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RhinoCAM 2015 MILL Reference - MecSoft Corporation

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RhinoCAM 2015 MILL Reference 2015 MecSoft Corporation

2RhinoCAM 2015 MILL ReferenceTable of ContentsWelcome to RhinoCAM 2015’s MILL Module31 Overview.of MILL Module32 Features.of MILL module43 Understanding.MILL Module64 Programming.Workflow95 Post-Processing. 9User Interface101 RhinoCAM.2015 Menu Item112 RhinoCAM.2015 MILL Browsers113 RhinoCAM.2015 Machining Browser12Brow ser Toggle.Tabs13Program Tab . 13Sim ulate Tab . 164 RhinoCAM.2015 Machining Objects (MObs) Browser18Tools Tab. 19Regions Tab . 23Features Tab . 25Understanding.Hole Features in RhinoCAM 201528Hole Features.Filters Dialog30Select/Load/Create.Operations for Creating Hole Features32Select from.Matching Know ledge Bases35K-Bases Tab . 375 Docking.Browsers38Creating 3 Axis Machining Operations401 Parallel.Finishing40Cut Param eters. 43Z containm ent. 46Entry/Exit. 48Control Geom.etry51Tool. 53Feeds & Speeds. 55Clearance Plane. 59Where to go for more helpIndex620 2015 MecSoft Corporation

Welcome to RhinoCAM 2015’s MILL Module3Welcome to RhinoCAM 2015’s MILL ModuleThe RhinoCAM 2015 MILL module offers fast gouge free solids/surface model machiningtechnology coupled with cutting simulation/verification capabilities running inside Rhino. Thisintegration allows for seamless generation of toolpath and cut material simulation/verificationinside Rhino, for programming milling machines that support 3, 4 and 5 axis continuousmachining. The MILL module also comes with numerous post-processors to output theprogrammed G-code to some of the most popular machines in the market. A simple and wellthought out user interface makes this system one of the most intuitive and easy to use millingsystems on the market. This online help system provides comprehensive help topics as wellas context sensitive help to help you become a productive user of RhinoCAM 2015.Related TopicsOverview of MILL ModuleFeatures of MILL moduleUnderstanding MILL ModuleProgramming Work-flowPost-ProcessingC opyright 2015/2016 MecSoft C orporationMonday, August 31, 20151.1Overview of MILL ModuleThe RhinoCAM 2015 MILL module offers fast gouge free solids/surface model machiningtechnology coupled with cutting simulation/verification capabilities running on standardWindows hardware. These features take the uncertainty out of the toolpath programmingprocess and allow you to produce toolpaths that you can send to the machine tool withutmost confidence. A simple and well thought out user interface makes this system one of themost intuitive and easy to use milling systems in the market. This feature makes RhinoCAMsuitable to be deployed in the shop floor to work in conjunction with your existing CAD/CAMsystem.The RhinoCAM 2015 MILL module supports milling operations from simple 2 ½ axis milling tocomplex 3 axis milling. Additionally drilling operations are supported in three axis mode. Mostof the popular machine tool controllers are supported out of the box. Additionally theRhinoCAM 2015 MILL module also includes a post-processor generator product that can beused to tailor the output to virtually any machine tool controller in the market.Related TopicsWelcome to RhinoCAM 2015’s MILL Module 2015 MecSoft Corporation

41.2RhinoCAM 2015 MILL ReferenceFeatures of MILL moduleThe list below summarizes the toolpath generation features found in MILL module.Data Import:Supports file formats that can be imported in Rhinoceros 5.0.2 ½ Axis Methods:Face Milling, Pocket Milling, High Speed Pocketing, Profile Milling, V-Carve Roughing,V-Carving, Engraving, Chamfering, Hole Pocketing, Hole Profiling, Thread Milling andT-Slotting**Hole Feature DetectionFull and Partial Hole Features can be detected automatically and managed forDrilling operations.2 ½ Axis Advanced Methods:Re-machining3 Axis Rough Milling Methods:Horizontal Rough Milling3 Axis Finish Milling Methods:Parallel Finish Milling and Horizontal Finish MillingCurve Based Finishing Methods:Radial Milling, Spiral Milling3 Axis Advanced Roughing Methods:Plunge Roughing, Horizontal Re-Roughing, Plunge Re-Roughing3 Axis Advanced Finishing Methods:Clear Flat Tops, Projection Pocketing, 3D Offset Pocketing, 3D Offset Profiling,Reverse Post Milling, Steeps Machining (Parallel Hill), Steeps Z Finishing (HorizontalHill), Plateau Milling, Curve Profile Milling, Between 2 Curves Machining3 Axis Re-Finishing Methods:Pencil Trace Milling, Valley Re-finishing3 Axis Machining Region Methods:Flats Regions, Steeps Regions, Silhouette Regions, Valley Regions, Check Regions, 2015 MecSoft Corporation

Welcome to RhinoCAM 2015’s MILL Module5Collision Regions4 Axis Methods:Index - Rotate Table Operation4 Axis Facing, 4 Axis Pocketing, 4 Axis Profiling4 Axis R-Level Roughing, 4 Axis R-Level Finishing, 4 Axis Finishing, 4 Axis ProjectionPocketing and 4 Axis Engraving5 Axis Methods:5 Axis Index – Using Setup and Set Work Zero Operation5 Axis Simultaneous Methods:Curve Projection, Flow Curve, Between 2 Curves, Drive Curve, Surface Normal,SwarfDrilling Methods:Drilling, Tapping, Boring, Reverse Boring4 Axis Drilling, Tapping, Boring, Reverse Boring2 ½ Axis T-Slotting is available in Expert, Professional and Premiumconfigurations.2½ Axis Advanced Methods, 3 Axis Advanced Roughing and FinishingMethods, 3 Axis Re-finishing Methods, 3 Axis Machining Region Methodsand index 5 axis Methods are available in Professional and Premiumconfigurations.4 axis methods are available in Expert, Professional and Premiumconfigurations.5 Axis Simultaneous Methods are available in Premium configuration.Multi-threading toolpath generationThis feature allows the usage of multi-cores in your computer when performingcalculations during the generation of toolpaths. This can yield performanceimprovements of an order of magnitude when compared with single threadedtoolpath generation.Tool Types:Ball End Mill, Flat End Mill, Corner Radius Mill, V Mill, Chamfer Mill, Taper End Mill, 2015 MecSoft Corporation

6RhinoCAM 2015 MILL ReferenceThread Tool, Face MILL**, Drill Tool, Center Drill Tool, Reamer, Tap Tool, Bore Tool,Reverse Bore Tool, Dove-Tail Tool**, Fillet Mill**, Lollipop Tool**, User Defined Tool**User customizable tool library:Create and save tools to library. Saves feeds and speeds to tool library.Feeds and Speeds:Customizable feeds and speeds table, Feeds and Speeds calculatorCut Material Simulation:Fast and fully integrated Material Cutting SimulationCreate true 3D in-process stock modelAdvanced cut material simulation** - includes tool holder collision and part stockcomparison.Machine Tool Simulation* - allows the graphical definition of machines andvisualization of machine motions.* Available in Professional and Premium configurations.** Available in Expert, Professional and Premium configurations.Post-Processors:Standard set of post-processors bundled with the product.Choose from our large set of standard post processors.Post-Processor Generator:Customize your Post Processor or create your own Post Processor from scratch.This post processor generator supports 3 axis posts.Related TopicsWelcome to RhinoCAM 2015’s MILL Module1.3Understanding MILL ModuleThe manufacturing process aims to successively reduce material from the stock model untilit reaches the final shape of the designed part model. To accomplish this, the machinist orprogrammer utilizes a machining strategy.Roughing Operations 2015 MecSoft Corporation

Welcome to RhinoCAM 2015’s MILL Module7A typical machining strategy employed in the manufacturing industry is to use largercutters to perform bulk removal of material early on in the manufacturing process.These operations are called roughing operations.Pre-Finishing OperationsThis is then followed by operations employing successively smaller cutters removingproportionately smaller amounts of material from the stock model. This is done untilthe part has a uniform amount of stock left. These operations are called pre-finishingoperations.Finishing OperationsThis is then followed by finish operations. Here the uniform stock remaining on thepart is removed by using a small cutter removing a constant amount of material withevery motion to produce the net shape.Standard MILL Module Work-flowThe standard work-flow of MILL module mimics this process and can be representedby the flow chart shown below.The w ork-flow of the MILL m odule m im ics the standard production process ofm aterial rem ovalPart Geometry 2015 MecSoft Corporation

8RhinoCAM 2015 MILL ReferencePart geometry is imported into the RhinoCAM 2015 MILL module via the various datainterfaces provided in Rhino. A stock model representing the raw stock from whichthe part needs to be manufactured can then either be created using the various toolsprovided in the MILL module or imported.Typical Machining StrategyYou then determine the machining strategy to be used in manufacturing the part.This can be done by loading a previously saved manufacturing operation sequenceor by creating a new one. This manufacturing strategy is represented by a sequenceof machining operations in the MILL module.To create a new machining strategy, simply select the tools and the machiningoperations in sequence and then generate toolpaths. The system automaticallyrecords this sequence. This record can be archived as an operation list that can beretrieved for later use.Here is a typical machining strategy:1. To create a new machining operation, select a tool followed by the type oftoolpath to be created. You set the parameters to use for machining andgenerate the toolpath.2. A 3D part is typically machined using 3 axis operations. It can be roughmachined initially by employing a horizontal roughing operation, followed by afinishing operation. The horizontal roughing toolpath will typically be generatedusing a relatively large flat end mill or an end mill with a corner radius toefficiently remove bulk of the material from the raw stock. This machiningoperation could be followed up with another horizontal roughing operationeither with the same tool or with a smaller tool to remove more material.3. The part can then be pre-finished by employing either the parallel finishingoperation or the horizontal finishing operation. Pre-finishing and finishingoperations typically employ ball end mills with or without a side angle.4. Finally a parallel finishing operation using a small radius ball tool andemploying a fine step-over is then used to finish the part to net-shape. Thismay or may not be followed by other re-finishing operations to reducehandwork on the part.For Prismatic PartsFor prismatic parts that have straight walls, it might be more expedient to use 2-1/2axis toolpath methods rather than the 3 axis methods described above. The strategyfollowed however will be similar where in bulk material removal or roughing will beperformed by a combination of facing and pocketing operations. These will then befollowed up with one or more profile finishing operations. It should be noted that for2-1/2 axis operations it is not necessary to have the complete 3D geometry defined.Curves that represent the sides of the part are sufficient to define the geometry formachining.Review, Manage and Post Process 2015 MecSoft Corporation

Welcome to RhinoCAM 2015’s MILL Module9Once all of the operations are completed you can then go back and review theoperation sequence, perform Tool and Cut Material Removal Simulations, re-orderoperations if desired and output the toolpath for post-processing. The MachiningBrowser can be used to manage these operations.Related TopicsWelcome to RhinoCAM 2015’s MILL Module1.4Programming WorkflowOnce the part is loaded, the typical work-flow is reflected in the layout of the tabs of theMachining Operations (MOps) Browser window. The work-flow is designed to allow you towork starting from the left most tab and ending at the right most tab. As each tab isaccessed, a ribbon toolbar with functions specific to the tab chosen will be displayed justbelow the tab. The functions in each of the toolbars corresponding to each tab are also bestaccessed in order from left to right.Thus you typically would start with the Program tab and access each of the buttons,optionally, in the toolbar that appears when this tab is selected in sequence from left to right.Once the setup functions are completed, you will then proceed to the Machining Operationsgroup to commence programming the part. Once machining operations are completed youcan simulate the operations by selecting the Simulate tab before finally sending the operationcodes to the machine tool.Step 1: Program TabStep 2: Simulate TabRelated TopicsWelcome to RhinoCAM 2015’s MILL Module1.5Post-ProcessingOnce the machining operations have been created and verified, they can be post processedto create G-code files. These G-code files can then be sent to the controller of the machinetool to drive the actual machine tool.Related TopicsWelcome to RhinoCAM 2015’s MILL Module 2015 MecSoft Corporation

10RhinoCAM 2015 MILL ReferenceUser InterfaceMILL module adheres to the Windows standard for user interface design and integrated intothe Rhino screen seamlessly.MILL Module DisplayedA screen shot of MILL module running inside of Rhino is shown below:A screen shot of MILL m odule running inside of RhinoMILL Modules 3 Interface ObjectsThere are 3 main interface objects created when MILL module is loaded.1. RhinoCAM menu bar entry under Rhino menu bar2. Machining Browser (MOps) window3. Machining Objects (MObs) Browser windowRelated TopicsRhinoCAM 2015 Menu ItemRhinoCAM 2015 MILL BrowsersRhinoCAM 2015 Machining Browser 2015 MecSoft Corporation

User Interface11RhinoCAM 2015 Machining Objects (MObs) BrowserDocking Browsers2.1RhinoCAM 2015 Menu ItemWhen RhinoCAM is loaded it will add a menu bar item, titled RhinoCAM 2015 to the mainRhino menu bar. Selecting this menu bar item will create a drop down menu as shownbelow.RhinoCAM m enu ItemTo run the MILL module, select MILL from the RhinoCAM 2015 drop down menu.Selecting MILL toggles the display of the Milling Browser window from the Rhino userinterface . If FreeMILL, Turning, Nesting or Art Browser is currently open selecting this willswitch to Milling browser.Related TopicsUser Interface2.2RhinoCAM 2015 MILL BrowsersThe Browser is a dock-able window that allows management of various entities or objectsthat can be created in MILL module. There are 2 browsers in RhinoCAM – MachiningOperations Browser (MOps) and Machining Objects Browser (MObs). 2015 MecSoft Corporation

12RhinoCAM 2015 MILL ReferenceRelated TopicsUser Interface2.3RhinoCAM 2015 Machining BrowserThe Machining Browser, sometimes called the Machining Operations (MOps) Browser, hastwo main modes of operation represented by tabs at the top of the window. These areProgram and Simulate. Each tabbed view also incorporates a ribbon toolbar at the top.These toolbars group all of the functions associated with the type of object in the tab.The Machining Operations (MOps) BrowserThe Machining Operations (MOps) Brow serRelated TopicsUser InterfaceBrowser Toggle TabsProgram tabSimulate tab 2015 MecSoft Corporation

User Interface2.3.113Browser Toggle TabsTabs available on the Machining Browser that allow you to toggle the display of both theMachining Browser and the Machining Objects Browser.Browser Toggle TabsLocating the Brow ser Toggle TabsSelecting this tab toggles between the MILL and the TURNMachining Browser.Select this tab to toggle the display of the Machining ObjectsBrowser.Related TopicsRhinoCAM 2015 Machining Browser2.3.2Program TabSelecting the Program tab in the MOps Browser provides access for specifying Machine,Stock and the definition of Machining Operations.The Machining Operations (MOps) Browser, Program Tab 2015 MecSoft Corporation

14RhinoCAM 2015 MILL Refere

2½ Axis Advanced Methods, 3 Axis Advanced Roughing and Finishing Methods, 3 Axis Re-finishing Methods, 3 Axis Machining Region Methods and index 5 axis Methods are available in Professional and Premium configurations. 4 axis methods are available in Expert, Professional and Premium configurations.