overview of EDM operations

FeatureWIRE offers five different machining cycles for different
purposes. Every operation type has a whole range of parameters and
options.
Overview - Contouring operation (see page 499)

Overview - Retract operation (see page 494)
Overview - Stop operation (see page 495)
Overview - Cutoff operation (see page 499)
Overview - Pocketing operation (see page 497)
Overview - Zig-Zag operation (see page 498)
Operations (FeatureWIRE)
The operations that you select control the types of strategy attributes that
are displayed on Strategy tab. More than one operation can be created
by selecting the primary operation from the menu and then selecting the
Cutoff or Contour check boxes that appear to the right of the menu.
Retract (see page 494)
Stop (see page 495)
Pocketing (see page 497)
Zig-zag (see page 498)
Cutoff (see page 499)
Contour (see page 499)
Retract operation
Available for both 2-axis and 4-axis features.
The contour is not cut completely but is stopped shortly before the
contour end point. The distance of this position from the contour end
point is set in the Stop Length field. This option is generally used when
cutting multiple contours whereby the cut part should not be separated
from the work piece - e.g. when the program should run automatically
overnight.
A cutoff operation is normally used after this operation to cut the part of
the contour that is not cut by the Retract operation. Cut Off machines
the left over part in the opposite direction to the machining curve.
Stop operation
A stop command is inserted into the wire path together with a further stop
at the end of the contour. The distance of the new stop position from the
contour end point is defined in the Stop Length field. If you wish to
overcut the contour end position, you can also define an Overlap. In
centerline simulation, the locations where the wire stops are shown as
small squares. A stop operation has two different locations where the wire
stops.
Overview of Pocketing Cycle

This cycle enables contour parallel area clearance of a closed curve.
Available only for 2-axis features.
General rules
The machining curve must define a closed pocket
The start position of the cut is set automatically to a point on the
boundary. The wire then feeds to the center of the pocket and then
cuts from the inside toward the boundary.
If you wish to ensure that the wire starts in a particular position (to
thread the wire for example) you should define a start point. The
toolpath then starts at the start point and then feed to the center of
the pocket.
No attempt is made to check if the stepover value is larger or
smaller than the wire diameter.
Cutter compensation does not apply to a pocketing operation
because it outputs a wire path that is already corrected (that is, no
compensation is entered on the machine).
Overview of Zig-Zag Cycle

This option defines a zig-zag area clearance cycle for a closed curve.
Available only for 2-axis features.
General Rules
The machining curve must define a closed pocket
The start position of the cut is set automatically to a point on the
boundary. The wire then feeds to the beginning of the zig-zag
pattern.
If you wish to ensure that the wire starts in a particular position (to
thread the wire for example) you should define a start point. The
toolpath then starts at the start point and then feeds to the beginning
of the zig-zag pattern.
By the definition of the cut Angle (see page 510) you can control
the direction of the wire path and also the start point of the cycle
(see page 498).
No attempt is made to check if the stepover is larger or smaller
than the wire diameter.
Cutter compensation does not apply to a pocketing operation
because it outputs a wire path that is already corrected (i.e. no
compensation is entered on the machine).
Start point for Zig-Zag Cycle

The start position that is automatically calculated by the software is
directly dependent upon the Angle of the Wire path as set on the Cycle
Data tab on the Segment Data dialog.
Angle = 0 Start point of the cycle
bottom left.
bottom right.
top right.
top left.
The chosen angle can naturally lie between the examples shown above. In
this case the start point is set to the nearest of the positions shown. On
extremely complex contours it may be necessary to experiment with the
cut angle to find the optimum start point.
Cutoff operation
This option is normally used after a contour has been cut with the Auto
Path option Retract.
Cut Off cuts the part of the contour that is left by the Retract option.
The machining takes place in the reverse direction to that of the
machining curve i.e. from the contour end point to the stop position. The
wire stops before pulling away from the part. This stop location is shown
as a small square.
Contour operation
This cycle is the generally applicable cycle for cutting contours.
General Rules
The curve can be open or closed. A contour operation traces the entire
length of the curve. The number of passes is determined by Contour
passes (see page 508). A contour operation can be optionally added to
retract, stop, pocket, zig-zag or cutoff operations by selecting the
Contour option on the Strategy tab.
If you want the contour to overlap, enter the amount of overlap you want
in the Contour Overlap box.
Attributes
Strategy tab
Click the Strategy tab in the feature's Properties dialog to access the
Strategy attributes:
Primary cut/offset direction

For closed curves, the Primary Cut Dir attribute controls the direction
of a cut. The options are CW (clockwise) or CCW (counter-clockwise).
For open curves the Primary Offset Dir attribute controls the direction
of a cut. The options are Left or Right. These settings are relative to the
machining-side setting.
Stop Length
This parameter is used for Retract, Stop or Cutoff operations.
It defines the distance from the normal contour end position to the
inserted stop or end position.
Total passes
The total number of passes to take to cut the feature. If a feature has a
Retract, Stop or Cutoff operation these operations will each be
performed Total passes - Contour passes. If a feature has a contour
operation, Total passes must be at least 2. Total passes must be between 1
and 9.
Leave allowance
Leave allowance is the amount of material to leave after the contour pass.
Retract length
The Retract Length attribute is used for Retract, Stop or Cutoff
operations.
It defines the distance that the wire retracts from the part at the conclusion
of an operation.
Offset method
The Offset Method attribute controls whether the offsetting of the wire
path is performed on the machine using cutter compensation (see page
506) or by FeatureCAM (see page 506). Select Cutter comp to perform
the offsetting on the machine, or Offset Toolpath if you want
FeatureCAM to perform the offsetting.
See also Working with wire radius compensation (see page 505).
Working with wire radius compensation
To cut a workpiece to the finished size the Wire radius compensation
function on the NC-machine is normally used. Activating this function
with a particular value causes the machine to calculate a new path for the
center of the wire. The compensation value is normally composed of the
wire radius plus the spark gap allowance plus any finishing allowance
that may be required. The compensation value is normally entered in a
Compensation Register on the machine.
If the erosion of a workpiece needs to be made in several cuts (roughing

and finishing), each cut normally uses a different compensation value or
compensation register. The values for the compensation are often given in
a table supplied by the machine builder or automatically entered in the
compensation registers via the technology tables built into the controller.
In every case you should ensure that the appropriate linear lead-in and
lead-out moves are contained within the program to enable the
compensation to be switched on and off.
The output of the commands to activate and deactivate the compensation
is automatically carried out by the software on the first and last moves.
For further information see:
Radius compensation on the Machine (see page 506)
Radius compensation in FeatureCAM (see page 506)
Wire radius compensation on the machine
When using the Wire Compensation command, the center path of the
wire will be calculated and corrected directly by the nc-machine. The
compensation amount is normally entered in a Compensation
Register on the machine controller and activated by an appropriate
command within the nc-program. The format of the command to activate
the compensation and to control the compensation direction is dependent
upon the nc-machine type. The FeatureWIRE software supports the
output of these commands both for single and multiple cuts
(backwards/forwards cutting or Main/Sub-Programs)
The following parameters control the use of wire compensation on the
machine:
Total passes (see page 504)
Contour passes (see page 508)
Uni-Directional (see page 508)
Uses macro (see page 508)
Wire radius compensation in FeatureCAM
If the wire radius compensation is carried out by FeatureCAM the
appropriate compensation value and direction will be automatically used
to produce a wire path that is already corrected. The path cannot be
altered by changing the offset register of the nc-machine. This may be
necessary for example, when cutting a contour which contains elements
or arcs which are smaller than the required compensation amount and
thus cannot be cut using the machine registers.
The following parameters control the use of wire compensation:
Total stock (see page 508)
Stepover (see page 509)

Contour stock (see page 509)
Overlap
This parameter is used for Stop or Cutoff operations.
It defines the distance by which the normal contour end position will be
overcut.
The run-off back to the end position of the contour will be at an

angle. On some machines (for example, Agie), an angled run-off
may not be allowable.
If the overlap is too large, a triangular piece of material will be left,
which may fall and halt the machine.
Contour passes
The number of passes to take for the contour operation.
Uni-Directional
Applies to Contour, Stop, Retract and Cutoff operations that use the
Offset Method of Cutter Comp.
For multiple passes, the cutting direction for each following pass is not
reversed and all passes take place in the defined direction. At the end of
each pass the wire is cut and the machine re-positions to the start point for
the next pass.
Uses Macro
Applies to Contour, Stop, Retract and Cutoff operations that use the
Offset Method of Cutter Comp. Available for 2-axis features only.
This option activates the automatic creation of sub-programs for the
machining of operations. The format and output of sub-programs must be
defined in the post processor. The use of sub-programs is particularly
useful when producing chain programs. In this case each machining
contour will be written to a separate sub- program. The main calling
program will then contain only the movements required to move to the
next start point.
For multiple pass, if the Uni-Directional (see page 508) option is
selected then only a single macro will be outputted containing a single
pass.
Total Stock
Applies to a Contour operation.
This parameter sets the amount of material that should be removed from
the contour when using the Offset Method of Offset Toolpath. If you
set this value to 0, only one cutting pass is made.
The calculated wire path represents the center of the wire, that is
the actual amount that will be left on the curve is dependant upon
the values set for cutter compensation.
Stepover
Used for pocketing and zig-zag cycles
This parameter defines the step over between passes for the Pocketing
and Zig-Zag cycles.
Contour stock
Contour Stock is the amount of material to leave for the contour
operation.
Cut Angle for ZigZag

The Cut Angle attribute sets the cutting angle for a ZigZag operation.
The angle is defined from the X-positive axis of the current UCS. Enter
the angle in degrees.
Cleanup pass
This option is used to create a finishing cut at the end of a ZigZag
operation. The contour will be cut with a contour parallel finishing path to
remove any rough edges left by the step-over between passes.
Finish allowance
This is the amount of material left after a ZigZag pass. Even if a cleanup
pass (see page 510) is used, the finish allowance still remains.
Stepover
This parameter defines the step over between passes for Cutoff, Stop,
Retract and Contour operations. It applies when the offset toolpath
(see page 505) option is selected.
Stop code
For stop operations you can choose the stop code from among the
following choices.
M00 is program stop. This stop will be always be performed.
M01 is optional program stop. There is a setting on the machine tool to
observe or skip these stops.
Start tab
Start/end point (FeatureWIRE)
When this page is displayed in the wizard, the feature is displayed by
showing a ruled surface. If the feature is not displayed, click here (see
page 486).
Leads are non-perpendicular by default. If you want the lead to be
perpendicular, select the Pick only perpendicular lead box
before you click the Pick location button. Click the start point and
FeatureWIRE highlights the corresponding perpendicular point
when you mouseover the curve segment. Click to accept it.
Die and Punch Features
For 2 and 4-axis die or punch features, a start point is automatically
calculated. You can change the start point for a die or punch feature using
the following procedure:
1. If the feature has multiple curves, select the appropriate curve from
the Curve list.
2. Click the Pick location
button.
3. Click the new Start point.

You must pick on the appropriate side for the feature type. For die
features, pick on the inside. For punch features, pick on the outside.
For side features pick on the machining side. If you pick a point in
the incorrect side, the approach moves will gouge the part.
1. Select the segment of the curve to connect the start point to by
moving the mouse over the feature until the segment of the curve
you want is highlighted and then click the mouse.
2. The X and Y coordinates of the new start point is displayed in the
dialog.
If you want to force the wire to start on the curve, you cannot simply
double-click. You must move your second pick (the one that indicates the
curve segment) slightly so that you are not picking the same point twice.
If you are creating a 4-axis feature, follow the above procedure for both
the upper and lower curves.
Side Features
For 2 and 4-axis side features, the default is to start at the first point of the
curve. To add new linear moves at the start or end of a curve:
1. If the feature has multiple curves, select the appropriate curve from
the Curve drop down list.
2. Click the Pick point
button for either the start or end point.
3. A line will rubber-band from the current start of end point.

4. Click a point at the new location.
5. Alternatively, you can simple enter the new end point coordinates.
Lead style (FeatureWIRE)
There are several choices for the type of moves for leading in and out of a
contour operation
Direct will move straight from the start point to the contour.
There are four different ramp styles that arc onto the contour. The
diameter of the arc is specified as a percentage of the tool diameter. The
same diameter arc is used to ramp off the contour and then the wire
returns to the start point.
The ramp styles available are:
Teardrop:
Bullet:
Arc:
U-Shape:
Misc tab
Wire cutting/threading
Wire cutting/threading offers four settings to control the output of wire
threading or wire cutting commands.
No wire threading or wire cutting commands are
output in the NC-program.
The commands to thread the wire and cut the
wire are output automatically at the start and
end of each operation within the feature.
The wire cutting command is output at the end
of each operation within the feature (but no wire
thread command at the start). When viewing the
toolpath in center line simulation, the Cut
location is denoted with a small circle.
The wire threading command is output at the
start of each operation within the feature (but no
cut wire command at the end). When viewing
the toolpath in center line simulation , the
Thread location is shown as a small plus sign.
Outside sharp corner toolpath

These options control how sharp corners are cut.
The following options are available for Retract, Cutoff, Stop and
Contour operations:
The machine will cut to the intersection point of the two lines.
Modify outside corners (see page 515)
Modify inside corners (see page 515)
Modify both (see page 516)
Modify outside corners
A radius will be inserted into the wire path at each outside sharp corner.
This can be useful for reducing unnecessary movements and for
producing cleaner corners.
Modify inside corners

Circular
A circle is inserted in the corners. The center of the circle lies on the
corner point.
Triangular
The path follows a triangular shape at an inside corner. Specify the length
and width of the triangle.
Rounded
The path rounds inside corners. Specify the radius.

Modify both
Both inside and outside corners are modified as shown below.
Auto round
If Auto round is set, arcs are inserted at all sharp corners. This is
applicable only if Cutter comp. is set and you have a leave allowance
or if Cutter comp is not set. If you already have modify outside corners
(see page 515) set, it will not perform any further rounding on these
corners. It will round inside corners (even if modify inside corners (see
page 515) is set) by inserting an arc before and after the circular corner as
shown below: The radius of the inserted arcs is equal to the radius of the
wire.
Cuting data tab

The Cutting Data tab provides the Feed, water and cutter compensation
registers (see page 518) for each pass of the operation. The usage of all
these settings is dependant upon the machine and controller type. These
values can also be set automatically from the current material database, or
they can be filled in manually. To display this tab:
1. Double-click a FeatureWIRE feature to bring up the properties
dialog.
2. Click an operation in the tree view.
See also Turning Post Variables.
New cutting condition

Add a new wire EDM cutting condition by filling in the following values:
Material: Pick an existing material or add a new material name by typing
it.
Thickness: Pick an existing thickness from the drop down list or enter a
new thickness. If you do not specify a unit then it defaults to the unit of
the part. For millimeter enter mm (that is 5 mm). For inches enter in. (that
is 0.25 in.). Do not forget the period.
Wire: Pick an existing wire type or type a new name.
Wire Dia.: Pick an existing wire diameter or enter a new one. The unit of
the diameter is handled the same as the wire thickness.
Machine: Select an existing machine name from the drop down list or
type a new machine name.
After you enter the values, click OK.
Cutting condition tables can contain values for cutting anywhere from 1
to 9 passes. Select the number passes and click the New button to add the
feed, water and cutter compensation registers (see page 518).
Feed, water and cutter compensation

registers
Most modern NC machines today have an integrated technology database
with which the machine uses to set up the optimum cutting conditions for
the workpiece. In this way the cutting will be accurate and will use the
full power of the machine. These settings for the cutting conditions are
usually stored in Registers in the controller and are activated by
particular codes in the NC program. The FeatureWIRE software enables
you to define these codes for up to nine cuts (either backwards/forwards
cutting or with sub-programs). You can also load pre-defined settings
from a database which you have prepared yourself.
Feed
This field is used to select the generator setting on the wire machine. The
generator setting controls the cutting speed of the machine by setting
parameters such as strength, pulse time and pause time between pulses of
the electrical current used to produce the spark. These parameters will
vary with the workpiece material, height and so on.
Water
This field is used to select the machine register that defines the water flow
during cutting. The parameters that are controlled include the water
pressure, flow rate and so on.
Comp. Reg.
This field sets the number of the Compensation Register of the NC
machine which is used for wire radius compensation. The value held
within this register is the amount by which the wire will be corrected to
the left or right of the defined wire path when the function for wire
correction on the machine is switched on (normally G41 or G42)
Comp. Val
This field sets the wire radius correction value for the given offset register
on the machine. The value is normally the sum of the wire radius + spark
gap + any finishing allowance required. For most machines, the
compensation value is referenced through the compensation register, so
there is no need to set this value.
Network security
version (Net)
If you are licensing three or more copies of FeatureCAM, you can now
purchase a network security version that removes the requirement of a
security key for each computer running FeatureCAM.
Centralized Administration - The licensing issues are all concentrated
on the server computer. This centralized administration provides easier
maintenance for large installations.
Flexibility - The FeatureCAM network licensing provides concurrent
licensing. This means that you purchase a certain number of licenses that
can be used anywhere on your network, and that computer does not need
to have a security key attached. For example, if you license 5 copies of
FeatureMILL, up to five copies can run simultaneously as long as the
computers are connected to the network.
Security Keys Not Required for Each Computer - With network
licensing, a security key is not required for each computer. Instead, the
licensing is performed across your company's internal network.
520 Network security version (Net)
Overview of multi-axis
multi-turret turning
(MTT)
FeatureCAM's multi-axis multi-turret turning is used for production
turning: for making large lot sizes of a particular part. Sometimes called
4-axis turning, synchronized turning, or twin-turret turning, It's all about
reducing the cycle time of a part. The NC programmer uses two 2 to 4
turrets to do multiple operations at once, thereby shortening the cycle
time. And when combined with the closely-related turn/mill capabilities
of FeatureTURN/MILL, you can achieve another benefit of being able to
machine complex parts in fully automated fashion with a single setup.
Machine Capabilities
FeatureSYNCTURN supports a variety of different machine
configurations
Multiple turrets. Each turret can cut on either main or sub spindle.
The turrets can be cutting simultaneously.
Multiple controllers. Typically one controller per turret. All of the
turrets can be cutting at the same time. Synchronization is done
with wait commands. Contrast this with a lathe with a single
controller in which only the active turret can move. The other turret
is locked out.
Multiple spindles. Main and sub.
B axis is supported. One of the turrets can be B-axis configuration
with a rotary tool.
Overview of multi-axis multi-turret turning (MTT) 521
XBUILD issues
Turret DB is entirely new and must be documented: C-Angle Offset is the
default location of the tool.
Keywords <TURRET-NUM> <SYNCH-NUM1-5>
Setting up a part for multi-spindle

turning
Setups
You need at least two setups for multi-spindle turning, one setup for the
main spindle and a second setup for the subspindle. The Z-axes of the two
setups must point in opposite directions.
If your NC controller requires that both coordinate systems point in
the same direction, this adjustment will be made in the post
processor.
The origin of the two setups can be positioned at any convenient point on
the part.
FeatureCAM automatically creates setups with nondescriptive names like
Setup1 or Setup2. For organizational purposes, you may want to rename
your setups with more descriptive names like Main Spindle.
The first setup will automatically be assigned to the main spindle. If you
desire that the first operations be performed on the subspindle, you should
create a blank setup as your first setup.
Associating features with setups
Features are associated with the current setup. For multiple turret cutting,
the setup associated with the feature will dictate which spindle will hold
the part while the feature is being cut. You can see what setup the feature
is associated with by looking in the part view.
Moving the part
The part must be moved between the two spindles using a collection
subspindle features and perhaps barfeed features.
Machine Simulation
Machine simulation shows each setup cut twice if there is a subspindle
move
522 Overview of multi-axis multi-turret turning (MTT)
Setting up a part for multi-turret

turning
The following issues must be considered for multi-turret turning:
1. Multi-turret machining can be performed with as few as one setup.
2. The post processor that is loaded while you are creating your part
must support multiple turrets.
3. For pinch or follow turning, your post processor must have
opposing turrets.
4. For appropriate machine simulation the post processor must have
the same turret and spindle description as the machine design file.
5. With the exception of automatically synchronized features (see
page 528), features are automatically associated with the first
turret. To move an operation to another turret, you must use the
Turrets tab (see page 523).
Turrets tab
The turrets tab is displayed in the Manufacturing Results Window
on the right-hand pane of FeatureCAM. It is only visible if you are doing
synchronized turning.
To display this tab:
1. Click the Results tab in the upper right corner of the FeatureCAM
screen.
2. Click the Turrets tab at the bottom of the window.
There are two viewing options for the Turrets tab, which you select from
the options at the top of the tab:
Time view (see page 524)
Operation view (see page 524)
Time view
The Time view lists each spindle on the left-hand side of the
window. Each turret that can operate on the spindle is listed below each
spindle. Along the top of the window is a time scale in minutes. The time
scale can be shortened or lengthened by rolling the wheel on the mouse or
clicking within the time scale and dragging. The operations performed on
each turret are listed in boxes under the time scale. In the example shown
below, the machine has two spindles and two turrets that can cut parts
loaded into either spindle. The main spindle has a roughing operation that
is performed simultaneously on both turrets. The identical length of the
boxes surrounding the roughing operations shows that they will take the
same time to cut.
Synchronizing operations
Assign an operation to a turret
Synchronization for a single operation
Operation view
Unlike in the Time view, the Operation view displays the feature
name alongside the operation name.
Operations are displayed vertically, in the order they are machined, in two
columns. Operations cut by the Upper turret are displayed in the
column on the left and operations cut by the Lower turret are displayed
in the column on the right. Drag and drop operations within the grid to
change their order or turret.
Select more than one operation by holding down the Ctrl key.
Pay attention to any warnings that display as a result of moving

operations.
Synchronizing operations
To control which operations are synchronized, that is run at the same
time, you add 'sync points'.
If you want two operations to happen at the same time:
1. Select an operation from one of the columns.
2. Press and hold the Ctrl key and select an operation from the other
column.
3. Either:
Right-click on either of the selected operations and select Set
sync point at oper start from the context menu; or
Click the Set sync at oper start
the Turrets tab.
button at the top right of
A red line is displayed in the list to show the sync point. The two
operations and all subsequent operations move below it.
You can also use synchronization to force one operation to run before
another.
In the example above, we want the hole2 drill operation on the Lower
turret to run before the main_off off Main spindle operation on the
Upper turret. To do this:
1. Select the operation that you want to run first, in this case hole2
drill.
2. Press and hold the Ctrl key and, from the other column, select the
operation that you want to run next, in this case main_off off
Main spindle.
3. Either:
Right-click on either of the selected operations and select Set
sync for 'radial_pattern1.hole2.drill' before
'main_off.off Main spindle'; or
Click the Set sync for 'radial_pattern1.hole2.drill'
before 'main_off.off Main spindle'
button at the top
right of the Turrets tab.
A red line is displayed in the list to show the sync point. hole2
drill is above the sync point and main_off off Main spindle and
all subsequent operations are displayed below it.
To remove a sync point, right-click on it and select Remove selected

sync point from the context menu. To remove all sync points, click the
button at the top right of the Turrets tab.
Remove all sync points
button, at the top
You can also use the Undo sync code changes
right of the Turrets tab, to remove your most recently created sync point.
Automatic synchronized turning

Using the Turrets tab, you can manually synchronize operations. For
cutting OD turning features, FeatureCAM can automatically synchronize
operations and load the appropriate tools in each turret. All of the
automatic synchronized turning requires a lathe with two opposing
turrets.
Pinch Turning
Pinch turning is also referred to as balanced turning. It can be used for
either roughing or finishing. With pinch turning, both tools cut the same
curve (all though one is above the axis of rotation and the other is below).
The feed rate that is calculated for each tool is doubled. The first tool
actually leaves a spiral of material after it's finish pass and the second tool
is positioned at min Z so that it will cut the spiral of material left by the
first tool. The tools cut at the same time so that the amount of time
needed for the finish pass is 1/2 as long. The tool that is selected for the
operation will be automatically inserted into both turrets.
The following picture shows an example of pinch turning.
The two tools are positioned identically in both the X and Z axes.
To set this strategy on a turning operation:

1. Bring up the Strategy tab of the turn operation
2. Make sure that the roughing or finishing pass is enabled by
selecting the Rough or Finish check box.
3. Select Pinch turning from the drop down list after the check box.
Follow turning
Follow turning is typically performed when roughing. Each turret
removes a standard depth of cut. The second turret removes a depth of cut
below the cut left by the first turret. The turrets wait or synchronize at the
start of the cut. One turret is a fixed distance in front of turret 2. The
image below illustrates follow turning. The top tool is in front of the
bottom tool and the bottom tool is cutting deeper in X.
To set this strategy on a turning operation:

1. Bring up the Strategy tab of the turn operation
2. Make sure that the roughing or finishing pass is enabled by
selecting the Rough or Finish check box.
3. Select Follow turning from the drop down list after the check
box.
4. Specify the Follow distance on the Strategy tab of the
operation.
Viewing a turret's NC code

For synchronized turning, a separate NC program is created for each
turret. The Part View has an entry called Turrets. Each turret is listed
under this entry. To display a specific turret's NC code, click the name of
the turret in the Part View. The NC code will then be displayed in the
Results window.
Machine simulation
(MSIM)
Machine design overview

In the New Part Document dialog there is an option for file type:
Simulation Machine Design. Files of this type, have a *.md
extension (.md for machine design). In these types of files you will design
solids that collectively represent a CNC machine and specify how these
solids interact or move according to how your machine operates. (Your
FeatureCAM must have the ability to at least import solids, that is, you
must have the solid import plugin installed which comes with
FeatureRecognition product, the 3D milling product, and the advanced
solid modeling product). Each solid will represent a particular part of
your machine, and it is important that you model each movable part of
your machine as an independent solid. That is, do not make use of the
solid wizard's Combine Solids Command to union two tables into
one solid, as you will eventually want to rotate one table independently of
the other. If, on the other hand, you have imported a file and it contains
one solid, you will want to make use of the solid wizard's Explode
command, allowing you to then reconstruct multiple solids from the
surfaces (probably constructing additional surfaces as well).
530 Machine simulation (MSIM)
In a *.md document, there are no manufacturing-like commands. That is,

there is no stock, no setups, no simulation, and no manufacturing
attributes, manufacturing menu, and so on. The purpose of the document
type is to design solids, and to assign attributes to the solids that match
your particular machine movement and machine hierarchy. An example
of a machine hierarchy is that tableA is on top of tableB and so, whenever
you rotate tableB, tableA is also rotated. This is called a parent/child
relationship, more on this later.
Some general guidelines for machine design follow:
The machine should be designed in its home state. Design the
machine in the file as it is when you have freshly powered on the
real machine.
All FeatureCAM movements are programmed relative to the tool
direction. For example, if FeatureCAM wants to move the tool in a
positive X direction, and your machine tool is stationary, but the
tables move, the +X tool direction is equivalent to moving your
table in a negative X direction.
If you are designing a 4- or 5-axis machine, a single solid can only
rotate about one axis. Unlike the human wrist, for example,
machine joints are modeled as single revolute joints (only allow
rotation about one mechanical axis).
Your *.md file should match your *.fm and *.cnc files - If, for
example, your part file (*.fm) is defined as Indexing around the
X axis, you should design your machine so that the degree of
rotation is about the world X also. (Although we have plans to
remove this restriction in the future, it will simplify the design
process if your wrapping axis matches your *.md file rotation
axis). Also consider your post (*.cnc file); if your *.md file
specifies two turrets, you must use a *.cnc file that enables twin
turrets or the simulation will be unpredictably wrong, and so on.
Using our approach, you should be able to model most lathes as
well as most of the traditional 4-5 axis machines. (Traditional
meaning table on table, rotating head(s), and so on). Nontraditional 4 or 5 axis machines such as a machine which 3 linear
motors push and pull 3 different points of the table (or tool) to
effectively rotate the table through A and B, are not supported by
the framework. (It may be possible to program these in our BASIC
API. More on this later).
Machine simulation (MSIM) 531
Mixing units is supported, that is, you may model your machine in
millimeters, and use it when simulating an inch *.fm document and
vice-versa.
Keep the model simple. Only the necessary details of a machine
should be modeled. Modeling every chamfer, fillet and tiny detail
is only going to slow the simulation down.
At the moment, there are several attributes which are based on the
name of the solid. This means if you wish to rename some or all of
the solids, you should use the rename commands before you begin
using the machine design commands.
At the moment, FeatureCAM cannot distinguish a crash
(sometimes called a clash or gouge) and the case where a table
slides along another table such that the two tables share a common
plane. It is therefore advisable to avoid modeling such solids. The
use of solid offset or transform by small amounts (for example,
.005 inches) will eliminate false gouges in the simulation.
Machine Design Concepts (see page 534)
Machine Design Tutorial (see page 539)
Full Machine Simulation Overview (see page 536)
Lathe Design Overview (see page 532)
Lathe design overview

The machine should be designed in its home state. Design the machine in
the file as it is when you have freshly powered on the real machine.
There are some important rules that the solid designer should follow in
terms of turret positions and orientations with respect to the chuck
position and orientation. That is, lathe tools, or more specifically, lathe
tool inserts cut the stock when they are parallel to the setup's XZ
plane. As such, you must design your lathe machine so that a lathe tool in
slot 1 can be moved into the XZ plane. FeatureCAM will not initially
rotate the turret. The figure below shows a turret that is modeled
incorrectly. The turret solid cannot be moved such that the tool in slot #1
can cut in the XZ plane of the chuck without rotating the turret. In this
situation, you should rotate the turret solid so that the tool is in the XZ
plane of the chuck.
FeatureCAM assumes that the tools will point toward the center of the
chuck. If that is not the case with the machine you are modeling,
FeatureCAM will need the flexibility to move the turret so that the tool
points toward the center of the chuck. In the example shown below, the
tools are parallel to the XZ plane, but they do not line up with the chuck's
center. In this case you should tell FeatureCAM that part of your machine
moves-in-Y, when in reality, your machine cannot move in the Y- axis.
FeatureCAM needs to move the turrets in Y so that the tools can be
translated into the chuck's XZ plane.
The machine simulation does not affect the NC code. No actual Y

moves will be included in the NC code.
It is not necessary or desirable to include the tool holders in the *.md file.
However, the tool blocks are part of the lathe machine.
Machine design concepts

MD Files
A machine is designed in an MD file, and that MD file can be associated
with a setup in a part file. Each setup can be assigned to a different MD
file, reflecting the idea that each setup of a part could be made on a
different machine.
What about fixtures, spindles, and toolholders? Are they part
of the machine?
When Machine Design was added to FeatureCAM 2006 we needed to
deal with the fact that certain portions of the machine are already
supported by FeatureCAM by other mechanisms in versions prior to
FeatureCAM2006. Specifically, the spindle, tool holders, tools, and
fixtures & vises were already handled in other ways within
FeatureCAM. So the *.md file contains just the machine definition: the
solids that represent the machine, plus the relationships between the
solids. But the spindle, tool holders, tools, and fixtures are not part of the
MD file. The MD file contains relationships, however, that bind the
spindle and fixtures to the appropriate places on the machine.
Parent/Child Relationships
A machine can be thought of as a hierarchy. For example, when the slide
on a lathe moves back and forth, the turret moves with it in lock-step. The
turret is considered to be a child and the slide is considered to be a
parent. In this manner, if the G-code specifies a certain movement, you
can assign that movement to the parent and all of the children will move
along with it. That way you don't need to specify how every piece of the
machine moves independently.
Movement
A piece of the machine can be assigned to a particular movement. For
example a slide on a lathe could be assigned the moves in Z movement.
So whenever the G-code has a Z move, then the slide moves
accordingly. Then if the slide is a parent of a turret, the turret will move
too.
Top-Most Table
A milling machine has a top-most table that the fixture, vise, or stock
from the FM file must mate to. A turning machine has a similar concept
with the main-spindle chuck.
Mate
A mate is a term from assembly modeling (or constraint-based
positioning). Suppose there are 2 similarly sized cubes in space, randomly
oriented and you want cube1 to be totally coincident with cube2 so that a
specific corner of each cube occupies the same point as a specific corner
of the other cube, and the edges are parallel and, in fact,
coincident. Suppose further that there is a UCS which describes the
position of the interesting corner of each cube and the orientation of the
edges of that cube. We wish to mate the UCS of cube2 to that of cube1,
that is, we find a transformation (translation and rotation) such that the
origins of the UCS's are made to be concentric, and the X, Y, and Z
directions are the same. That is, there is one transformation (and only
one) which takes cube1 (or cube2) and moves it to where you want it.
Full Machine Simulation overview

FeatureCAM's full machine simulation (FMS) gives the user the ability to
see the entire machine in a view that is similar to FeatureCAM's 3D
simulation. FMS is intended to complement the existing simulation
techniques of centerline, 2D simulation, 3D simulation and Rapidcut.
With these other types of simulation a user can only see the stock and the
current cutting tool. While sufficient for the simplest machines, more
complex machines such as multi-axis turning and 5-axis milling demand
simulation of the entire machine in order to help the user understand how
the machine will cut his part. Odd motions and collisions can be detected
so that the program can be adjusted long before code is sent to the CNC
machine. A user can expect to save a lot of time by proofing his NC code
on the PC before sending it out to the machine.
A few simple machines ship with FeatureCAM to serve as examples and
demonstrations. But the ability to design a machine from scratch is also
included in FeatureCAM as a new document type called a Machine
Design document. The file extension is *.md. The process of designing
a machine consists of creating solids and establishing movement
relationships between them. Since machine design relies on solids, the
user will need to either create them in FeatureCAM or import them from
another CAD system. Solid modeling or solid import must be enabled on
the dongle depending upon your method of creating a machine. Once the
solids are present in an MD file then the user establishes relationships
between them. This capability is part of the MD document type and is
independent of solid modeling or solid import.
FMS applies to every machine except wire. The full range of milling
machines is supported, such as 2.5-axis, 3-axis, 4-axis indexers and rotary
tables, and 5-axis machines of all types. Turning is also fully supported:
simple 2-axis turning, Y-axis, C-axis, turn/mill with rotary (live) tooling,
subspindle, all the way through multi-axis multi-turret turning. Auxiliary
machine functions like parts catchers, tool changers, bar feeders, etc. are
also possible, possibly requiring some coding in BASIC using
FeatureCAM's API.
Using Full Machine Simulation (see page 537)
Machine Design (see page 530)
Specifying file for machine simulation

The machine simulation file is associated with the Setup. For files where
you will simulate multiple setups such as indexed or turn/mill parts, the
machine file should be associated with the first setup of a part.
To specify a machine simulation file:
1. Double-click the first setup of the part to bring up the Setups
dialog.
2. Click the Edit button.
3. Click the Next button until the Setups - Simulation
Information dialog is displayed.
4. Follow the instructions (see page 537) in that dialog.
Setup simulation information

This dialog serves two purposes. First you indicate an offset for loading
the part onto the machine. Second you can select the machine simulation
file that will be displayed during simulation.
The Xoffset, Yoffset and Zoffset parameters represent offsets for
loading the part onto the machine. For simulating single milling or
turning setups these offsets are applied to the setup after the part is
aligned with the top most location (see page 549). For indexed parts or
turn/mill parts, the offset is relative to the stock axis.
Simulation machine design file
If you purchased the machine design option, you can select the machine
design model in this dialog.
You can identify a specific file by selecting Always use this one and
selecting the file. Remember that the number of turrets and locations of
the turrets must match the selected post processor. You can also select
Use the one specified in the .cnc file to use the machine specified
in the post processor *.cnc file.
Using Full Machine Simulation

In order to use full machine simulation you need to establish several
different things:
1. Establish a machine
2. Choose a corresponding post processor

3. Open a part file that uses the kind of machining done on the chosen
machine
Choosing a Machine
In order to use full machine simulation you first need to specify a
machine for each setup. Every setup can have its own machine (MD file).
You can change which machine is used by the setup by editing the setup
properties.
Post Processor
It is important to have an appropriate post processor loaded. So make sure
that you've got an MD file that works well with the post processor that
you have selected.
Choosing Machine Simulation
Once you've established a machine for the setup, then you can choose
Machine Solid Simulation from the View>Simulation menu. Or choose
the corresponding button in the Simulation toolbar. Then press play to see
the animation.
Examples
You should try running the examples that ship with FeatureCAM. In the
Examples\Machine Design folder you will find several folders each
containing three files:
1. A machine design file (*.md)
2. A post processor file (*.cnc);
3. and a sample part file (*.fm)
If you
1. Load the post processor,
2. Load the *.fm file, and
3. Set the *.md file as the machine design file for each setup,
Then you'll be able to see full machine simulation.
Removing objects from the simulation

During a machine simulation you can remove an object from the scene
by:
1. Clicking the Select
button.
2. Clicking on an object.
This just temporarily removes the object from the simulation. It does
not delete it permanently.
Machine design tutorial

This tutorial will guide you through the design of a simple 3-axis milling
machine. We start the tutorial by opening a *.md file that already
contains all of the solids that represent the machine. This tutorial gives
you instructions that help you establish the relationships between the
different solids. You will be guided in establishing movement,
parent/child, and top-most table relationships.
Define Motions
1. First, open 3axFerarriMachine Notcomplete.md from the
Examples folder, in the Machine Design subfolder.
Let's specify how the machine moves. The first piece is the quill.
The quill is represented as a single solid in the part file. You can
see the quill displayed in the Part View and in the graphics
window as shown in the following screen grab.
2. Select Machine Design > Specify Movement from the menu.

In the Specify Movement dialog, set the quill to move in Y as
shown:
3. Set movesin_z to move in Z under the Tool quill section and set
mvs_in_x to move in X under the Table section.
Define Parent/Child Relationships

Next, we will define some parent-child relationships between various
solids. The screen grab below illustrates the first set of parent-child
relationships that we will establish. The machine is the parent of fx1,
which in turn is the parent of movesin_z, which in turn is the parent of
quill. If fx1 moves, then movesin_z needs to move with it, and if
movesin_z moves, then quill needs to go along as well.
1. Using Parent/Child Relationships dialog in the Machine

Design menu, assign each of the following relationships:
machine>fx1, fx1>movesin_z, and movesin_z>quill. The
machine>fx1 relationship is shown in the screen grab below.
Don't forget to click Apply after each assignment.
2. Do likewise for machine>fx2, fx2>mvs_in_x,

mvs_in_x>toptable, mvs_in_x>what_is_this.
Define Stock Attachment Point
Next, we need to define the top-most table so that FeatureCAM knows
where to put the stock whenever this machine is used in simulation.
1. Using the usual UCS tools, create a new UCS based upon the
STOCK UCS. Translate it up in Z by 100mm. This will place it on
the top of toptable as shown below. Let's say that you called it
UCS2.
2. Using the Top-Most Table dialog accessible from the Machine

Design menu, define the top most table and the UCS (in our case,
we are calling it UCS2) that will be used for aligning the fixture or
vise. We could have assigned the top-most table and created the
UCS all in one step by using the Create UCS and go to alignment
wizard radio button of the dialog shown below.
Define the Spindle Attachment Point

Next, we will define a place where the spindle will mate to the quill.
1. Using your UCS creation tools, create a new UCS using the
alignment wizard. Use the Revolved Surface option, and select
face_31 of the quill solid. This new UCS, let's say it is called
UCS3, will be a mating point for the spindle.
2. Then, using the Add Tool Location menu item from the
Machine Design menu, establish your new UCS (UCS3) as
being on the quill. You could have just visited the Add Tool
Location dialog and created the UCS from within there instead.
Save Your New Machine
Save your machine in a new file. Use the Save As command so that you
don't overwrite the example file so you can run the tutorial again
sometime.
Using Your New Machine
In order to use your new machine, perform the following steps:
1. Open a *.fm file.
2. Edit the setup that you want to simulate (if you have more than
one setup, then you'll need to edit each one).
3. Change the offset as needed. Usually, if the part-program zero is on

the top of the part, then the offset will be a negative Z.
4. Change the machine design file as needed. Use the Browse button
to find your new machine file.
5. Select Machine Simulation mode in the Simulation Toolbar and
press Play.
Below is a screen grab of the page that allows you to edit the setup
information related to machine simulation.
Don't forget to use graphics hardware to make the simulation go fast.
Specify movement
If a part on a machine moves independently, the way it moves must be
specified using the Specify movement dialog. If the solid moves only
through the association with its parent solid, you do not need to specify
any additional movements for that solid.
There are two major categories of movements. There are translational and
rotational check boxes for each category. Those movements specified
under the Tool Quill category move in the same direction as the tool. If
the tool moves in the +X direction, the solid will also move in the +X
direction. Solids in the Table category move in the opposite direction. To
affect a +X tool movement, a table solid must move in the -X direction.
Once you determine whether the solid is a Tool Quill or a Table solid,
you should indicate how the solid moves by checking the appropriate
check boxes. For Tool Quill solids, check Moves +delta X, Moves
+delta Y, or Moves +delta Z for translational movements. Check
rotates +A, rotates +B, or rotates +C for rotational movements. For
Table solids the translational choices are Moves -delta X, Moves delta Y, or Moves -delta Z and the rotational movements are rotates A, rotates -B, or rotates -C.
1. Select the solid.
2. Check the appropriate type of movements.
3. Click Apply.
Parent/child relationship
The first step in creating a simulation machine is to specify the
relationships between the different solids. In the figure below, the Table
C is located on top of Table A. If Table A moves, then Table C should
move along with it. This is specified by indicating that Table A is the
parent of Table C. You specify this type of relationship by using the
Parent/child relationships item in the Machine Design menu.

1. Select the parent solid.
2. Select the child solid.
3. Click Apply.
All solids must be associated with the Machine. The machine is not an
actual solid, but it represents the top level of the machine. All solids must
be connected to the machine to be included in the simulation. The
parent/child relationships are displayed in the part view under the
Machine category. The following image shows the hierarchy for a
simple table-on-table machine.
Top-most table
The top-most table solid is the solid to which the stock and clamps will be
attached. That is, the stock and clamps in the machine simulation will
move around with the solid that is specified in this dialog as if they were
children of the solid.
For a lathe, this will be the main spindle or chuck. For mills, it will be the
top table solid. Use the Top most table command in the Machine
Design menu.
1. Pick the solid.
2. Pick the UCS on the top of the solid where you want the part
mounted. Note that if your part has its coordinate system located on
its top, you can offset the solid in the Simulation Information page
of the Setup wizard.
3. Click Apply.
For a lathe or turn/mill machine, make the main spindle or (main) chuck
the top-most table (there's also a Subspindle command), and set the
UCS as you would on a turning part, that is, X is up and Z is left-toright. Recall that the UCS mating is done considering the Setup's
directions. That is, the origins of the UCS are made to be concentric, and
the X, Y, and Z directions are the same.
For 4-axis indexed parts, the combination of the .fm's setup's clamp
location and the Top- most table location should translate the stock
such that the index axis of the part is aligned with the table's
rotation axis. If this is not true, the simulation cannot rotate the
machine about the index axis.
The Top-most Table UCS is the most crucial UCS to get right
especially for a turning machine. FeatureCAM's simulation will align
(transform) the whole machine so the the top table UCS is aligned with
the setup (minus the offsets found in Edit Setup - Simulation
Information page). That is, the machine is transformed such that the +X
of the top table UCS is aligned to the setup's +X, +Z to +Z, and the
machine is translated such that the setup's origin minus Simulation
Information offsets is the same point as the top-table UCS origin. With
a turning machine, the +X direction should point towards the main/upper
turret (if there is no upper turret, it points away from the lower turret),
and should have its origin at the center of the main spindle. The
simulation movements take place in this coordinate system. That is, if
you've used Machine Design - Specify Movement to indicate that a
turret slide can move in X, it is the X direction of the top-table UCS that
indicates the direction of translational freedom.
Subspindle
If you are modeling a lathe with a subspindle, the solid representing the
subspindle must be identified. Use the Subspindle command from the
Machine Design menu to identify the solid.
2. Click Apply.
This command allows you to designate which solid represents the
subspindle. In a sense, this is akin to the Top-most Table dialog, that is,
FeatureCAM has to know which solid holds the part when cutting on the
subspindle.
If the stock is ever parted with a cutoff operation, the right-most
stock will become a child of the subspindle solid.
The Local coordinate system (see page 555) of the subspindle is

important in terms of simulating subspindle positioning
features. Typically the subspindle is positioned with respect to a machine
coordinate system and not the part program (or setup) zero. Set the local
coordinate system's Z direction to match the machining subspindle
commands, that is, if the machine's subspindle moves to the left in
response to a negative W (or sometimes B), set the Z direction of the LCS
pointing to the right (like the main spindle or turning main setup). On the
other hand, sometimes the positive W axis points to the left, that is, the
machine moves to the left in response to a positive W (assuming W=0 is
the home position). The home W and max W can be set in the .cnc
file (Edit the *.cnc file, and go to CNC-Info - Spindles).
Here, the subspindle's LCS's (UCS shown) Z direction points to the

right; this would be correct for a machine where a move the
subspindle in to grab the part is a negative W and the move the
subspindle home is a W of zero.
Add tool location

A machine must have at least one tool location specified. The Add tool
location command on the Machine Design menu performs this task.
Milling Machines
For most milling machines, the tool location is a single point at the center
of the base of the spindle as shown below. The +Z axis points away from
the part. The choice of the X and Y directions of the UCS are relatively
arbitrary.
To complete this dialog for milling machines:

2. Click Existing UCS and then select the UCS from the graphics
window or click Create UCS use alignment wizard and then
create the UCS.
3. Click Apply.
Lathe Overview
For lathes, tool locations represent locations to mount tool blocks. The
bottom half of the dialog is specific for turning turrets. If a turret solid has
a local coordinate system (see page 555), multiple tool locations can be
added all at once given the UCS for tool location slot number 1. The UCS
for slot 1 is rotated around the solid's LCS origin and Z axis the given
number of times. For instance, if a turret holds 12 tools, create a UCS for
tool slot #1 with the -Z axis pointing toward the part. Using that UCS,
type the number 12 into the # of tools edit box, and 12 tool locations will
be added to the turret solid. If you add a single tool location to a solid and
click ok, the next time you add a tool location to the same solid, adds a
tool location for slot #2 to the solid. The exception to this rule is when
you add multiple tool locations using the multiple turret locations. In this
situation existing locations are overwritten. Also particular to turning
machines, you must specify the mounting direction of the tool intended
for this tool location. That is, does it specify a tool position on the face of
the turret for cutting on the main spindle, a tool position on the face for
cutting on the subspindle, or an OD mounted tool which could cut in
either direction. The figure below illustrates these kinds of tools.
When adding a tool location for a turret, the Which turret section tells
FeatureCAM if this is a main turret or sub turret, and also specifies
whether the turret is above or below the stock. These settings should
match the information in the .cnc file.
Lathe Details
Follow these steps to complete this dialog for lathes:
2. Click Existing UCS and then select the UCS from the graphics
window or click Create UCS use alignment wizard and then
create the UCS. Remember that the -Z axis of the UCS should
point away from the part you will be cutting.
3. If your solid has a local coordinate system (see page 555) you can
specify additional locations that will be replicated around the local
coordinate system origin by entering a positive number for # of
tools. See the description under lathe overview for more details.
4. Specify the mounting direction as described above.
5. Specify the turret location as either Main upper, main lower,
sub lower or sub upper.
6. Click Apply.
The directions of the tool location UCS may be somewhat confusing
when adding a tool location for a turning machine/turret, but think of it in
terms of a milling machine. An OD turning lathe tool (or a rotary-X tool)
is going to be aligned such that the tool holder is parallel to the -Z axis
of the tool location's UCS. That is, the positive Z axis of the UCS should
point into the turret. This is true for an upper or a lower turret.
Tool location orientations are the same for milling and turning. +Z points
into the quill or turret. In the image below both a machine tool spindle
and lathe turret for illustration purposes only.
Local coordinate system

For any machine part that rotates during the simulation, a center of
rotation, its local coordinate system must be specified using the Local
coordinate system command in the Machine Design
menu. Rotating parts include turrets and rotating tables. Parts that rotate
about the A axis will rotate about its local X axis. B axis rotations are
performed about the local Y axis and C axis rotations rotate around the
local Z axis.
Turrets rotate about their local Z axis.
If a solid rotates only if the parent rotates, you do not have to define
a local coordinate system.
1. Pick the solid.
2. Pick the UCS or click Create UCS and go to the Alignment

wizard to create a new UCS.
3. Click Apply.
Tool block for turret

For a mill/turn machine, the holder is held by tool blocks. The tool blocks
are most likely supplied by your machine tool vendor. As such, they are
stored in the machine design file. Each tool block must be represented by
a separate solid model. Tool blocks should not be associated with the
machine through a parent/child relationship. The solids only have to be
identified as a tool block and the appropriate block will be displayed
along with the selected tools during machine simulation. The tool blocks
can be modeled in any location.
You may design your tool block solids out in space, or in place such that
they plug into tool slot #1. That is, the Tool block for Turret dialog will
require two UCSs - the purpose of the left-hand's UCS is to transform the
tool block into the turret and the other is used to mate the tool and the tool
block. If you design your tool block out in space, the left UCS will tell
FeatureCAM how to transform the tool block into the turret. That is, this
UCS will mate with the tool location on the turret (positionally as well as
rotationally). FeatureCAM will transform the tool block such that the
position, +X, and +Z are all matched to the turret tool location, that is the
+X of this UCS matches with the +X of the tool location on the turret,
origin is origin, and +Z is +Z. If you design your tool block in tool slot #1
(that is, there is no need to transform the tool block into the turret), use
the same UCS as the tool location slot #1 on the turret. The right UCS is
used to position the tool relative to the tool block. In some sense, you can
think of this as adding a tool location to a tool block solid, that is the tool
holder is aligned with the minus Z direction of the mating tool UCS.
There are three basic types of tool blocks - those that hold OD turning
tools, those that hold X-rotary tools, and those that hold ID turning tools
(boring bars), drills, and other Z-axis aligned milling tools. Additionally,
you may wish to differentiate between a OD turning toolblock for lefthanded tool versus a right-handed tool.
There is also an option for X-rotary tools - you can mount them on the
OD of the turret or on the face of the turret. If, when adding a tool
location on the turret, you specified the tool position was on the face of
the turret, you should use the face-mounted option here in this dialog as
well. (The converse is also true, if the OD mounted tool was used as a
tool location, please use the OD mounted X-tool block). Currently, if you
use any left-handed turning tools, you must add a left-handed tool
block. (Eventually, FeatureCAM could use a mirror of the right-handed
tool block). If you cannot mount a tool to the OD of your turret, you do
not need to define an OD mounted tool block. You must, however, have
at least one solid tool block defined for every tool-type that you intend to
simulate.
If you do not define an OD-turning toolblock, FeatureCAM will attempt
to use an OD mounted X-tool block for any OD turning tools. In this
manner, you can generally define a machine with only two toolblocks,
one for OD turning and X-tools, and another for ID boring bars and other
Z-tools. Currently, you cannot use same solid for different types of
toolblocks.
This may be somewhat confusing when adding a tool location to a
toolblock, but think of it in terms of a milling machine. The tool is going
to be aligned such that the tool holder is parallel to the -Z axis of the tool
location's UCS. This is true whether you are considering milling live-tool
holders, OD turning holders, or ID turning boring bars, or Z-aligned
drills. The positive Z direction will point into the tool block.
You need only to define tool blocks for the main turret. Tool blocks with
appropriate transformations will be used for the sub-turret automatically.
Solids are identified as tool blocks by using the Tool block for turret
command from the Machine Design menu.
2. Select the first UCS. This UCS is the mounting location to turret
shown in the figure below. This location will be mated with the
tool location specified for the turret. The dialog labels this location
as: This UCS will match up with the tool location on the
turret.
3. The second required UCS is labelled The tool is located by

this UCS. This is the location where the actual tool will be placed
on the tool block. In the example below, this UCS is labelled Tool
Location. See Positioning turning tool holders in a tool block (see
4. Identify the type of block. This information will be used to select

the appropriate tool block for a particular tool. Currently, you
cannot use same solid for different types of toolblocks.
OD turning (for right handed tool)
OD turning (for left handed tool)
X mounted tool on turret OD
X tool not mounted on OD
ID boring or drilling
5. Click Apply.
G53 Z0 before indexing

The Machine Design menu has a check box embedded mainly for 5axis machines. The G53 Z0 Before Indexing Command will
simulate the movement of the tool to Z=0 in the machine's coordinate
system before performing the indexing rotations. The effect of putting
such a line in the segment start is that the tool will retract to a safe
position before the tables and/or head index to a new set of angles.
This command does not affect the G code. It only performs the
simulation of this move.
G28 before tool change

Output a G28 to move the tool to turret home before changing the tool.
Click this option from the Machine Design menu to enable the
simulation of it. It will not affect the NC code.
Delete tool location

This command is found in the Machine Design menu and it removes
any tool locations associated with a solid.
1. Pick the solid.
2. Click Apply.
Positioning turning tool holders in a

tool block
The tool location UCS for a turning tool block should be located at the
back of the holder at the bottom of the tool block as shown below.
The tool holder will be positioned with the back of the tool along the Z
axis of the tool location UCS and will extend below the tool block by the
Tool holder width labeled A in the Holder tab (see page 96) of the
Turning tool properties dialog. Additionally, the tool tip is located a
distance of the Tip-to-back Dimension labeled F in the Holder tab of
the Turning tool properties in the local X direction of the tool location
UCS (the turning stock Z direction).
How does
FeatureCAM make its
decisions?
How holes are manufactured

FeatureCAM follows this process for drilling holes:
1. Analyse the hole size, type, and attributes to determine what tools
to use.
2. Pick feeds and speeds based upon the material being drilled.
3. Prepare the site with spot drill and pilot drill operations.
4. Twistdrill to depth.
5. Size and counter cutting operations.
6. Tap, or bore/ream if set.
7. Holes are output as either canned cycles or computed moves.
There are infinitely many variations on this process, particularly with
patterns of holes and hole macros. The basic hole process can by finetuned primarily in two places. To fine-tune for all holes in general, use
the Drilling tab of the Default Attributes dialog, and to tune only a
feature, use the Tools (see page 309), Drilling, Strategy and Misc.
property tabs for the feature. The tooling database also has a large impact
on how a hole is drilled, and the feed/speed database to determines the
feeds and speeds used.
How bosses are manufactured

FeatureCAM follows this general process:
1. Analyse the curve to determine what tool to use.
2. Pick feeds and speeds based upon the material being machined.
3. Generate a roughing pass, possibly in multiple Z steps based on the
height of the boss.
4. Generate a finishing pass.
5. If the boss has a draft angle, cross section curve or corner radius,
see Manufacturing draft angles or bottom radius regions (see page
568).
The process can be fine-tuned primarily in two places: the Default
Attributes dialog, to tune only a feature, use the Tools, Milling, Strategy
and Misc property tabs for the feature. The tooling database also has a
large impact on how a boss is machined, and the feed/speed database
helps to determine the feeds and speeds used.
See also boss features
How is a chamfer machined?

In general, FeatureCAM uses the following process:
1. Choose a tool based upon the width and depth of the chamfer, and
on the tightest bend in the curve.
2. Pick feeds and speeds based on the material being machined.
3. Generate a roughing pass.
There are many variations on this process. The process can be fine-tuned
primarily in two places:
the Default Attributes dialog.
to tune only a feature, use the Tools (see page 309), Milling,
Strategy and Misc. property tabs for the feature.
The tooling database also has a large impact on how a boss is machined,
and the feed/speed database helps to determine the feeds and speeds used.
See also chamfer features
562 How does FeatureCAM make its decisions?
How faces are manufactured

FeatureCAM typically follows this process:
1. Select a facing tool.
3. Generate a facing pass, possibly in multiple z steps depending upon
the amount of material to remove.
There are some variations on this process. The process can be controlled
in the Stepover tab of the Default Attributes, and on the Tools,
Milling, Strategy, and Misc. property tabs for the feature. The tooling
database also affects the decisions, and the feed/speed database helps to
determine the feeds and speeds used.
See also Face features and FeatureMILL 2D Milling algorithms.
How is a face groove machined?

Regular grooves are machined much like pockets, and include both a
roughing and finishing pass. More often than not, a simple groove is
preferred (see the Simple (Engrave) check box on the Dimensions
page). Simple grooves are described in the next section. For a regular
groove, FeatureCAM uses the following process:
1. Determine what tool to use based only on the groove width and
depth.
3. Generate a roughing pass, possibly in multiple z steps depending
upon the depth of the groove.
See also face groove.
How is a simple face groove

machined?
Simple grooves, also called engraving grooves, offer a single-pass
approach to milling a groove. The following process is used:
1. Determine what tool to use based only upon the groove width.
2. Use slotting feeds and speeds based upon the material being
machined.
3. Generate a single pass, possibly in multiple z steps depending on
the depth of the groove.
See also groove feature
How is an ID or OD groove machined?

ID/OD grooves are machined using keyseat cutters, and include both a
roughing and finishing pass. For an ID/OD groove, FeatureCAM uses the
following process:
1. Determine what tool to use based on the groove width and depth.
3. Generate a roughing pass. The groove is first cut down the center
of the groove, with subsequent passes alternating on either side of
the center. Different allowances are possible on the walls and
bottom of the groove.
4. Generate a finishing pass. The finishing pass is based on the Finish
walls and Wall pass attributes.
There are infinitely many variations on this process. The process can be
fine-tuned primarily in two places: the Default Attributes tabs, and the
property tabs of a feature. The tooling database also has a large impact on
how a groove is machined, and the feed/speed database helps to
determine the feeds and speeds used.
See also face groove.
How pockets are manufactured

1. Analyse the curve to determine what tool to use.
3. Generate a roughing pass, possibly in multiple Z steps depending
upon the depth of the pocket.
5. If the pocket has a draft angle, cross-section curve or corner radius,
see Manufacturing draft angles or bottom ra (see page 568)dius
regions.
See also pocket feature.
How rectangular pockets are

manufactured
1. Analyse the pocket dimensions to determine what tool to use.
upon the depth of the pocket.
See also rectangular pocket feature.
How is a round machined?

In general, FeatureCAM uses the following process:
1. Choose a tool based on the desired radius of the round, and on the
tightest bend in the curve.
3. Generate a roughing pass.
How sides are manufactured

1. Analyze the curve to determine what tool to use.
depth of the side.
5. If the boss has a draft angle, cross-section curve or corner radius,
see Manufacturing draft angles or bottom ra (see page 568)dius
regions.
See also side features.
How slots are manufactured

1. Analyse the slot dimensions to determine what tool to use.
depth of the slot.
See also slot features.
How Step Bores are manufactured

1. Analyse the dimensions to determine what tool to use.
on the depth of the step.
See also Step Bore features.
Manufacturing draft angles or bottom

radius regions
Manufacturing steps for basic milled features
Manufacturing steps for milled features with bottom radius regions
or cross sections
Modifying steps for milled features with bottom radius regions
Manufacturing milled features with

tapered walls
Features with a taper have additional steps as shown in this figure Side
view of milling for features with tapered sides.
1. Rough up to bottom radius with flat end tool leaving finish
allowance on bottom.
a. Rough down to bottom radius with flat end tool.
b. Rough bottom radius region with radiused tool to reduce stair
steps on wall.
or
c. Rough along wall with tapered tool in regions 1a and 1b.
2. Finish floor with flat end tool.
a. Finish tight corners missed by steps 1 and 2 using a radiused
cutter.
3. Finish corner radius and walls with radius tool.
If using tapered tools, walls are finished in a separately.
See also Modifying steps for milled features with bottom radius regions.
How a turn feature is manufactured

FeatureMILL follows this general process:
1. Determine what tool to use.
upon the depth of the feature.
4. Generate a semi-finishing pass.

How a bore feature is manufactured

upon the depth of the feature. The toolpaths are the same as a turn
feature.
4. Generate a semi-finishing pass. The toolpaths are the same as a
turn feature.
5. Generate a finishing pass. The toolpaths are the same as a turn
feature.
How a turned groove feature is

manufactured
3. Generate a rough pass, possibly in multiple Z steps depending upon
the depth of the feature.
How a thread feature is manufactured

3. Optionally create a rough and/or finish pass to turn the part down
to the diameter of the thread. The creation of these operations is
controlled by the Rough and Finish check boxes on the
Strategy page. See How a turn feature is manufactured (see page
568) for more details.
4. Optionally generate a roughing pass for the relief groove. The

existence of this operation is controlled by the Relief Groove
check box on the Strategy page.
5. Generate a threading pass.
How a cutoff feature is manufactured

This is how a cutoff feature is manufactured:
3. Generate a cutoff pass.
How a turned face feature is

manufactured
3. If roughing has been requested generate a roughing pass possibly in
multiple X steps depending upon the depth of the feature.
3D manufacturing
3D manufacturing is not as automated as 2.5D manufacturing is.
3D Milling tool selection is governed by the Tool diameter and Tool
end radius settings in the Surface Mill tab of the Default Attributes
(open Default Attributes by selecting Default Attributes in the
Manufacturing menu). FeatureCAM uses that tool to manufacture the
part unless you override the selection on a feature by feature basis.
In areas where the tool fits, the surfaces are milled within the finish
allowance up to the tolerance setting for the surface feature. If the tool is
too large to fit in the more constrained areas of a surface, that area is left
unmilled. If the surfaces contain a gap smaller than the tool diameter, that
gap is bridged by a straight line.
The feature is milled up to the check allowance (see page 402) for any
check surface(s) (see page 277) set with the feature.
How do I get the file to

the machine?
Configuring HyperTerminal
HyperTerminal is easy to use to send and receive NC code from the
machine. The first time you use HyperTerminal, set up an icon for
communication with the machine tool. All the parameters for machine
communication are linked to the icon link you created. In later sessions,
you only have to double-click the icon instead of re-entering the
communications settings.
1. Launch Hyperterminal from the Start menu.
2. Double-click the Hypertrm.exe icon. You may or may not see the
.exe extension depending on your computer's configuration.
3. You may be prompted to install a modem. If you don't have one,
click No and proceed with setting up a communications icon.
4. Enter a name for the icon and pick an icon from the group.
5. Click OK.
6. Set the list box at the bottom of the screen to Direct to COM1 (or
whichever port you will communicate through. Click OK and a
communications properties box appears.
7. Your machine tool should have recommended communication
settings. If so, use those settings here.
8. Click OK. HyperTerminal is configured to communicate with your
machine.
572 How do I get the file to the machine?
You may also need to review how to send and receive files from the
machine.
EZ-UTILS
To run the EZ-UTILS program, double-click the EZ-UTILS icon. When
the EZ-UTILS main screen appears, there are three menus at the top of
the screen: To CNC, From CNC, and Other. These menus contain
commands to communicate with various CNC controls.
EZ-UTILS is an unsupported module that is provided to
FeatureCAM users free of charge. FeatureCAM regrets that it
cannot provide customer support on this application.
To CNC menu
From CNC menu
The From CNC menu shows three commands. These are all used to
accept a file sent from a CNC control to the FeatureMILL system via a
hard-wired cable which is attached to both the CNC control and the
FeatureMILL computer.
Settings menu
Connecting to the SX15 or DX32
Connecting the EZ-UTLS system to BOSS 8, 9, or 10
Connecting to the EZ-Trak SX
Connecting to Heidenhain Interact I and II
Cables
You will need an RS-232 adapter cable to connect the computer to the
communications cable leading to the CNC machine. The adapter cable
may also be used to connect the computer to a serial port expander (ABC
switch box). The adapter cable can be plugged into the COM1 or COM2
port, at the back of the main unit.
The cable can be a 9-pin or 25-pin connector at the computer end.
The manual contains an illustration of the required wiring pattern
for the cable.
How do I get the file to the machine? 573
Serial port pinouts

The necessary communications cables for connecting the computer to any
device or CNC control can be made with parts available from most
electronics supply stores. The pin functions for a standard 25-pin RS-232
port and a standard 9-pin RS-232 port are shown below. Check your
computer owner's manual for the correct information.
574 How do I get the file to the machine?
Support information
Technical support
Technical support is available through:
Your FeatureCAM reseller
FeatureCAM website
Delcam USA. Send mail to sales@FeatureCAM.com or call 1-888393-6455 for pricing information.
What does this warning mean?

General information on manufacturing errors
Since only one stage is displayed at a time, an error may occur in another
stage in the document, but will not appear in the operation sheet currently
displayed.
FeatureMILL will not switch stages to take you to the first error.
A single problem will often result in multiple errors. When multiple
errors occur, it is recommended to fix the tooling errors and regenerate
the toolpaths. In many cases, the other errors will be resolved.
Warnings are also shown in the operation sheet, but do not prevent
FeatureMILL from continuing to generate tool paths. FeatureMILL does
not draw attention to the warnings it gives since the tool path generation
was successful.
Support information 575
Manufacturing errors
Manufacturing errors occur when FeatureMILL is unable to complete the
tool path generation for a part. When an error occurs, the user is unable to
run any simulation, post to NC code or save NC code. Errors appear
between lines of asterisks (*) in the operation sheet listed after the
operation in which the error occurred. Errors are also displayed in the Op
List tab with a red exclamation point icon in the left margin. Warnings
are also tagged using an exclamation point on a yellow triangle icon.
If an error is detected during toolpath generation, the Code generation
failed dialog is displayed.
If you click Yes in this dialog, the first error in the operations list will be
highlighted. If you click No, the errors will still appear in the operations
list, but you must explicitly ask to step through the errors by clicking
Next Error.
If an error occurs during toolpath generation, three error buttons appear in
a separate toolbar in the left-hand corner of the window to enable you to
read and fix the errors. The buttons perform the following functions:
Selects the next error in the operations list.
Selects the previous error in the operations list.
Provides options for fixing the error that is selected.
If you click Hint while an error is selected in the Manufacturing
Operations Sheet, a series of dialogs appears to help you fix the error.
See also Error hints dialog (see page 576).
Error hints dialog box

Manufacturing errors (see page 60)
Error code explanation (see page 581)
Warning codes (see page 577)
How the error hints dialog box works
How the error hints dialog box works
Every Error Hints dialog contains an error code, an error category, and a
description of the error. See Warnings and Error Codes for a
complete list of FeatureMILL error codes. Each dialog also provides an
option for fixing the error. The following buttons appear at the bottom of
the dialog to help you fix the error:
576 Support information
Prev Display the previous option for fixing the error. This button is
only for navigating through the errors. Pressing it does not commit you to
accepting this approach to fixing the error.
Next displays the next option for fixing the error. This button is only for
navigating through the errors. Pressing it does not commit you to
accepting this approach to fixing the error.
Action accepts the proposed method of fixing the problem. The specific
types of actions proposed include: Add Tool, Manager, and Override.
If you select this option, FeatureMILL will step you through fixing the
error.
Troubleshooting 3D toolpaths (see page 426)
Warning codes
Code
Cause
TSD02W Could not find a spiral tool,

substituting with a gun style.
Suggested Action
1. Accept Copy tool from
another crib.
2. Create a tool.
3. Override with a different
tool
4. Select a different crib.
5. Modify feature.
TSD12W Could not find a plug tool,

substituting a bottoming tap
See TSD02W.
TSK12W Chamfer tool can't cut chamfer.

1. Override with a different
tool.
2. Copy tool from another
crib.
3. Create a tool.
5. Modify feature.
TSK22W Counter sink tool can't cut

chamfer
See TSK12W
TSK03W Tool cant cut round.
See TSK12W
TSJ11W
Tool must be ground before

use, zigzag operation
Grind tool.
TSH11W Tool must be ground before

use, slotting operation.
Grind tool.
TSK11W Tool must be ground before

use, profile milling operation.
Grind tool.
TSI02W
This tool must be adjusted by

operator for correct diameter--.
boring operation
Adjust diameter prior to

running part.
TPL02W
Improperly defined stock curve
Stock curve is a point or is

undefined somehow
TPL03W
profile lies outside stock

boundary
No feature curve defined or

feature curve does not overlap
with stock curve.
TPL04W
Ignoring improperly specified

start point.
Change start point.
TPL05W
Ignoring improperly specified

end point.
Change end point.
TPL06W
Ignoring Tool Nose Radius

Compensation. Disabled in post
Cutter comp is turned on for

the feature but off in the post
options
TPL07W
Undercut detected
Unable to completely rough

feature with this tool.
TPL08W
Undercut detected. Unable to

completely finish feature with
this tool.
Operation did not completly

cut the feature. some material
remains
TPP01W
Cant extend ends of toolpath.

The lead in/out distances
cannot be applied to an open
toolpath, because it would
result in a gouge. No leadin/out moves are applied to the
toolpath.
1. Use smaller endmill. See

How to change tools (see
page 80)
2. Change lead distances or
angles.
3. Set a plunge point
Note this can result in a posting

error if you are using cutter
compensation.
TPP02W
Cant find ramp-in arc. The

ramp-in arc cannot be applied
to a closed toolpath, because it
would result in a gouge. No
ramp-in moves are applied to
the toolpath.

How to change tools
2. Change stepovers.

compensation.
TPP03W
Cant fine ramp-out arc. Cant

find ramp-out arc. The rampout arc cannot be applied to a
closed toolpath, because it
would result in a gouge. No
ramp-out moves are applied to
the toolpath.

How to change tools
2. Change stepovers.

compensation.
DCT02
W
Bottoming tap required for this

feature.
1. Accept
2. Modify feature
Error codes
Code
Cause
TSA01 Tool not found for standard

drilling operation
Suggested Action
1. Copy a tool from drilling
operation another crib.
2. Create a tool.
3. Override with another tool.
5. Modify feature.
TSA02 Tool not found for drilling

operation before ream.
See TSA01 Action
TSB01
Tool not found for spotdrilling

operation.
See TSA01 action
TSC01
Tool not found for reaming

operation.
See TSA01 action
TSD01 Tool not found for tapping

operation.
See TSA01 action
TSE01
Countersink tool not found for

chamfer operation.
See TSA01 action
TSF01
Tool not found for countersink

operation.
See TSA01 action
TSG01 Tool not found for counterbore

operation.
See TSA01 action
TSH01 Tool not found for slotting

operation.
See TSA01 action
TSH02 Selected tool not valid for

slotting operation.
See TSA01 action
TSI01
Tool not found and unable to

create a custom tool for boring
operation.
See TSA01 action
TSJ01
Tool not found for zigzag

operation.
See TSA01 action
TSK01 Endmill tool not found for profile See TSA01 action
milling operation.
TSK02 Selected tool not valid for profile
chamfering operation.
See TSA01 action
TSK03 Tool not found for profile

rounding operation.
See TSA01 action
TSM0
1
Tool not found for profile milling See TSA01 action

operation during decomposition
of the feature.
FS001
Feed/speed table not found for

the given operation.
1. Add a new feed/speed table.

2. Override the feeds and
speeds.
3. Select a different tool.
FS002
Feed/Speed table not found for

the given operation. This error
indicates that a BRIGHT tool
material table could have been
used but was unable to find it.
See FS001 action
FST01
Feeds and speeds were not

computed because a tool was not
available.
Fix tool selection error
TPD03 Successive moves on the same

line
Check feature curve.
TPD04 Feature curve cannot end inside

stock boundary
Look at boundaries or feature

curve.
TPD14 Tool insert is too large to cut

curve cleanly.
Change selected tool
TPD18 No Cutting area determined
Check feature or stock curve.
TPD19 Feature curve start or end point

in material.
Change start or end point.
TPD20 Feature curve start or end point

in material.
Change start or end point.
TPD21 Unable to determine area to be

machined.
Check feature curve or stock

curve.
TPD22 Unable to cut in specified

direction.
Cut in a different direction.
TPD52 Illegal value for cut depth.
Check depth feature parameter.
TPD54 First infeed is too small
Check threading parameters.
TPD56 Second infeed is too small
TPD58 Memory overflow
Contact distributor.
TPD60 Depth is smaller than infeed
TPD61 Check retract/engage angles and

depth
Change parameters
TPD64 Tool undefined
Change tool.
TPD65 Illegal value of engage or

withdraw angle
Change parameters.
TPD66 Illegal tool shape
Adjust tool.
TPD67 Tool wider than slot
Change tool.
TPD68 Slot deeper than max tool depth
Change tool or slot parameters.
TPD69 Unable to verify, check path
Check feature curve.
TPD70 Check tool dia value
Check tooling parameters
TPD71 Check zstep value
Check feature parameters.
DCT0
1
Fix tool selection error
Feature was unable to be

decomposed.
Index
.
.md file 536
<
<ABS-SHIFTY> 135
<ABS-SHIFTZ> 135
<ABS-STEP1> 135
<ABS-ZCLEAR> 135
<ABS-ZRAPID> 135
<ANG-CFEED> 135
<ANG-DPM> 135
<ANG-FPM> 135
<ANG-INVTIME> 135
<ARC-X> 135
<ARC-Y> 135
<ARC-Z> 135
<BOL> 135
<BOT-LALLOW> 135
<CHIP-TAP> 135
<COMP-END> 135
<COMP-MID> 135
<COMP-NUM> 135
<COMP-ON> 135
<COMP-START> 135
<COMP-STAT> 135
<COMP-VAL> 135
<COOLANT> 135
<CW-SPINDLE> 135
<CYCLE> 135
<CYCLE-DONE> 135
<CYCLE-MACRO> 135
<CYCLE-RTRCT> 135
<DATE> 135
<DEEP-TAP> 135
<DEPTH> 135
<DRILL-CPTED> 135
<DRILLING> 135
<DWELL> 135
<EOB> 135
<EXP-LENGTH> 135
<FEED> 135
<FINI-ALLOW> 135
<FIXTURE> 135
<FLOAT-TAP> 135
<FM-NAME> 135
<FSHIFTX> 135
<FSHIFTY> 135
<FSHIFTZ> 135
<HELIX-PITCH> 135
<HOLDER-NAME> 135
<INC-DEPTH> 135
<INC-MACX> 135
<INC-MACY> 135
<INC-MACZ> 135
<INC-STEP1> 135
<INDEX> 135
<INDEXING> 135
<IS-INC-MAC> 135
Index 585
<IS-WORLD> 135
<IS-ZINDXCLR> 135
<LAST-TOOL> 135
<MACH-TIME> 135
<MACRO#> 135
<MCSID> 135
<MIN-STEP> 135
<MOTION> 135
<NEXT-TL> 135
<NO-DRAG-X> 135
<NO-DRAG-Y> 135
<NOSE-RAD> 135
<OFFSET#> 135
<OFFSET-CH> 135
<OP-PASS> 135
<OP-TYPE> 135
<OV-LENGTH> 135
<P1> 135
<PITCH> 135
<PLANE> 135
<PROG-NAME> 135
<RADIUS> 135
<REGION-DATE> 135
<RIGID-TAP> 135
<ROT1-ANSI> 135
<ROT1-MATH> 135
<ROT1-WIND> 135
<ROT2-ANSI> 135
<ROT2-MATH> 135
<ROT2-WIND> 135
<SEG-CMT> 135
<SEGM-ID> 135
<SEQ> 135
<SHIFTX> 135
<SHIFTY> 135
<SHIFTZ> 135
<SIDE-LALLOW> 135
<SPEED> 135
<SPINDLE> 135
<SPND_S_OFF> 135
<SPND_S_ON> 135
<S-RAD> 135
<START-ANG> 135
586 Index
<STEP1> 135
<STEP2> 135
<STEPOVER> 135
<TIME> 135
<TOOL> 135
<TOOL-CMT> 135
<TOOL-DIAM> 135
<TOOL-ID> 135
<TOOL-LENGTH> 135
<TOOL-NAME> 135
<TOTAL-ANG> 135
<TPI-PITCH> 135
<UDF-COMMENT> 135
<UDF-TEXT> 135
<USE-FIXTURE> 135
<WAS-WORLD> 135
<WRAP> 135
<WRAP-Z-DOWN> 135
<WRAP-Z-UP> 135
<X-CEN> 135
<X-CHANGE> 135
<X-COORD> 135
<X-VECTOR> 135
<X-WRAP> 135
<XY-PLANE> 135
<Y-CEN> 135
<Y-CHANGE> 135
<Y-COORD> 135
<Y-VECTOR> 135
<Y-WRAP> 135
<YZ-PLANE> 135
<Z-CEN> 135
<Z-CHANGE> 135
<Z-CHANGED> 135
<ZCLEAR> 135
<Z-COORD> 135
<Z-DOWN> 135
<Z-INC> 135
<Z-INDEX-CLR> 135
<ZRAPID> 135
<ZSURF> 135
<Z-UP> 135
<ZX-PLANE> 135
3
3D Attributes 399
3D leads/step tab 310
3D Manufacturing 570
3D Milling tab and Manufacturing
attributes 314
3D Strategy tab 277
4
4-axis Die feature (Wire) 488
4-axis match curve 492
4-axis Punch feature (Wire) 489
4-axis Side feature (Wire) 489
4-axis turning 521
4th axis indexing - How the clearance
plane is calculated 149
4th axis indexing - Specifying the tool
change position 148
4th axis indexing with a single setup Positioning features 146
4th axis indexing with multiple setups
147
5
5-axis positioning
Overview 465
Saving and opening parts 463
Using a single coordinate system
473
Using fixture offsets 475
A
ABS-DEPTH 135
ABS-SHIFTX 135
ABS-SHIFTY 135
Add surface curve 223
Adding a new material 119
operations 78
Adding a single point to a 4-axis wire

curve piece 492
Adding default tools and feed/speed
tables to the database 125
Adding points uniformly to a 4-axis
wire curve 492
Adding Tools 83
Adding tools to an existing toolcrib
77
Additional trimming restrictions 206
Arc ramp parameters 314
Arcc/line approx. 391
Assigning a Macro to a Toolbar
Button 431
Associating curves with user defined
holders 106
Auto Path Cut Off Option
Contouring Cycle 499
Auto Path Retract Option
Auto Path Stop Option 495
Auto round 517
AutoCAD 36
Export settings 36
Importing files from 17
Mechanical Desktop Import 19
Simplifying 3D Data for 2D Import
18
Solid Import 19
Automatic boss recognition on solid
models 445
Automatic feature recognition error
445
Automatic flipping 280, 281
Automatic pocket recognition on solid
models 446
Automatic side recognition on solid
models 448
B
Barrel Cams 155
How to Create 156
Index 587
Beginning a turnmill part 478

Blend surface 225
Boring bars for milling 85
Boss recognition 439
Boundaries for spiral toolpaths 329
Boundaries for technique other than
spiral 333
Boundaries tab 288
Boundary Curve allowance 332
Breakpoints in op list tab 66
C
Cables 573
Cams 155
Barrel 155
Cap example 191
CATIA V4 direct import 26
CATIA V5 direct import 27
Center point 339
Centerdrills 90
Chamfer mills 85
Change link to arc 223
Change link to line 222
Change point 222
Changing the direction of a segment
of a parting surface 264
Changing the fonts for the reports in
the Manufacturing Feedback
window 65
Check allowance 402
Check allowance (default attribute)
425
Check surfaces 277
Closed lofted solids 243
Common milling tool parameters 84
Comparision of surface surface
intersection and trimm a surface
with a curve 219
Comparison of surface and solid
modeling 232
Completing the multiple fixture part
166
588 Index
Configuration 163
Configuring HyperTerminal 572
Contour passes 508
Contour stock 509
Contouring - wire radius
compensation 505
Contouring Cycle Cut Off Option Auto Path 499
Contouring Cycle Overlap 507
Contouring Cycle Retract Option Auto Path 494
Contouring Cycle Stop Length 501
Contouring Cycle Stop Option - Auto
Path 495
Controlling the shape of solid fillet
joints 250
Coolant 281
Coons example 183
Counter bores 86
Counter sinks 86
Counterbore 83
Countersink 83
Creating a constant radius solid fillet
249
Creating a cube solid design feature
246
Creating a form tool 81
Creating a shell solid design feature
254
Creating a solid form core or cavity
faces of a solid 260
Creating a solid from the stock
dimensions 246
Creating a solid modeling operation
from a feature 245
Creating a tombstone machined part
462
Creating holder curves 106
Creating or modifying spindles 112
Creating or modifying tool holders
113
Creating silhouette curves or splitting

faces of a solid at silhouette curves
256
Creating Toolbar Buttons for Macros
430
Curve unwrap 155
Cut direction 404
Cut data dialog box 517
Cut depth 105
Cut Off Option Auto Path Contouring Cycle 499
Cut sides perpendicular to index axis
157
Cut using Y-axis coordinates 479
Cutting a solid with parting surfaces
251
Cycle Contouring 499
Cycle Overview Pocketing Cycle
497
Cycle Overview Zig-Zag Cycle 498
Cylinder 195
Cylinder example 196
Cylindrical Cams 155
D
Default conical corner 487
Default feed/speed values for turning
124
Defining the base solid in the solid
wizard 237
Delete surface curve 223
Deleted features 457
Deleting a feed/speed table 121
Deleting faces 262
Derive surface from feature 221
Detecting gouges 58
Detecting of gouging with tool
holders and spindles 111
Die feature (Wire) 484
Digitized data import/export options
28
Display a single Z level 66
Displaying a profile of an existing

tool 82
Displaying holder and insert geometry
in the graphics window 107
Displaying spindles or tool holders
during simulation 111
Draft a face 264
DWF import 17
DWG import 17
E
Edge protection 286
Edge rollover 286
Editing a multiple fixture design 163
End angle 100
End Clearance 100
End cut 101
Endmill 83
Endmill tools 87
Error codes 581
Error hints dialog box 576
Example of multiple fixture part 162
Examples of solids of revolution 239
Explode solid 263
Export 31
Exporting DXF Files 37
Exporting IGES Files 38
Extend 201
Extend example 202
Extrude 170
Extrude sample 171
Extrude solid design feature 237
Extrude surface solid design feature
246
EZ-UTILS 573
EZ-UTLS" 573
EZ-UTLS:To CNC 573
F
face 230
Face mills 88
Index 589
Facemill 83
Feature and operation editing using
the oper. list tab 69
Feature location 480
Feature recognition 432
Feature recognition examples 435
Feature recognition surface
requirements 451
Feature to surface example 221
FeatureCAM Addins 427
Features appropriate for millturn 479
FeatureWIRE feature types 483
Feed optimization 130
Feed optimization parameters 131
Feed rates for millturn features 481
Feedrate optimization example 133
Fillet 210
Fillet restrictions 214
Finish allowance 510
Finish allowance (3D) 425
First feed override % 412
Five axis machine types 466
Fixture and clamp collision detection
59
Flat 196
Flat example 197
Flat srf support 341
Flowline guide 361
Form Tools 81
Format of digitized files 29
Fourth axis rotation 145
Fourth axis wrapping 143, 150
Full Machine Simulation 536
G
General Import/Export Options 32
General information on manufacturing
errors 575
Generate single program for all setups
481
590 Index
H
Holder tab 96
Holder Type 105
Hole recognition 436
Honeycomb pattern 285
Horizontal + vertical strategy 367
Horizontal + Vertical with Parallel on
Shallow 367
Horizontal + Vertical with Spiral on
Shallow 368
Horizontal Tombstone Machining
458
How a bore feature is manufactured
569
How a cutoff feature is manufactured
570
How a thread feature is manufactured
569
How a turn feature is manufactured
568
How a turned face feature is
manufactured 570
How a turned groove feature is
manufactured 569
How bosses are manufactured 562
How chamfers are machined? 562
How faces are manufactured 563
How federates are scaled 124
How holes are manufactured 561
How is a face groove machined? 563
How is a round machined? 566
How is a simple face groove
machined? 564
How is an ID or OD groove
machined? 564
How pockets are manufactured 564
How rectangular pockets are
manufactured 565
How sides are manufactured 566
How slots are manufactured 567
How step bores are manufactured
567
How to add an operation to an

existing surface milling feature
269
How to combine solids 253
How to create a 3D boss from font
curves 334
How to create a cylindrical CAM
156
How to create a fillet surface 212
How to create a NC program using
4th axis wrapping 153
How to create a pencil mill operation
366
How to create a remachining
operation 378
How to create a surface from a curve
mesh 185
How to create a surface milling
feature 269
How to create a Z level roughing
operation 349
How to create an indexed program
144
How to create blend surfaces 227
How to delete a toolcrib 78
How to explicitly set a tool for a
milling operation 80
How to explicitly set a tool for a
turning operation 80
How to export feed/speed tables 123
How to export tooling 79
How to generate toolpaths 41
How to import feed/speed tables 121
How to import tooling 78
How to put two tools in the same tool
slot 80
How to recognize all holes in a setup
451
How to recognize drafted features
454
surfaces 449

surfaces using curve chaining 452
How to recognize pockets and bosses
from top or bottom surfaces 453
How to recognize pockets
automatically from solids 453
How to trim surfaces against other
surfaces 218
How to untrim a surface 208
How to use an insert drill to drill and
bore in the same program 80
I
IGES import 29
Iimporting STEP files 27
Import/Export Options 34
Importing 17, 20, 26
ACIS 19
AutoCAD 17
Catia 26
IGES files 29
Mechanical Desktop 17
Parasolid 19
SolidEdge 19
SolidWorks 19, 20
Unigraphics 19
Importing Solidworks files 20
Importing Autodesk Inventor files
20
Importing Catia Files 26
Importing Catia V5 files 27
Importing dimensions from DXF and
DWG files 18
Importing DWG and DXF files 17
Importing IGES files 29
Importing Pro/E files 27
Importing SolidEdge files 28
Importing Solidworks assemblies 20
Include hidden silhouettes 257
Indexing 143
Individual blocks 164
Index 591
Initializing EZFeatureMILL databases

75
Inscribed circle diameter 94
Insert shape 96
Interaction between viewing and
simulation 41
Interactively extracting chamfers from
a solid or surface model 446
Introduction to FeatureWIRE for
FeatureMILL users 482
Invoking the automatic feature
recognition wizard 445
Invoking the automatic option of new
feature wizard 445
Iscar CUT-GRIP tooling 83
ISO cylindrical corner 487
Isoline milling 358
K
Keep toolpaths with view change 52
L
Layout 163
Lead in/out plane 312
Lead style (FeatureWIRE) 512
Leave allowance 412, 504
Length (C) 102
Limitations of planar remachining
379
Loading a part program 135
Loading the Example Add-ins that
Were Installed with FeatureCAM
428
Lofted example 188
Lofted solid design feature 242
Lofting 186
M
Machine Design 536
Machining Contouring Cycle 499
592 Index
Machining - Overview of Strategies

493
Machining Overview Pocketing
Cycle 497
Machining Overview Zig-Zag Cycle
498
Machining - Start point for Zig-Zag
Cycle 498
Machining - Wire radius
compensation 505
Machining - wire radius compensation
on machine 506
Machining - Wire radius
compensation via Software 506
Machining side tab 279
Manufacturing Attributes
Feed Override % 281
Maximum Spindle RPM 281
Plunge Clearance 281
Plunge Feed Override % 281
Priority 281
Retract to Plunge Clearance 281
Spindle RPM Override % 281
Spline Tolerance 281
Manufacturing Attributes" 281
Manufacturing
Attributes:Manufacturing Attributes
Tool Dia. Override % 281
manufacturing databases 75
tooling 75
Manufacturing draft angles or bottom
radius regions 568
Manufacturing errors 60
Manufacturing milled features tapers
or cross section curves 568
Manufacturing Operations 63
Manufacturing operations sheet 64
Manufacturing Tool Detail 64
Manufacturing tool detail sheet 65
Max TPI 99
Maximum surface slope 305
Measure 98
Merge 215
Methods of feature recognition 442

Methods of Z-level roughing 341
Milling macros 140
MillTurn feature type dialog box
479
Min diameter 102
Min plunge diameter and Max plunge
diameter 106
Min TPI 99
Minimum surface slope 306
Misc. attributes 281
Mixing 3D simulation and rapid cut
57
Modified features 457
Modify 222
Modify both 516
Modify example 224
Modify Inside corners 515
Modify outside corners 515
Modifying existing feed/speed tables
119
multi-axis turning 521
Multiple curves in a single 2-axis wire
EDM feature 484
Multiple fixture part 162
N
Name 98
NC part program 65
Nested 164, 165
Network Security Version 520
New Crib 76
New cutting condition 517
New feature - pocket recognition
options 454
New feature new strategy 277
New feature strategy 283
New features 457
New material button 98
New Tool 76
Next row stepover 414
Non-solid result 230
Number of first feed paths 414
O
Offset method 505
Op list tab 65
Operations (FeatureWIRE) 494
Orientation tab 107
Outside sharp corner toolpath 514
Overlap Contouring Cycle 507
Overriding the tool feed or speed for
multiple operations at once 70
Overview - Machining strategies
493
Overview Pocketing Cycle 497
Overview Zig-Zag Cycle 498
Overview of 4th axis wrapping 151
Overview of blend surfaces 226
Overview of combine solids 252
Overview of cut solid with parting
surface 250
Overview of feature recognition 433
Overview of feeds and speeds 117
Overview of fillets 211
Overview of indexing 144
Overview of isoline milling 359
Overview of pencil milling 365
Overview of planar remachining 376
Overview of plunge roughing 368
Overview of projection milling
methods 323
Overview of select core/cavity 258
Overview of shell solid design feature
254
Overview of silhouette curves 255
Overview of solid fillets 248
Overview of solid from 2.5D feature
245
Overview of solids 230
Overview of spindles and toolholders
110
Overview of stitching 244
Index 593
Overview of surface from curve mesh

184
Overview of surface manufacturing
268
Overview of surface surface trimming
216
Overview of the feature rerecognition
wizard 456
Overview of tooling 73
Overview of trimmed surface 204
Overview of untrimming surfaces
207
Overview of Z level finishing 350
Overview of Z level roughing 340
P
Parallel angle 324
Parallel angle (default attribute) 425
Parallel toolpaths 323
Part Compare 45
Part compare example 46
Part compare rest material > 54
Part surfaces 276
Part View for solids 232
Parting surface 263
Parts List 164, 166
Pause on gouge 50
Pausing a toolpath simulation 43
Pencil milling 365
Planar remachining operation 375
Plunge roughing 368
Pocket recognition 441
Pocketing Cycle Overview 497
Polar interpolation in turn/mill 481
Post options FeatureWIRE 138
Post options for Milling 135
Posting your program 135
Power calculation samples 49
Power graph samples/min 49
Preview simulation button 44
Previewing the automatically selected
tool 73
594 Index
Primary cut direction 501

Printing 70
printing and print preview 71
Priority Attributes 281
Program Options 138
Program point tab 107
Protect edges 286
Punch feature (Wire) 485
R
Radial toolpaths 339
Rapid cut converston tolerance 54
Ream 83
Reams 88
Recognition 432
Recreating tooling and feed/speed
databases if they become corrupt
129
Region example 198
Region of interest 43
Removing curve pieces from a 4-axis
wire curve 492
Removing tool life restrictions on a
tool 116
Reorder 348
Reports 63
Restrictions for tool life management
114
Restrictions of 4th axis wrapping
159
Restrictions of indexing 149
Restrictions of isoline milling 360
Restrictions of plunge roughing 369
Restrictions of projection milling
techniques 325
Restrictions of surface from curve
mesh 186
Restrictions on blend surfaces 228
Retract length 504
Retract Option Auto Path Contouring Cycle 494
Revolved example 174
Revolved solid design feature 238

Revolved solid from surface design
feature 247
Rotate view when indexing 50
Rotation of primary axis 476
Rough pass stepover for plunge
roughing 369
Rounding 83
Rounding mills 88
Ruled example 180
Running the API Examples Provided
with FeatureCAM 429
S
Save NC 138
Save Options 140
Save result files during rapid cut 51
Save STL Dialog Box 38
Saving an NC part program to disk
138
Saving and opening multiple fixture
parts 166
Scallop height 392
Scallop height (default attribute) 425
Scallop height checkbox 391
Scallop height stopovers 426
Selecting core or cavity faces from a
solid 259
Selecting solids 234
Selecting tools by diameter 92
Serial port pinouts 574
Setting a feed or speed value for a
milled operation 124
Setting the length of tool extending
past the holder 111
Shaft Height (A) 103
Sheet 230
Show holder 47
Show pause on gouge dialog 50
Show spindle 48
Show tool animating 52
Side angle 100
Side clearance 101

Side cut 105
Side feature (Wire) 485
Side feature restrictions 486
Side mills 89
Side recognition 441
Sidemill 83
Silhouette Curves 255
Simulated slug removal 483
Simulating 3D toolpaths 56
Simulation control using the oper. list
tab 66
Simulation Speed 48
Single block 164
Slop limits tab 304
Slot recognition 438
Smooth animation 53
Solid 230
Solid operations 252
Solid wizard 235
SolidEdge Import 19
SolidM 432
SolidWorks Export settings 34
SolidWorks Import 19, 20
Sphere 192
Sphere example 193
Spindle properties dialog box 111
Spindles and tool holders dialog box
110
Spiral toolpaths 328
Split 209
Split face 261
Spotdrill 83
Spotdrills 89
Sprial toolpath example 329
Start point(s) 417
Start/end point (FeatureWIRE) 511
Step over 510
Stepover 418
Stepover rapid distance 418
Stepover type 315
Stitching surfaces into solids 244
Stock 165
Index 595
Stock curve (3D) 419

Stock overcut % (3D) 332
Stop Length Contouring Cycle 501
Stop Option Auto Path - Contouring
Cycle 495
Styles of automatic feature
recognition 443
Surface 230
Surface control tab 307
Surface definition 168
Surface design hints 168
Surface editing 169
Surface editing hints 169
Surface manufacturing 267
Surface mill attributes 424
Surface milling feature dimensions
tab 276
Surface Normal offset 200
Surface of revolution 172
Surface Region 197
Surface Reverse 199
Surface surface trimming restrictions
219
Surface Wizard 167
Surfaces 225
Blending 225
Cap 191
Cylinders 195
Editing 169
Extending 201
Extruded 170
Fillet 210
Flat 196
From 2.5D feature 221
From surface region 197
Lofted 186
Merging 215
Modifying 222
Offset 200
Reversing 199
Revolved 172
Spheres 192
Splitting 209
596 Index
Sweep 175
Trimming 203
Trimming with another surface
216
Untrimming 207
Surface-surface trimming 216
Sweep 175
Sweep example 178
Sweep solid design feature 241
Switches 388
T
Tap 83
Taps 90
Target horsepower 134
Target part tessellation tolerance 55
Technical Support 575
The Stock axis 150
Thread mills 91
Tip angle 94
Tip radius 95
Tolerance (3D) 421
Tolerance (default attribute) 425
Tombstone 462
Adding a part to the tombstone
462
Coordinate systems from already
placed parts 460
systems on the tombstone 461
Creating tombstone document 462
Delete button 463
Edit button 463
Order of operations 462
Overview 459
Reload button 464
Specifying tombstone physical
dimensions 459
Tombstone edit button 463
Tombstone Machining 458
Tool colors 47
Tool cutting tolerance 50
Tool diameter 425

Tool end radius 425
Tool Groups 76
Tool holder selection 113
Tool life dialog box 115
Tool life management overview 114
Tool load 61
Tool Manager 75, 76
Tool Manager dialog box 76
Tool Mapping 108
Tool selection for 3D milling features
273
Tool selection for MillTurn features
480
Tool visual tolerance 50
Toolholder properties dialog box
111
Tooling 72
Tooling database 75
Tooling Groups 76, 83
Toolpath update 54
Tools tab 309
Total passes 504
Transforming a solid 235
Translucent 49
Translucent tool 50
Tree view for surface milling features
275
Trim 203
Trimming a surface with a curve 205
Trimming examples 207
Trimming restrictions 206
Troubleshooting Z level finishing
356
Troubleshooting 3D toolpaths 426
Troubleshooting isoline milling 360
Troubleshooting pencil milling 367
Troubleshooting planar remachining
379
Troubleshooting projection milling
methods 325
Troubleshooting shell solid design
features 255
Troubleshooting stitching 245

Troubleshooting swept solids 242
Troubleshooting Z level roughing
350
Turn operation order 69
Turning canned cycles 142
Turning tool overrides tab 92
Turnmill Overview 477
Turnmilling 478
Turret location 116
twin turret turning 521
Twist drills 91
Twistdrill 83
Twists in surfaces or solids with
closed cross sections 181
Types of features that can be
recognized 434
Types of wire EDM tapers 486
U
Unattached design features 233
Unchanged features 457
Unigraphics Import 19
Untrim 207
Update graphics every ____
machining minutes 54
Use arc ramp in/out 313
Use lead in/out 311
Use linear lead in/out 313
Using a form tool or insert drill for
drilling operations 82
Using an insert drill for both drilling
and boring 83
Using open curves for solid extrudes
238
Using open curves for solids of
revolution 240
Using simulation VCR controls 42
V
Variable taper table 488
Index 597
Verifying that a solid is valid 234

View independent 51
&frac34 48, 49
Viewing centerlines for an operation
67
Viewing feed/speed tables 118
Viewing intermediate shaded
simulations 68
Viewing the stock axis 150
W
Warning codes 577
Width 98
Wire cutting/threading 514
Wire EDM cut data 119
Wire EDM Taper 486
Wire radius compensation 505
Wire radius compensation - on the
machine 506
Wire radius compensation via the
software 506
Wire visual diameter 56
Working with imported geometry 31
Wrap feature around Z-axis 479
Wrap tolerance 151
Wrapping 150
Wrapping overview 151
Z
Z end 424
Z increment (3D) 424
Z index clearance 149
Z level finish 350
Z level rough 339
Z level slice classification 285
Zig-Zag Cycle - Define Start point
498
Zig-Zag Cycle Overview 498
598 Index

Delcam FeatureCAM 15.0 Reference Help 2-2

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Delcam FeatureCAM 15.0 Reference Help 2-2

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FeatureCAM 15.

Release Issue 1.0

FeatureCAM 15.0 Reference Help

Simulating parts ...........................................................................................40

FeatureCAM 15.0 Reference Help

Turn operation order ....................................................................................69

Overview of tooling .....................................................................................73

FeatureCAM 15.0 Reference Help

Feeds and speeds

Overview of feeds and speeds .................................................................. 117

FeatureCAM 15.0 Reference Help

Creating a text file for wire material databases ........................................ 122

Posting your program................................................................................ 135

4th Axis (2.5D & 3D)

Indexing .................................................................................................... 143

FeatureCAM 15.0 Reference Help

Overview of 4th-axis wrapping ........................................................ 151

Multiple fixture documents (2.5D & 3D)

Example of multiple fixture part............................................................... 162

3D surface modeling (3D)

Surface wizard .......................................................................................... 167

FeatureCAM 15.0 Reference Help

Surface primitives ..................................................................................... 192

3D solid modeling (Solid Modeling)

Overview of solids in FeatureCAM.......................................................... 230

FeatureCAM 15.0 Reference Help

Overview of solid from 2.5D feature........................................................ 245

3D surface manufacturing (3D)

Overview of 3D surface manufacturing ................................................... 267

FeatureCAM 15.0 Reference Help

Tree view for surface milling features.............................................. 275

FeatureCAM 15.0 Reference Help

FeatureCAM add-ins................................................................................. 427

Feature Recognition (RECOG or 3D)

Overview of feature recognition ............................................................... 433

FeatureCAM 15.0 Reference Help

Tombstone machining (TOMB)

Overview of tombstone machining........................................................... 459

Overview of 5-axis positioning (5-axis Pos) 465

Turnmilling ............................................................................................... 478

Introduction to FeatureWIRE for FeatureMILL

FeatureCAM 15.0 Reference Help

Side feature restrictions .................................................................... 486

Network security version (Net)

Overview of multi-axis multi-turret turning (MTT)

FeatureCAM 15.0 Reference Help

Machine simulation (MSIM)

Machine design overview ......................................................................... 530

How does FeatureCAM make its decisions? 561

FeatureCAM 15.0 Reference Help

How a turned face feature is manufactured .............................................. 570

How do I get the file to the machine?

Configuring HyperTerminal ..................................................................... 572

Technical support...................................................................................... 575

FeatureCAM 15.0 Reference Help

AutoCAD files (3D for embedded

AutoCAD files (3D for embedded

FeatureCAM 15.0 Reference Help

Industry standard neutral CAD

Bridgeport EZ-CAM 2D geometry

Parasolid-based solid models (3D)

ACIS-based solid models (3D)

SolidWorks files (3D)

SolidWorks assembly files (3D)

Importing .dwg, .dxf files

Importing dimensions from .dxf and .dwg files