Tutorial 2 - More 2D Machining

In this tutorial, you will learn how to machine the part shown above using the following procedures:
Creating a Setup
2D Contouring
Pocket Machining
Drilling
Tapping
Counterboring
Countersinking
Chamfering
Post Processing
Before proceeding, please open the part Tutorial2.ipt in Inventor HSM.
Note: The files used in these tutorials, as well as other sample datasets, can be found in
theC:\Users\Public\Documents\Autodesk\Inventor HSM 2016\Examples subfolder.
Topics in this section

To Create the Setup (Tutorial 2)

To Contour the Part (Tutorial 2)
To Machine the Internal Pocket
To Drill the Threaded Holes
To Tap Holes (Tutorial 2)
To Drill the Counterbored Hole
To Machine the Counterbore
To Machine the Countersinks
To Machine the Chamfer
To Post Process the Toolpaths (Tutorial 2)

To Create the Setup (Tutorial 2)

Normally a machining operation is started by creating a Setup. A setup defines a number of general
properties for a set of machining operations - including the Work Coordinate System (WCS), the stock
geometry, fixtures, and the machining surfaces. If you do not create a setup manually before adding your
first operation, a setup with default parameters is created for you automatically. This is what occurred in
Tutorial 1, where you went directly into a facing operation without first creating a setup.
In this second tutorial, you will create a setup to define the origin of the WCS and to select your model.
1. Click CAM tab

Job panel

Setup

to display the Setup dialog box.

2. You can also right-click on Tutorial2.ipt Operation(s) at the top of the CAM Browser and select New
Setup... from the pop-up context menu.

The Setup operations dialog box appears with the Setup tab active

Set the Work Coordinate System (WCS) Origin

In the graphics window, the stock material is created automatically around the bounding box of the part.
The model orientation is shown by the WCS at the top center of the part. The XYZ orientation is correct,
but we need to change the WCS origin.

1. In the Work Coordinate System (WCS) group, select Stock box point from the Origin: drop-down
menu.
2. Click the Stock point button and select the point (represented by a black dot) at the lower left corner on
the top face of the stock. Alternatively, you can also select Top corner 1 from the Bounding box
point: drop-down menu.

The Top corner 1 bounding box point

The WCS is now re-oriented at the lower left of the top face of the stock

Define the Model Surfaces

As with the stock, defining the machining surfaces is not strictly necessary. But we do it here as an
exercise for more complicated setups.
1. In the Model group, click the Model button.
2. Click the model within the stock, to select the part as the machining surfaces.

Selecting the model within the bounding box

3. Finally, click
at the bottom of the Setup dialog box, or right-click in the graphics window
and select OKfrom the marking menu, to exit the setup procedure.
Continue to To Contour the Part...

To Contour the Part (Tutorial 2)

Begin the contouring operation by running a tool along the outer edges of the part to machine its outer
planes.
1. On the ribbon, click CAM tab
2D Milling panel
2D Contour
.
This creates a new operation, and opens the Operation dialog box where you can edit the individual
parameters controlling the toolpath, as well as selecting the actual geometry to machine.
Each tab on the Operation dialog box is divided into a number of groups. In this tutorial, the necessary
settings are changed in each appropriate group as you go along.

Tool tab
1. On the Tool tab, click the

button to open the Tool Library dialog box.

2. From the Sample Libraries > Tutorial tool library, select tool #3 - 10 mm flat.
3. Click

to close the Tool Library dialog.

Geometry tab
To machine around the outside outline of the part, select a chain of edges from the model.
1. Click the Geometry tab. The Contour selections button should be active.
2. Select the bottom front edge on the model. Notice that Inventor HSM automatically creates a chain
around the part.

3. If the direction arrow does not appear as shown, click the arrow to reverse the toolpath direction.
Tip: By clicking closer to the desired start of an edge you can determine the direction of the contour.
For climb milling, click close to the bottom right side of the edge.
You can machine the indent around the top of the part in the same operation.
4. Zoom in on the top right corner of the part
5. Select the edge inside the indent.

Heights tab
By default, the heights for the 2D Contour operation are set so that the bottom of the toolpath is at the
level of the selected contours. The remaining heights depend on the stock and model geometry.
If you view the part from the side, it should look like this:

The default height values are fine in this example, and they need not be changed.

Start the Calculation

1. Click
at the bottom of the Operation dialog box, or right-click in the graphics window
and select OK from the marking menu, to automatically start calculating the toolpath.
The toolpath is now calculated and a preview appears in the graphics window.
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Continue to To Machine the Internal Pocket...

To Machine the Internal Pocket

A 2D Pocket strategy is now used to machine the internal pocket of the part.
1. On the ribbon, click CAM tab

2D Milling panel

2D Pocket

Tool tab
This operation uses a 10 mm bull nosed mill tool with a 1 mm corner radius to match the fillet radius at the
bottom of the pocket.
1. On the Tool tab, click the

button.

2. From the Sample Libraries > Tutorial tool library, select tool #11 - 10 R1 mm bullnose.
3. Click

to close the Tool Library dialog.

Geometry tab
Now select the contour of pocket to be cleared.
1. Click the Geometry tab. Make sure that the Pocket selections button is active.
2. Select the face (or one of the edges) at the bottom of the pocket.
The selection should now look like this:

Heights tab
The parameters in this group control the different heights where toolpaths are generated. In this example,
we want the 2D pocket operation to machine down to the bottom of the inside cut.
1. Click the Heights tab.
2. Set the Clearance height offset to: 15 mm
3. Set the Retract height offset to: 10 mm
4. Set the Feed height offset to: 8 mm

Passes tab
This group controls how the 2D pocket toolpath is calculated. To clear out the pocket, a toolpath is
generated in a number of Z levels, starting from the top of the stock and going down in steps of 2 mm to
the bottom of the pocket. The depth of the pocket is 25 mm.
Change the following parameter values, and leave all others at their defaults.
1. Click the Passes tab.
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2. Set Maximum stepover to: 5.0 mm

3. Enable the Multiple Depths check box.
4. Set Maximum roughing stepdown to: 5.0 mm
5. Set Finishing stepdowns to: 2
Leave some stock on the sides, as we will need to finish the fillets with a smaller tool later on anyway.
However, the bottom can be finished by the pocket, and we should remove the vertical stock to leave.
6. Enable the Stock to Leave check box.
7. Set Radial stock to leave to: 0.5 mm
8. Set Axial stock to leave to: 0.0 mm

Linking tab
Assuming that this part is made of a soft material where we can do full width cuts, we can avoid some
ramping by allowing the tool to stay down inside the pocket.
1. Click the Linking tab.
2. Enable the Keep tool down check box.
3. Change Maximum stay-down distance to: 250 mm.
Leads & Transitions

Leave all settings in this group unchanged. We will use a Helix ramp type for plunge to material with the
default settings from the program.

Start the Calculation

1. Click
at the bottom of the Operation dialog box, or right-click in the graphics window
and select OK from the marking menu, to automatically start calculating the toolpath.
The toolpath is now calculated and a preview appears in the graphics window. The toolpath should
appear as shown below:

Continue to To Drill the Threaded Holes...

Drill the Threaded Holes

There are four holes in the part; one is clear and three are threaded. Begin by drilling the three threaded
holes with a 4.3 mm drill.
1. On the ribbon, click CAM tab

Drilling panel

Drill

Tool tab
1. On the Tool tab, click the

button.

2. From the Sample Libraries > Tutorial tool library, select tool #34 - 4.3 mm drill.
3. Click

to close the Tool Library dialog.

Geometry tab
1. Click the Geometry tab. Ensure that Selected faces is selected from the Hole mode: drop-down menu
and that the Hole faces selection button is active.
2. Select the cylindrical face of one of the three 4 mm holes.

3. Enable the Select same diameter check box.

Notice that the two other 4 mm holes are selected.

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Important: If Select same diameter is disabled (grayed out), you have most likely selected the edge of
the cylinder instead of the face. Be sure to select cylindrical faces to use this feature. Selecting faces
instead of edges has the added benefit in that the depth of each hole is automatically determined from the
height of the cylinder.
Depending on the selection, you may want to activate the Optimize order check box. The optimization
reorders the holes to make the linking distance as short as possible.
Activating the Order by depth check box keeps holes with the same depth and plane together. Doing so
may reduce the number of cycles in the output, but may not result in the shortest toolpath, even
if Optimize order is enabled.

Heights tab
For a drilling operation, the Heights tab controls the heights of each hole, and the heights used when
moving between the holes. Because the holes are chamfered, the actual cylinders start a bit lower. This
can be adjusted by making the top start from the top of stock instead.
1. Click the Heights tab.
2. From the Top Height drop-down menu, select Stock top.
Note: Having selected cylinders for the holes, all heights are relative to the top of the cylinder, and the
depth is relative to the bottom. And, as mentioned previously, this allows you to avoid entering the depths
of the holes manually. If edges had been selected (which do not have a height), depth would have to be
entered manually.

Cycle tab
1. Click the Cycle tab.
2. Select Chip breaking - partial retract from the Cycle type: drop-down menu.
3. Change Pecking depth to: 2.5 mm

Start the Calculation

1. Click
at the bottom of the Operation dialog box, or right-click in the graphics window
and select OK from the marking menu, to automatically start calculating the drilling toolpath.
The calculated toolpath should look like this:

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Tip: Drilling toolpaths are often best displayed on a wireframe model. To obtain a wireframe view, on the
ribbon, click View tab

Appearance panel

Wireframe

from the Visual Style drop-down.

Continue to To Tap Holes...

Tap Holes (Tutorial 2)

A tapping operation differs only from a drilling operation in the type of cycle chosen from the Cycle tab. To
simplify this step of the operation, we will just copy the existing drilling toolpath and edit it to create the
new tapping toolpath.
1. In the CAM Browser, right-click on the Drill1 node. (Do not be concerned if your Drill node appears
with a number other than Drill1.)
2. Select Duplicate from the pop-up context menu. This creates a copy of the operation below the original
one.
3. Left-click on the new operation (Copy of Drill1).
4. Enter a new name, such as Tapping M5 and press Enter.
Next, you edit the tool and parameters.
5. Right-click on the operation Tapping M5.
6. Select Edit from the pop-up context menu.

Tool tab
Select a new tapping tool.
1. On the Tool tab, click the

button to open the Tool Library.

2. From the Sample Libraries > Tutorial library, select tool #43 - 5 x 1 mm 0 right tap.
3. Click

to close the Tool Library dialog.

Heights tab
To avoid breaking the tap, reduce the depth so it is less than the drilled depth.
1. In the Bottom Height group, change Bottom offset to: 2.0 mm
This reduces the depth by 2 mm.

Cycle tab
Next, change the drilling cycle to a tapping cycle.
1. Click the Cycle tab and select Tapping from the Cycle type: drop-down menu.
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Start the Calculation

1. Click
at the bottom of the Operation dialog box, or right-click in the graphics window
and select OK from the marking menu, to automatically start calculating the tapping toolpath.
The toolpath is calculated and shown in the graphics window.
Continue to To Drill the Counterbored Hole...

To Drill the Counterbored Hole

Next, drill the single 4.5 mm hole.
1. On the ribbon, click CAM tab

Drilling panel

Drill

Tool tab
1. On the Tool tab, click the

button.

2. From the Sample Libraries > Tutorial tool library, select tool #33 - 4.5 mm drill.
3. Click

to close the Tool Library dialog.

Geometry tab
1. Click the Geometry tab. Ensure that Selected faces is selected from the Hole mode: drop-down menu
and that the Hole faces selection button is active.
2. Select the lower cylindrical face of the last hole.

Heights tab
Because this hole is counterbored, the cylinder starts a bit lower. Adjust for this by making the top start
from the top of stock instead.
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1. Click the Heights tab.

2. From the Top Height drop-down menu, select Stock top.

Cycle tab
1. Click the Cycle tab and select Chip breaking - partial retract from the Cycle type: drop-down menu.

Start the Calculation

1. Click
at the bottom of the Operation dialog box, or right-click in the graphics window
and select OK from the marking menu, to automatically start calculating the toolpath.
The toolpath is calculated and shown in the graphics window.
Continue to To Machine the Counterbore...

Machine the Counterbore

Use the 2D Pocket strategy with a 4 mm flat end tool to machine the counterbore on the single 4.5 mm
hole.
1. On the ribbon, click CAM tab

2D Milling panel

2D Pocket

Tool tab
For this pocket, a flat tool with a diameter less than 4.5 mm is required to plunge into the pre-drilled hole.
1. On the Tool tab, click the

button to open the Tool Library dialog box.

2. From the Sample Libraries > Tutorial tool library, select tool #5 - 4 mm flat.
3. Click

to close the Tool Library dialog.

Geometry tab
1. Click the Geometry tab. Make sure that the Pocket selections button is active.
2. Select the edge at the bottom of the counterbore.

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Passes tab
On the Passes tab, change the following parameter values and leave all others at their defaults.
1. Set the Maximum stepover to: 0.5 mm
2. Disable the Stock to Leave check box.

Linking tab
To make sure that the tool plunges at the center of the hole, disable the lead-in.
1. Click the Linking tab.
2. Expand the Leads & Transitions group and disable the Lead-in (entry) check box.
Now, adjust the lead-out slightly to obtain a smoother exit.
3. Set the Linear lead-out distance to: 0.0 mm
4. Set the Horizontal lead-out radius to: 1.0 mm
Finally, make the tool plunge into the pre-drilled hole.
5. Expand the Ramp group, and select Plunge from the Ramp type: drop-down menu.

Start the Calculation

1. Click
at the bottom of the Operation dialog box, or right-click in the graphics window
and select OK from the marking menu, to automatically start calculating the toolpath.
The toolpath should appear as shown below.

Continue to To Machine the Countersinks...

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To Machine the Countersinks

Three of the drill holes have small countersinks that can be machined in a single Drill operation using a
countersink tool.
1. On the ribbon, click CAM tab

Drilling panel

Drill

Tool tab
1. On the Tool tab, click the

button.

2. From the Sample Libraries > Tutorial library, select tool #60 - 10 mm 90 countersink
3. Click

to close the Tool Library dialog.

Geometry tab
1. Enable the Select same diameter check box.
2. Select the countersunk face of one of the holes.

The countersunk faces of the other two holes are automatically selected since they are identical to the first

Start the Calculation

1. Click
at the bottom of the Operation dialog box, or right-click in the graphics window
and select OK from the marking menu, to automatically start calculating the toolpath.
The toolpath should appear as shown in the following image:

Continue to To Machine the Chamfer...

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To Machine the Chamfer

Use the 2D Contour strategy with a chamfer mill to machine the chamfer along the outside edge.
1. On the ribbon, click CAM tab

2D Milling panel

2D Contour

Tool tab
1. On the Tool tab, click the

button to open the Tool Library dialog box.

2. From the Sample Libraries > Tutorial library, select tool #50 - 10 mm 45 chamfer.
3. Click

to close the Tool Library dialog.

Geometry tab
Since the chamfer already exists as a model feature, there are two edges from which to choose for the
geometry - one at the top of the chamfer and one at the bottom. Inventor HSM allows either to be used,
but in most cases choosing the bottom edge allows for the easiest setting of parameters. However, in both
cases Inventor HSM automatically calculates the correct horizontal offset, and only the additional vertical
tip offset needs to be specified
1. Click the Geometry tab and select the edge at the bottom of the chamfer as the contour selection.

Passes tab
When a chamfer mill is selected as the tool, the Chamfer option is automatically enabled and displays
the Chamfer widthand Chamfer tip offset chamfering parameters.
Since an edge on the actual chamfer feature in the model was selected, it is not necessary to set
the Chamfer width. But to ensure that the tool tip is not coincident with the lower edge of the chamfer,
the Chamfer tip offset must be specified.
1. Click the Passes tab.
2. Set the Chamfer tip offset: to: 0.25 mm

Start the Calculation

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1. Click
at the bottom of the Operation dialog box, or right-click in the graphics window
and select OK from the marking menu, to automatically start calculating the toolpath.
The toolpath should appear as shown in the following image:

This completes the toolpaths for this part. You can now simulate and post process the result.
Continue to To Post Process the Toolpaths...

To Post Process the Toolpaths (Tutorial 2)

In this final step of the tutorial, all toolpaths are post processed to produce the NC-code to be used by the
machine tools. Before starting the post processing, it is good practice to regenerate all toolpaths and then
simulate them. Doing so enables you to spot any errors in the toolpaths and rectify them.
1. Start by clicking Setup1 at the top of the CAM Browser.
2. On the ribbon, click CAM tab
Toolpath panel
Generate
.
You may receive a dialog box message that the selected operation is already valid. This means that
your toolpaths are good. You can click Yes to optionally regenerate them, or click No to leave them
untouched and exit the dialog box.
3. Now, click CAM tab
Toolpath panel
Simulate
.
Tip: As an alternative, you can also right-click on the Setup folder in the CAM Browser and
select Simulate (All) from the pop-up context menu.
The Simulation player is displayed in the graphics window.

4. Click the Play button on the Simulation player to playback the defined toolpaths.
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5. When the simulation is complete, click the Close button in the Simulation dialog box, or right-click in
the graphics window and select Close from the marking menu.
6. Next, click CAM tab
Toolpath panel
Post Process
.
The Post Process dialog box is displayed.
Tip: As an alternative, you can also right-click on the Setup folder in the CAM Browser and select Post
Process (All)from the pop-up context menu.
7. Select heidenhain.cps - Generic Heidenhain from the Post Configuration drop-down menu.
8. Accept the default output folder or choose another.
9. Accept the default program name/number or provide another.
10. Start the post processor by clicking the Post button.
11. Click the Save button.
12. Because the Open NC file in editor check box is enabled by default in the Post Process dialog box,
the post processed file is automatically loaded into Inventor HSM Edit.
From the editor you can edit, inspect, and transfer your NC program to your CNC machine. The editor
provides a number of CNC code-specific functions including line numbering/renumbering, XYZ range
finder, and file comparison. The editor also features a DNC link for reliable RS-232 communications with a
variety of CNC controls.
Remember: You can also post process individual operations by right-clicking the operation in the CAM
Browser, and selecting Post Process from the pop-up context menu.
Congratulations! You have completed this tutorial.

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