FeatureCAM

Training Course
 FeatureCAM 2012

Training Course
FeatureMILL 2.5D
FeatureCAM

Copyright © 1995-2011 Delcam plc. All rights reserved.

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.
The functionality and user interface in this manual is subject to
change without notice in future revisions of software.
The software described in this manual is furnished under licence
agreement and may be used or copied solely in accordance with the
terms of such licence.
Delcam plc grants permission for licensed users to print copies of
this manual or portions of this manual for personal use only.
Schools, colleges and universities that are licensed to use the
software may make copies of this manual or portions of this manual
for students currently registered for classes where the software is
used.

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.

FeatureCAM Version: 2012 Date: 03 August 2011 11:10

Contents
FeatureCAM overview 1

Introduction to FeatureCAM 4
What is a Feature .................................................................................................... 5
How are Features created? .................................................................................... 6
Comparing FeatureCAM ......................................................................................... 8

Beginning FeatureCAM 10
The User Interface .............................................................................................. 10
Creating your first part ........................................................................................ 14
Stock types ......................................................................................................... 20
User Interface exercise ....................................................................................... 25

Snapping and Geometry 32

Snapping ...............................................................................................................34
Line construction ...................................................................................................44
Circle / Fillet / Arc construction..............................................................................48
Editing tools (Clip, Trim/Extend & Infinite) ............................................................68

Curve Creation 72
Chaining ................................................................................................................72
Open and Closed Curves......................................................................................73
Curve constructors (Curve from Curve / Surface) ................................................81

Basic 2.5D Features 109

Features from Dimensions ..................................................................................115
Features from Curves .........................................................................................136
Features from Features ......................................................................................143

2.5D Advanced Milling 153

Multiple curves in one Feature ............................................................................153
Pockets with Islands ......................................................................................... 155
Multiple Side Features ...................................................................................... 156
Multiple Plunge Point Curves ..............................................................................157
Using Cross Sections ..........................................................................................159
2.5D Plunge Milling .............................................................................................162
Grooving ........................................................................................................... 165

FeatureCAM 2012 Contents • i

 4 Axis Indexing and Wrapping ............................................................................168
Form Tools ..........................................................................................................188

Multiple Fixture Documents 194

Introduction..........................................................................................................194
Getting Started ....................................................................................................194
Multiple Fixture Interface .....................................................................................195
Steps ...................................................................................................................195
Fixture ID ........................................................................................................... 195
Parts ....................................................................................................................195
Examples.............................................................................................................195

Feature Recognition 210

What is Feature Recognition...............................................................................210
How does Feature Recognition work ................................................................ 211
Requirements for Feature Recognition ...............................................................211
Automatic Feature Recognition...........................................................................212
Interactive Feature Recognition ..........................................................................228

Part Library 258

Introduction..........................................................................................................258
Creating a Part Library Feature ..........................................................................258
Using Part Library Features ................................................................................261
Saving Patterns and Groups to the Part Library .................................................262
Patterning Part Library Features .........................................................................264
Saving Solids to the Part Library.........................................................................266
Paste Special ......................................................................................................270
Streams ...............................................................................................................274

Creating Machining Set-Ups 276

Introduction..........................................................................................................276
Creating Setups from the Stock ..........................................................................276
Creating Setups Using Geometry ..................................................................... 280

Creating Tool Libraries (Cribs) 288

Introduction..........................................................................................................288
Setting a Tools Operation type .......................................................................... 292

Machining Configurations 294

Introduction..........................................................................................................294
Machining Configurations....................................................................................294
What are Machining Attributes? ..........................................................................295
Creating Machining Configurations .....................................................................297
Machining Attributes Explained ......................................................................... 298

FeatureCAM 2012 Contents • i

2 • Introduction FeatureCAM 2012
FeatureCAM overview

FeatureCAM is a CAD/CAM software suite that automates machining

and minimizes programming times for parts on mills, lathes, and
wire EDM. Unlike operations-based CAM systems, FeatureCAM
generates toolpaths based on the features of the part, and
automatically selects appropriate tools, determines roughing and
finishing passes, and calculates feeds and speeds. The selections
made can be based on the built-in machining knowledge that
Delcam supplies 'out-of-the-box' with FeatureCAM, or from
experience captured from your company, project or individual users'
preferences.
FeatureCAM includes five stand-alone modules:
 2.5D Milling - 2.5D design and toolpath generation for 2- and 3-
axis mills.
 3D Milling - 3D surface modeling and 3-axis toolpath generation.
 3D Lite - a limited version of 3D milling.

3D Lite lets you mill only one surface per feature, but you
can create multiple features. The strategies available in 3D
Lite are Z-level rough, Parallel rough, Parallel finish, Isoline,
and 2D spiral.
 Turning - 2-axis design and toolpath generation for 2-axis lathes.
 Turn/Mill - Supports lathes with C and Y-axis milling capabilities.
 Wire EDM - 2- and 4-axis wire EDM toolpath creation.
The following add-on modules are also available:
 RECOGNITION - 3D surface and solid import and the recognition
of 2.5D features from solid models. Accelerates making 2.5D and
turned parts from solid models.
 Tombstone - Multiple part manufacturing for horizontal or vertical
milling machines with indexers.

FeatureCAM 2012 FeatureCAM overview • 3

  Solid Modeling - Solid modeling and tools for creating molds from
solid models.
 5-Axis Positioning - Manufacture 2.5D features from 5-axis
orientations.
 Native Import Modules - Native data can be read directly from
SolidWorks, SolidWorks Assemblies, Autodesk Inventor,
SolidEdge, Catia, NX, Pro-Engineer, and Step files.
 Machine Simulation - Modeling and simulation of a CNC machine.
 Advanced Turn/Mill (MTT) - Includes support for Turn/Mill in
addition to support for B-axis (5-axis positioning) and multiple
turret synchronization.
 Network Database and Licensing - Flexible product licensing allows
sharing FeatureCAM licenses across a network.
 5-Axis Simultaneous - Manufacture 3D features while changing
the tool axis.

Why creating toolpaths is so fast

FeatureCAM has the unique ability to generate toolpaths and create
NC code to run the machines with a minimum amount of user input.
Traditional CAM systems are operations-based and require you to
program every operation, one at a time, to create your part.
FeatureCAM is feature-based; this means the part is created using
features that describe that part, from simple holes, to complex
pockets, to turned grooves. Machinable features contain information
and rules describing how and where material removal should occur,
cutting depths, whether to use climb cutting, whether to spot drill or
center drill, and preferred machining strategies for roughing and
finishing. This means that after you import or draw the part and
identify its features, FeatureCAM automatically:
 Selects the most appropriate tools and operations;
 Recommends machining strategies;
 Calculates speeds and feeds;
 Generates toolpaths and creates the NC code.

You can customize this built-in 'intelligence' to your own style

of cutting.

4 • FeatureCAM overview FeatureCAM 2012

FeatureMILL2.5D Introduction to FeatureCAM

Introduction to FeatureCAM
Introduction
This module will familiarize you with Delcam FeatureCAM’s history, describe what
FeatureCAM is and show how it is advantageous over other CAM systems.

Increased shop productivity is the primary goal of all FeatureCAM products. Traditional
CAM systems are operations based and require you to program every operation, one at a
time, to create your part. All the manufacturing details are left to the machinist. That means
that you must specify the details for every spot drill, drill, ream and roughing pass of your
part.

With FeatureCAM you generate your part using features such as a tapped hole, a boss, or a
turned groove and the operations are automatically created. FeatureCAM also manages the
details of the manufacturing process such as tool selection, speed and feed rates, and
toolpaths. To modify any element of the part program, just change a few settings on a feature
and a whole new set of operations are generated to reflect your changes.

Ease of use is another guiding principal of FeatureCAM products. Our system was originally
developed as a graphical Windows-based program. As a result it does not suffer from an
outdated DOS look. FeatureCAM programs are full of graphical feedback, step-by-step
wizards and tutorial-style animations that run directly in the program dialog boxes. Ease of
use has always been a FeatureCAM advantage and we continue to study ways to make our
system even easier to learn and use.

The Image above shows a part that may be quickly programmed in FeatureCAM

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What is a Feature?
If we look at a part such as that shown on the previous page and consider how we would
manufacture it we can see that it can be broken down into a series of machining operations.
For example we would probably want to start by facing off top of the part, then machine
around the two raised areas down to the next flat level. Outside area of the part would need to
be roughed out and then the side of the part finished. There are then a series of pockets which
would need to be rough and finish machined and finally we would drill the holes and add
chamfers to the part. Each of these areas of the part, Face, Side, Pocket, Hole, Chamfer and
so on is a Feature of the part.

FeatureCAM defines a part in terms of Features using common shop terms so for instance
and area that looks like a pocket can be machined using a Pocket Feature. When you define
an area as a Pocket, FeatureCAM will then automatically decide what operations to use to
machine that area. All you have to do is say “This is a Pocket” and FeatureCAM will select
suitable roughing and finishing operations, tooling, speeds and feeds. You are then free to
modify these default values to suit your particular situation. By automating the generation of
operations the overall time taken to program a part can be drastically reduced.

The image above shows some of the features of the part. There are many more feature types
that can be created, the illustration is just to give you an idea of how the part can be broken
down into its component features for manufacturing purposes.

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How are Features Created?

There are a number of different ways in which features can be created in FeatureCAM, which
method you choose will depend upon the data available to you. In broad terms the methods
are:

From Dimensions
If you are working from a print then often the quickest way of creating features is to pull the
dimensions from the print and enter them directly into FeatureCAM. For example you can
create a rectangular pocket by entering its length, width, depth and location. Additional
attributes for the feature can also be added such as a draft angle, fillet radius or chamfer.

From Curves
If you have a print or a 2D drawing of a part in electronic format you can create curves for
more irregularly shaped parts and then create the feature from the curve.

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Automatic Feature Recognition (AFR)

If you are working from a solid model then FeatureCAM has the capability to analyze the
part and identify features automatically. Basically you say, “Here is the part, go and program
it”. FeatureCAM then looks for Pockets, Bosses, Sides, Holes and so on and prepares the
necessary machining operations, selects the tools and feeds & speeds. This can work very
well on simple parts but on more complex parts it may require some manual tweaking to get
the optimal toolpaths.

Interactive Feature Recognition (IFR)

This also works off a solid model in a similar manner to AFR. The difference is that you tell
FeatureCAM what type of feature it is that you are looking for, for example “Look only for
Side features” or “Look for holes with a diameter of less than 0.75in”. This takes a little
longer than AFR but gives you greater control over how the features are created and often
results in a shorter cycle time for machining.

CAM Software Strategies

There are three main different types of CAM software strategies for creating toolpaths in
today’s modern CAM software. These strategies are Operation based, Processed based and
Feature Based. Some of these strategies use Knowledge Based Machining (KBM). KBM
is when machining intelligence is built right into the CAM software. KBM is used at various
levels and degrees in different CAM systems.

Operations-based CAM systems require the user to go through multiple steps to machine
each part. The user must select which type of operation to use, select the machining boundary
and the type of toolpath, then manually select tools, feeds and speeds and multiple machining
options such as stepover distance and the incremental step in Z. These multiple steps must be
repeated one at a time for every operation on a part, making it a time-consuming process that
is prone to error. These systems offer little to no KBM.
Process-based CAM systems attempt to reduce these steps by grouping operations in standard
processes. KBM is used as the program remembers the used processes and repeats them for
future operations. However, this method only works when a shop uses the same processes
over and over for the same types of parts.
When a process is applied to different types of parts, or parts made of different materials, the
CNC programmer must still verify that the correct operations were used and that the correct
tools, stepovers and speeds and feeds were selected because a static machining process does
not automatically adapt to every part.
Feature-based CAM systems use a set of interrelated machinable features to describe a
complete part. The beauty of features is that they not only describe shape, but these also are
made up of one or more associative operations that describe the preferred method for cutting
that shape at the NC machine. A predefined set of machining rules and user preferences are
applied to a part. KBM in these systems streamlines the manufacturing process by building
the highest level of machining intelligence right into the CAM system. Machinable features
contain information and rules describing how and where material removal should occur,
cutting depths, whether to use climb cutting, whether to spot drill or center drill and preferred
machining strategies for roughing and finishing. The CAM system evaluates the part
geometry and part material, selects the most appropriate tools and operations, recommends
machining strategies, calculates feeds and speeds, then automatically generates the NC code.

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Below is a chart showing a comparison of the three different CAM strategies:

Feature Based CAM Operations-Based CAM Process-Based CAM

1. Draw or Import Your Part 1. Import or draw part. 1. Import or draw part.
2. Identify Features 2. Select a rough operation. 2. Identify features.
3. Click Simulation 3. Select rough boundary. 3. Select machining processes.
4. Select type of toolpath. 4. Click simulation.
You Are Done! 5. Select roughing tool. 5. Create NC code.
6. Select feeds and speeds.
FeatureCAM Automatically: 7. Select stepover and Z ???Are You Done? No.
steps.
• Determines Rough and 8. Select a finish operation. You must analyze and verify:
Finish Operations 9. Select finish boundary.
10. Select type of toolpath. • Does the process have
• Selects ALL Tools Sizes 11. Select a finishing tool. the correct operations?
12. Select stepover and Z
• Calculates Feeds & steps.
Speeds 13. Select feeds and speeds. • Does the process use the
14. Click simulation. correct size tools?
• Determines Stepover & 15. Create NC code. • Are the correct feeds and
Z Increments speeds used?
• Does the process have
• Generates Toolpath the correct stepover and
Z increments?
• Creates NC Code

Feature-based machining has many advantages such as:

 Dramatically shorter part programming time.
 Part revisions do not require reprogramming.
 NC code is consistent and predictable regardless of the CNC programmer.
 Tools are optimized and tool changes reduced.
 Toolpath is automatically optimized for faster machining.

FeatureCAM is a Feature Based programming system with advantages listed above.

Additionally FeatureCAM is very easy to use. A programmer new to FeatureCAM or new to
programming can quickly learn the product and create G-code with the appropriate tools,
feeds and speeds.

Below is a list of key points that makes FC very easy to use.

• User Friendly Interface (Steps & Wizards)

• Automatic Tool Selection (2D & 3D)
• Automatic FeatureRECOGNITION
• Standard Databases (Tools, Materials, Feeds & Speeds)
• Customizable Post Processors
• Outstanding Technical Support

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Built in intelligence

A major advantage of FeatureCAM is users' ability to define their own set of machining
preferences. FeatureCAM comes with predefined machining rules programmed into the
CAM system which are based on a standard set of material properties and standard toolcribs.
You can then customize these settings for specific materials that you use and the tooling that
you actually have available in your shop. Once you have these defined, you simply select a
material for your workpiece and the toolcrib you want to work with and FeatureCAM will
then make selections of tooling for a feature automatically. If you change the toolcrib or the
material then FeatureCAM automatically updates all of the toolpaths in the part. This means
that a part may be programmed for one machine with the tools available there and then
shifted to another machine simply by changing the toolcrib. Similarly if you wish to cut a test
part in Aluminum and then cut the final part in Stainless Steel you program the part with
Aluminum set as the material. Once you have cut the test piece you change the material to be
Stainless Steel and FeatureCAM will update the toolpaths by changing feeds, speeds, depth
of cut, stepovers etc. without any further intervention from the operator.

By providing a set of standard machining rules already in place, it's easier for you to
customize the software to reflect the machining preferences of your shop.

Setting up your own machining preferences and rules in FeatureCAM not only reduces the
time it takes to generate programs, but it also streamlines production because the approach to
machining every part is predictable and consistent. Machine operators can rely on the fact
that each job will be machined in a predictable manner regardless of who did the
programming.

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Beginning FeatureCAM
Introduction
This module will provide the user with an understanding of the basic user interface and
different stock types. At the end of the module the user will be able to generate a program for
a simple part.

User Interface
The user Interface is the entire viewing area of FeatureCAM and is designed to be intuitive,
easy to use and provides the many functions to assist you in creating programs accurately and
in the fastest possible time.

Tool Bars
Menus
Results
Part View

Graphics Window

Geometry Bar
Status Bar
Steps
Menu Bar Located at the top. Like many
other Windows based software,
FeatureCAM includes a series of drop down menus.
These menus are unique to FeatureCAM and
provide one or more functions used to facilitate the
constructing, manufacturing, viewing and
editing of your part program.

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Tool Bars Located in View and Toolbars.

Tool Bars are usually located at the top but
may be docked in other locations. Can consist
of one or more buttons and are used to create
objects in the Graphics Window, such
as the Geometry constructors for
drawing the shape of your part.

Steps Located on the left side. A systematic

sequence to guide, especially the beginner, as to
the order of which needs to be completed first,
second, etc.

Part View Located behind the Steps. This area

gives a listing and provides access to the properties of
the stock, setups, features, turrets, curves, (surfaces and solids
when available).

Browser Located on left side “Toolbox” below Steps.

Your computer must be connected to the internet and the
Browser provides a direct link to the internet. Learn about
the Browser by participating in the various sections with
downloadable examples on the opening page then Click on
the links and explore the contents.

Results Located on the right side. It contains the

Operation list. Whereas the Part View contains all of
the features, the Operation List contains all of the hits.
It also provides the details of each operation, including
a tool list. The NC code is also here. All of the
information residing in this area may be printed.

Graphics Window Located in the center.

This is where most of the activity is takes
place. These activities include: creating stock,
importing drawings, solid and surface models,
constructing geometry, chaining with curves,
creating features, and simulating the tool path
in 3D or center line of the tool.

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Geometry Bar Located near the

bottom. This area is constantly
used and is where the dimension
boxes are used to locate the
geometry on your stock material
in the Graphics Window.

Status Bar Located at the very

bottom of FeatureCAM. It
displays the plane you are
working in (XY–XZ-YZ), the
unit of measure (inch-metric), the
layer you are working in, the active setup, post processor, the
tool crib, and how many CPU cores are being utilized.

o The basic interface has three different sections. On the

left is the Steps toolbar.
o The steps toolbar is an outline for the flow of the
program. The steps are numbered sequentially in the
order they should be executed and can be a guide for
creating your part.
o For example suppose you have a 2D drawing on your
desk and would like to create a solid model and a CAM
program for it. To do this we would follow the steps
sequentially:
1. Specify type of stock and stock dimensions,
2. Draw Geometry
3. Create Curves from Geometry
4. Create Surfaces (ignored since creating a solid model)
5. Create Solid from Curves.
6. Or 7. to create Features
8. To view toolpaths and
9. To generate NC Code

o You can access a majority of FeatureCAM’s functions

through these buttons. A summary of each steps function follows.

Note: We recommend that if you are just starting out with the program or demonstrating it to
others that you use the steps toolbox instead of toolbar buttons in other areas of the interface
to keep the interface simple.

Step 1 - Stock. The Stock Wizard steps you through entering the shape and dimensions of
the stock, the stock material, part program zero and the coordinate system for modeling.

Step 2 – Geometry. Points, arcs, lines and other shapes are used to describe the overall
shape of parts. Many different geometry tools are available. Geometry can also be imported
from CAD systems.

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Step 3 – Curves. Shapes that involve more than a single line or arc are described as curves

Step 4 – Surfaces, opens the surface wizard

Step 5 – Solids, opens the solid wizard

Step 6 – AFR (Automatic Feature Recognition)

Step7 – Features. Features are common shop terms like pocket, or thread. They are created
from curves and dimensions. These objects describe your part in 3D and are used to generate
toolpaths.

Step 8 – Toolpaths. Toolpaths are generated from collections of features. You can simulate
them in FeatureCAM using toolpath center lines, 2D shaded or 3D solid shaded simulations.

Step 9 – NC Code. Machine-specific G-codes are generated from the toolpaths. Translators
are provided for many different NC controls and include a program for creating new
translators.

Customize Manufacturing. FeatureCAM automates the entire part programming process;

you can customize all of the system settings including feed/speed tables (Stock Properties),
tooling databases (Tool Manager) or feature settings (Machining Configurations in another
Module)

Note: In Steps, some steps may not be displayed depending on

which options you have purchased or have turned on.

o Above the Steps Toolbar is the Part View Tool Box. This
contains the names of the objects that are created on the
screen. Objects that can be contained in this area are stock,
setups, curves, surfaces, solids and stl.
o Clicking on the objects in the part view enable different
functions. Left-click selects the object in the graphics
window. Right-click reveals menu of options available for
the object. Clicking on a “+” to expand the view will
reveal objects that are subordinate.

On the right is the Manufacturing

Results Window. The automatically
generated documentation and part
programs are shown in this window.

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Your First part exercise

• From the New Part Document Wizard

select Milling, then select Inches as
unit of measure then press the
Finish button.

Notice the different types of documents

available. The different types of documents
available; depends on the modules that you own
and are licensed for.

• In the stock dimensions dialogue

Enter 4” for the Width, 4” for the
Length and 1” for the Thickness then
press the Finish then OK.

• From the steps view on the left

hand side of the screen click the
Features button.
• Select Hole and press Next.

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• In the New Feature Dimensions

window Enter the hole dimension as
0.5” in Diameter, 1.0” in Depth, then
check the Through checkbox and
press Next.

• For the X location Enter 3”, the Y

location enter 3” and the Z location
enter 0. Press Finish then OK.

• From the steps view on the left

hand side of the screen Click the
Features button.
• Select Rectangular Pocket.
Next.

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• On the Dimensions tab Enter 2.0”

for the Width, 2.0” for the Height
and 0.5” for the Depth then press
Next

• On the Location Tab Enter 0.5” for

the X location, 0.5” for the Y
location then press Finish and
OK.

• Right-click in the Graphics window then press isometric.

• From the steps menu Click on the Toolpaths. Simulation bar flies out,
unless already out.
• Using the Simulation Bar; Read the purpose of and Execute each button.

Region
3D of
Centerline 2D Rapid Stop To End Next Interest Speed

Eject 3D Mach Sim Play Single Clear Load

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o Show centerline: A line drawn of the center of the tip of the tool is displayed.
o 2D simulation: A two-dimensional simulation showing the regions cut by each
operation is displayed. The view is changed to the top view automatically.
o 3D solid simulation: A 3D solid simulation is displayed where the tool is animated
through all of its moves.
o Rapid Cut simulation: In this mode a 3D simulation is performed but the tool is not
animated. Only the final result is displayed. For most parts, the simulation takes only
a few seconds to complete. Note this type of simulation is only available in
FeatureMILL3D.
o Machine Simulation: A 3D solid simulation is displayed where the tool is animated
through all of its moves along with the machine tool
o Eject removes the Simulation toolbar from the screen and erases the simulation from
the graphics window.
o Stop cancels a simulation.
o Play starts the selected simulation (Centerline, 2D, 3D or Rapid Cut), or restarts a
paused simulation.
o Pause pauses the simulation. The Play button transforms into the play button after it
is pressed. If the Pause button is pressed during a simulation, it pauses the graphics.
o Single step moves the simulation ahead one tool move. The keyboard accelerator for
this button is ALT+F3.
o Next operation continues to simulate until the next operation. This button is actually a
fly-out menu. By clicking on the triangle to the right of the button the following
additional options are revealed
:

o Next rapid simulates until the next rapid tool move.

o Next tool change simulates until the next tool change.
o Next Z level will simulate the next Z of a Z level toolpath. For other toolpaths it will
play the entire next operation
o Clear erases any centerline toolpaths on the screen.
o Region of interest limits the portion of the part that is simulated.
o Show tool load indicates whether or not to display a graph of the tool load when the
next 3D Simulation is performed.
o To adjust the speed of a centerline, 2D or 3D simulation, use the 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
Rapid Cut 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 slower Rapid
results.

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• Click the show centerline from the simulation toolbar.

• Adjust the simulation slider button to the minimal setting by Left-clicking
and Dragging then click the Play.

A centerline display of the

toolpath is shown where the line
displayed represents the center of
the bottom of the tools movement.
Green lines represent rapid
movement where black lines show
feed moves. Press the Eject.

• Click 3D Simulation and Play.

• In conjunction with 3D, Click on

Options and Simulation from the
menu bar. Check show holder
displayed on the General Tab and on
the 2D/3D Shaded Tab Check the
Pause on gouge and Show pause on
gouge dialog. Click OK.

This will not only show the holder for the milling
tool, but reveal any tool striking the stock in rapid
traverse, or if the holder touches any part of the
stock. These gouges will show as pink in color, the
simulation will stop, and a pop up will appear
telling of a possible gouge.

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• In the Manufacturing results window on the right hand side of the screen
Click on the Op. List tab at the bottom of Result Window.

Op List shows each operation listed in

the order they are to be machined,
feature name, tool used, Feed and
Speed data. Properties may be
accessed here also (double click on
each operation).

• Click on the Details tab.

You will see an operation summary

showing the Part name, Setup name, Date,
Stock Dimensions and Stock Material
followed by the summary of each
operation. This shows the feature name,
operation name, F/S, Tool used, power,
stepover and depth of cut. The Tool List
button at top provides a list, in detail, all
tools being used and where they are placed
on the tool changer.

• Click on the NC code tab.

NC code is generated during simulation

and the output is in accordance with the
post processor for the machine that is
going to be used to run your part. The
Part Program number on the O line and
the G54, line N50 are automatically
entered in the code.

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FeatureMILL 2.5D Beginning FeatureCAM

• Click on File then Save NC. Click the

radio button save to other directory,
then Type in “C:\”. This will save the NC
code to the C drive. In the selection
window Uncheck all check boxes and
only check NC Program. Then Press
OK. The check boxes will create a text
document that can be printed.

Now that the NC code is saved it can be downloaded

to the machine and the part with the simple pocket
and hole can be machined.
• Close this document and Save it if you
want to keep it.

Stock Types
Inside of FeatureCAM milling document there are several different stock types. The stock
can be defined as a block, round, stock curve or user defined.

Stock Exercise

• Open a New Milling Document in

inch. Finish.

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FeatureMILL 2.5D Beginning FeatureCAM

The stock wizard dialogue will appear. By default block will be selected. You can enter the
rectangular dimensions of the stock here.

• Click on the Round radio button.

The ID, OD and length of the round stock

may defined. Additionally the axis of the
stock may be defined as needed for 4 axis..

• Click on the N-Sided Radio button.

When this button is pressed the stock can be
defined along a specific axis with a multiple
number of sides such as hex.

• Enter the stock dimensions as

shown to the right and press Next.

A Hexagonal outline of the stock will

appear in the display window. The Axis
may also be selected like the round stock.

• Press Next.

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FeatureMILL 2.5D Beginning FeatureCAM

On this page of the stock wizard you

can select the Material, Unit
Horsepower, Hardness and Hardness
Units. You can also access the existing
Feed and Speed tables for the material
or create a new Material

• From the pull-down

menu select Aluminum
then press Next.

The multi-axis positioning options

appear.

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FeatureMILL 2.5D Beginning FeatureCAM

• Press No to Multi-axis
positioning and press Finish. Do
not press OK at this time.

• Right Click in the Graphics

window, off the part, and Select
an isometric view. The stock is
hex shape and FeatureCAM
simulates that shape in 3D
simulation and also uses it as the
stock boundary when
determining where cuts start. Right Click in the Graphics window and
select a Top view. Click OK.

The Fourth way to create a Stock shape is by

drawing the shape using geometry and then
chaining a curve, it is called a Stock Curve.
(Creating shapes using geometry and curves
will be covered in a later module and you may
wait until you finish with them and then return
to this step and create the Stock Curve although
the following steps are easy).

Note: The Stock Curve must lie in the XY Plane.

In the Top View, this is the XY Plane when the
UCS (Part Program 0) is in this position (Lower
Left)

• Click on Stock in the Steps on the left

side of FeatureCAM. Select Block and enter in the Width as 6.0, Length
6.0, and Thickness 6.0. Click Finish and OK. Center the stock by holding
CTRL and L keys simultaneously.

• Draw by Clicking on Geometry from the Steps and from the Geometry
Constructors use Line/Connected Lines and Draw freehand a shape
similar to the one above. Be sure the geometry is connected.

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FeatureMILL 2.5D Beginning FeatureCAM

• Click on Curves from Steps

and Click on Closed Curve
(red check).

Chain a closed curve on the Geometry by

Clicking once on any line then Click on the
Create button at the bottom of the screen.
The curve (blue) will close all the way around the
closed Geometry. The Curve must be closed and in
the XY Plane.
o XY Plane is Top View.
o XZ Plane is Front View.
o YZ Plane is Left View.
This Curve now becomes the NEW shape of the Stock
and is used for Stock Boundary and 3D simulation
stock solid.

Click on Stock in the Steps and then Finish.

• On the Dimension Tab, of the Stock

Properties dialog, Click on the Stock Curve button and from this list Check
the box in front of the curve just created. OK and Apply, then OK. The
Stock now changes its shape.

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FeatureMILL 2.5D Beginning FeatureCAM

User interface exercise

In this exercise you will become more familiar with the FeatureCAM user interface.

• From the Beginning FeatureCAM Data folder, or the FeatureCAM 2.5D

Data folder. Double Click on the file Caliper.fm.
• Click on the Part View on the left hand side of the screen.

Observe all the different objects the part

contains under the part view. At the top level
of the part view is the part name. In the level
directly below the part name you have stock,
setup1, setup2, curves, surfaces, and solids.

• Double-click on
stock in the part view
for the Stock
Properties showing
Length, Width
Thickness and an
offset in Z for facing
stock. OK.

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FeatureMILL 2.5D Beginning FeatureCAM

• From the Part View menu

Double-click on top.

The setups dialogue is displayed. From

here an existing setup may be modified or a
new setup may be created.

• Click on Edit
Observe that the current setup location is
highlighted in Red in the graphics window. The setup location is on the upper left hand
corner of the stock. The setup, fixture name and part name can be edited from this window.

• Enter Fixture ID of 54 then press

Next.

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FeatureMILL 2.5D Beginning FeatureCAM

The part program zero window is displayed. In this window we have the ability to change the
setup location or the part program zero. This is where fixture ID 54 is and where the machine
tool fixture offset 54 zero is.

• Select the Align to Stock Face

and press Next.

A page appears that will enable you to change the setup location. Currently the setup is
located in the upper left hand corner.

• Change the setup to the upper right;

Press the Hand next to UR.

You should see in red in the upper left hand corner

the previous location of the setup, and highlighted
in blue is the new location of the setup.

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FeatureMILL 2.5D Beginning FeatureCAM

• Click Finish.

• Select to Keep Features

in the same location.
OK and Close.

• In Part View Click the +

Plus Sign next to top to expand and reveal all of the Features for Setup1.

Notice how the features in setup1 have been displayed, in the order they were created.

• Double-click on fc1 from the part view or Right Click on feature for
Properties.

The feature properties

from setup1 are
displayed. From here
the face properties
may be changed. All
the feature properties
may be accessed from
the part view by
simply double
clicking on them.

• Click OK.

Cut, Copy and Paste are Windows functions that are available in FeatureCAM. There are
two Setups on this Part and Setup2 needs to be faced off. You already have a face feature in
Setup1 so you will copy it from Setup1 and paste it in Setup2.

• In the Part View, Right Click on the Face feature in Setup1 and Click
Copy.

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FeatureMILL 2.5D Beginning FeatureCAM

• Click on Setup2 to select which Setup you wish to place it in. Right Click
on the same Face feature you copied from and Click Paste. This adds the
Face feature to Setup2.

Now both sides have a Face feature by simply copying and pasting. You can even copy from
one Document and Paste into another Document.

• In Part View Click Setup1 then Right Click in Graphics Window and Click
Isometric View.
• In Steps Select Toolpaths and the Simulation toolbar flies out. (unless it is
already visible) It may be dragged to several docking areas of your
choosing.
• On the Simulation Bar, Click 3D simulation and Click Play. (Setup1)
• Do NOT cancel 3D Simulation. Now in Part View Click on Setup2 then
Right Click in Graphics Window and Click Isometric View and Run the 3D
Simulation again. (Setup2)
Setup1 Setup2

o When you run the Simulation, the NC G-Code that will go to the machine is
generated.

o The Post Processor is what determines what the code contains and it must correspond
to the machine control that it will be loaded into.

o There are many Post Processors that come with FeatureCAM and the correct Post
must be selected before running the simulation to obtain the proper code. Post
processors for Milling are located in C:\Program Files\FeatureCAM\
Posts\Mill.

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FeatureMILL 2.5D Beginning FeatureCAM

• Click on Manufacturing then Post

Process to open the Post Options
window.

• Click on Browse and

enter the previous path
given to search for and
Select your Post. Open
and OK.

• Simulate either 3D or
Centerline Simulation
again.

• From Results Click the NC Code

tab.

This is what will be sent to the

machine control. It is a text file and
may be edited but the goal is not to
edit the Code but to correct the
Post so as to eliminate any editing.

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FeatureMILL 2.5D Beginning FeatureCAM

There might be a slight delay to receive the NC Code

in the results window. This is because the NC is
generated once the NC Code tab is pressed.

• From the file menu click on Save NC.

• Save the code to the C:\ drive by

choosing “Save to other directory”. Check
NC Program only in the selection window
then press OK.

o If additional boxes are checked a text file will be generated for each that may be
printed and sent to the shop to facilitate setup. Check them only as needed because a
file is saved on your computer every time you save NC if you have boxes checked
even if you do not need them.
o Now you can take the Caliper.txt NC code file from the C:\ drive and transfer it to the
machine to cut setup1 for the part. The Caliper.txt NC file contains G code for setup1
only.

In the Stock Properties and the Indexing tab, if you check the box “Generate Single Program
with program stop between setups” then the NC Code will include both setups with a stop
between setups. This is so you can run Setup1 then the machine will stop to flip the part then
you push the machine
start button again to run
Setup2.

To open the Stock

Properties window,
double click on stock1 in
the part view window on
the left side of
FeatureCAM.

The Part is Complete.

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FeatureMILL2.5D Snapping and Geometry

Snapping and Geometry

Introduction
This module will provide an understanding of how different snapping modes work and how
Geometry is created within FeatureCAM. By the end of the module the user will be able to
construct geometry and understand how each snapping mode functions.

User Interface
Geometry constructor commands can be accessed in three different areas of the user
interface.

• Commands can be accessed by clicking the Geometry icon in the Steps

view:

• Can be accessed through the File Menu by

clicking on Construct

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FeatureMILL2.5D Snapping and Geometry

• Or may be
accessed by the
geometry toolbar
(to show the
geometry toolbar
from the File Menu
click on View then
Toolbars then
check the Geometry checkbox and press OK)

The geometry toolbar uses flyout menus. The last item previously selected is displayed as an
icon in the tool bar.

• Click on the triangle to reveal the flyout menu.

These flyout menus are used throughout FeatureCAM and are useful for easy access to many
program functions.

Snapping mode commands can

be accessed in two different
areas of the user interface.

• Snapping mode
commands can be
accessed through the
file menu by clicking on
options then snapping
modes

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FeatureMILL2.5D Snapping and Geometry

• Snapping modes may also be accessed through the snapping toolbar(to

show the snapping toolbar, from the file menu click on view then toolbars
then check the snap mode checkbox and press OK).

Snapping

• Open FeatureCAM by double-clicking the FeatureCAM shortcut icon on

the desktop:
• Click on Open an existing file in the New Part Document wizard window
then press Next.
• Browse to the examples folder and click on “Snapping.fm” then press
open

The part when open should look similar to the image below:

• Make sure the snapping toolbar

is shown. To show this menu
from the File Menu click on
View then Toolbars then check
the Snap Mode checkbox.
Also make sure Standard and
Geometry are also checked
then press OK.

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FeatureMILL2.5D Snapping and Geometry

The snapping toolbar will appear:

Looking at each icon from left to right we will give a short summary of each item’s function:

Snap to grid causes the cursor to snap to predefined increments defined under
Options and Snapping Grids

Snap to Point snaps to a point object

Snap to Endpoint snaps to the ends of finite lines and arcs. Endpoint also applies
to the corners of the stock and vertices of a solid

Snap to Midpoint snaps to the middle points of finite lines and arcs.

Snap to Section snaps equal intervals of a finite line. The number of sections is
controlled by the Sections parameter of the Snapping Grids dialog box.

Snap to Intersection snaps to the intersection of lines, arcs and circles.

Snap to Center snaps to arc and circle centers. This setting also controls the
display of circle and arc center points.

Snap to Quadrant snaps to the four points on a circle corresponding to 0°, 90°,
180° and 270°.

Snap to Object snaps to a point on another object. This includes lines of surfaces
and is convenient for snapping points to locations on a surface.

Snap to Tangent snaps the point so that the object you are creating will be tangent
to the object you snapped to.

Snap to Toolpath will snap to toolpath lines

The Snap Discrimination dialog button displays the Snap Discrimination dialog
box whenever there is an ambiguous pick. This dialog box will list the possible points
to snap to and ask you to pick the one you want.

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FeatureMILL2.5D Snapping and Geometry

Snapping Exercise
The exercise below will review each of the snapping modes on the snapping toolbar from left
to right. When complete it will provide a basic overview of each snapping modes function.

• Make sure none of the snapping buttons are depressed

• Right-click on the Orange circle and

press Center Selected

• Click on the connected line constructor button from the geometry toolbar

• Draw a square in the center of the circle by clicking once in the upper left,
then upper right, then lower right, then lower left then upper left.

If your hand does not move perfectly it will be

impossible to do this. We have a tool that can help
snap to a Cartesian grid

• Press Undo until the line segments

disappear. This button is at the top of
FeatureCAM.

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FeatureMILL2.5D Snapping and Geometry

• Make sure none of the snapping buttons are depressed then press the
Snap to Grid button

You should then notice a faint grid appears

• Draw a square in the center of the circle by clicking once in the upper left,
then upper right, then lower right, then lower left then upper left.

Click on the Select icon at the top of FeatureCAM on the Standard

Toolbar to cancel the line drawing. Use this button at any time to exit
selection mode.

You should notice that the square created was much easier to create. This is because the
cursor snaps to a predefined grid designated under the File Menu under options then
snapping options. Snap to grid overrides all other snapping options so it is suggested to
leave this option off if you need to use any of the other snapping modes.

• Uncheck the snapping grid and check snap to point on the snapping
toolbar. Select connected line from the geometry toolbar again.

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FeatureMILL2.5D Snapping and Geometry

• Move the mouse cursor around the screen and try to get it to snap to an
object on the screen

Notice that the only object we can get this to snap to is a point. The only object snap to point
will snap to is a point. There is a point inside the square you just created, snap to it.

• Uncheck Snap to Point and check snap to endpoint.

• Locate the teal horizontal line segment located in the upper left hand of the
screen. If you are still zoomed in, right click your mouse in the graphics
window, off the part, and select Center All. Select connected line again
from the Geometry toolbar.

• Move the mouse cursor from the left to the right over the line.

Observe that only the line segment endpoints are snapped to. Snap to Endpoint snaps to the
ends of finite lines and arcs. Endpoint also applies to the corners of the stock and vertices of a
solid.

• Uncheck Snap to Endpoint and check Snap to Midpoint. Again position

the mouse cursor over the teal horizontal line segment. Hover the mouse
cursor over the center of the line segment.

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FeatureMILL2.5D Snapping and Geometry

The cursor should snap to the center of the line segment.

• Locate the black arc below the teal horizontal line segment

• Snap to the center of the line segment

Snap to Midpoint snaps to the middle points of finite lines and arcs.

• Click on options then snapping grids then change Section to 8.

• Uncheck snap to midpoint

then check snap to
segment

• Hover the mouse cursor over the teal line segment and move mouse
cursor slowly from left to right.

Notice how the line segment snaps to 8 different sections.

• Uncheck snap to segment then check snap to intersection

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FeatureMILL2.5D Snapping and Geometry

• Locate the violet horizontal and vertical line segments towards the lower
right hand part of the stock hover the mouse cursor over the intersection.

Notice it snaps to the intersection of the lines. This snap mode works for the intersections of
arcs, lines and circles.

• Uncheck the snap to intersection button and make sure no snap modes
are enabled. Observe the center of the large circle on the left hand side of
the part. Then toggle the snap to center button then re-examine the
center of the large circle.

What you should notice is that a cross-hair appears at the center of the circle. This is the snap
point for the center of the circle

• Hover the mouse cursor over the cross-hair and notice the cursor snaps to
that location

Snap to center snaps to arc and circle centers. This setting also controls the display of circle
and arc center points.

• Uncheck snap to center then check snap to quadrant

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FeatureMILL2.5D Snapping and Geometry

• Locate the large circle and move the mouse cursor around the perimeter of
the circle.

The circle will snap in four places. Snap to quadrant snaps to the four points on a circle
corresponding to 0°, 90°, 180° and 270°.
• Uncheck snap to quadrant and check snap to object

• Hover the mouse over all objects in the viewing window.

What you will see is that the cursor snaps to all objects in viewing window. This snapping
mode is very useful to snap to any type of object including solids and surfaces.
• Uncheck snap to object and then check snap to tangent

• Click on the line from 2 points constructor.

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FeatureMILL2.5D Snapping and Geometry

• Click once on the large orange circle.

• Click next on the small yellow circle on the left.

• Click again near the top of the small yellow circle on the left, then click
near the top of the yellow circle on the right.

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FeatureMILL2.5D Snapping and Geometry

Observe that Snap to Tangent snaps the point so that the object you are creating will be
tangent to the object you snapped to.

• Uncheck Snap to Tangent then check Snap to Toolpath

• Click on the toolpaths icon from the steps menu

The simulation toolbar should appear

• Click on the play icon from the simulation toolbar

• Right-click in the viewing window and click isometric

Notice the green line representing the toolpath for the drilled hole feature.

• Select a line from 2 points again from the Geometry toolbar and hover
the mouse over the toolpath

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FeatureMILL2.5D Snapping and Geometry

Observe how the cursor snaps to the toolpath at any point along that toolpath

Line Constructors

We will now give a summary of what each items function on the line constructor flyout
toolbar followed by an exercise.

• Click on the line constructor flyout menu from the

geometry toolbar
2 Pts: Line created with two endpoints.
Connected: Multiple lines created in succession.
Endpoint of one line becomes start point of next line.
Horizontal: Infinite horizontal line created through a
point.
Vertical: Infinite vertical line created through a point.
Pt. Angle: Infinite line created through a point at an angle specified in degrees.

Offset: Line, circle or arc created offset from another. New lines have the same
length as original

Line Constructor Exercise

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FeatureMILL2.5D Snapping and Geometry

• Open Lines_example.fm
• From the snapping toolbar click on Snap to Circle/center.

• From the line constructor flyout menu select Line from

Two Points.

• Use a 2 point Line to create a line from

A to B. To do this click once on the
circle center at A then click again at
point B.

• Use a 2 point Line to create a line from A to D.

• From the line constructor flyout menu click on

connected.

• Now use a connected line to create a line from B to E to D. Click once on

B then click once on E then once on D.

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FeatureMILL2.5D Snapping and Geometry

• Use the horizontal line to place a line through C. Click on the horizontal
line constructor from the flyout menu

Click once at point C to create a

horizontal line

• Use the vertical line tool to place a line through C. Click on the
vertical line constructor from the flyout menu

Click once at point C to create a

vertical line

Use the Pt, Angle line to make a 45 deg line through C. Click on the pt,
angle line constructor from the flyout menu

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FeatureMILL2.5D Snapping and Geometry

Click below the Assistance Bar and specify the line angle as 45.

Then click at point C

• Use the Pt, Angle line to make a 135 deg line through C. Click below the
Assistance Bar and specify the line angle as 135

Then click at point C.

• Use the offset command to offset line A-C-E 0.5 inches

on each side. Click on the Offset Constructor from the
flyout menu
Click once on the Infinite Line through A-C-E

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FeatureMILL2.5D Snapping and Geometry

Then click once on either side of the line

Repeat for the other side of the line

Use the offset to offset line B-C-D 0.5

inches on each side. Do the same as the
previous step but now offset the infinite line
B-C-D on both sides

Circle Constructors
Below is a summary of what each item’s function is on the circle constructor flyout menu
followed by an exercise.

• Click on the Circle Constructor Flyout Menu from the geometry toolbar

Center, Radius: Creates a circle by clicking on the center and specifying the radius
or dragging the mouse to a radius

Center, Edge: Creates a circle by clicking once on the center then again on the
edge

Diameter: Creates a circle with two points with the diameter being the distance
between the two points

Tangent Two: Circle created by snapping the circle's edge tangent to two objects

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FeatureMILL2.5D Snapping and Geometry

2 Pts, Radius: Creates a circle by specifying two points and a radius

3 Pts: Creates a circle from three points

Circle Constructor Exercise

• Open circles_example.fm
• From the snapping toolbar enable snap to point, snap to endpoint, snap
to centerpoint then snap to intersection

• From the circle constructor flyout menu click on 3 Pts

• In the upper left hand corner locate the 3 points and

click once on each point

• From the circle constructor flyout menu click on

Center, Radius

Below the assistance bar there is a field for the circle

radius. Enter 0.625”.

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FeatureMILL2.5D Snapping and Geometry

Then click on the corner of the Geometry in the lower left

• From the circle constructor flyout menu click on

Tangent Two

Click once on the line segment in

the upper left area as shown below

Then Click again on the line segment perpendicular to it

• From the circle contructor flyout menu click on

Diameter

In the square located on the center of the

part Click once on the left vertical line
segment

Then Click again on the right vertical line segment

• From the circle constructor flyout menu click on

Center, Radius

FeatureMILL2.5D 2012 19
FeatureMILL2.5D Snapping and Geometry

• In the assistance bar below the display window enter a Radius of 0.5”

Click once where the perpendicular and vertical lines

meet close to the right hand corner:

• From the circle constructor flyout menu click on

Center, Edge

Snap to the rectangular corner located toward the

upper right hand of the part and Click once

Then Click again at the end of the vertical line

segment to the right

• From the circle constructor menu click on 2 Pts,

Radius

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FeatureMILL2.5D Snapping and Geometry

• Enter a Radius value below the assistance bar as 0.625”.

Snap to the corner of the geometry segments shown below and click

Then click again snapping to the opposite corner shown below

When finished the project should look like the image below

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FeatureMILL2.5D Snapping and Geometry

Fillet Constructors
Below is a summary of each item’s function is on the fillet constructor flyout menu followed
by an exercise.

• Open fillet_example.fm
• Click on the fillet constructor flyout menu from the geometry toolbar.

Corner fillet creates a fillet in a corner originally

defined by an intersection of lines or arcs.

Two point fillet creates a fillet in a corner originally

defined by an intersection of lines or arcs.

Three points defines a fillet by selecting three

points, similar to the three point circle..

Chamfer creates a chamfer in a corner originally defined by an

intersection of lines or arcs.

Fillet and Chamfer Constructor Exercise

• From the part view Right-click on stock then Left-click on Hide Stock.

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FeatureMILL2.5D Snapping and Geometry

• From the Fillet Constructor flyout menu select Corner Fillet

• Below the assistance bar enter 0.438” for the Radius.

• Move the mouse close to C then Left-click.

• From the Fillet Constructor flyout menu select 2pt

fillet.

• Below the assistance bar enter 0.375” for the radius value.

• Create a 2 Pt Fillet between A and D shown below by clicking once on the

vertical line segment I - A then once on the horizontal line segment passing
through A – D.

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FeatureMILL2.5D Snapping and Geometry

• Below the assistance bar enter a value of 0.875”.

• Click once on the line segment between A – G and once on the line
segment A – E.

• From the fillet fly out menu Click on 3 Pt Fillet

• Click once on the line segment D-F

then again on the line segment F-G

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FeatureMILL2.5D Snapping and Geometry

• then once more on the line segment E-H

• From the Fillet Flyout Menu click on the Chamfer

command
From the assistance bar enter the width and height of
0.20”

• Move the mouse near the line

intersection at point B and click

When this exercise is finished you should see

results similar to that shown on the right.

Arc Constructors
Below is a summary of what each items function is on the arc constructor flyout menu
followed by an exercise.

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FeatureMILL2.5D Snapping and Geometry

• Click on the arc constructor flyout menu from the geometry toolbar

Arc from three points constructs an arc through a start point, edge
point, and a finish point.

Arc from two points, radius constructs an arc through two points with a
specific radius.

Arc from center, beginning, end constructs an arc from a center point
and given beginning and end points.

This selection constructs an arc with a specific center and radius with
the starting and ending points determined by angles.

Arc Constructor Exercise

• Open arcs_example.fm
• From the snapping toolbar click on snap to point and snap to endpoint
as the only snapping modes checked

• Click on the arc from three points constructor from the arc constructor
flyout menu

26 FeatureMILL2.5D 2012
FeatureMILL2.5D Snapping and Geometry

• In the upper left hand quadrant of the stock click once on A, B then C.

• Click on 2 Pts, Radius from the arc

constructor flyout menu

• Below the assistance toolbar enter a radius of 1.25”

• Click once at point G then again at point H

• Below the assistance toolbar enter a radius of 2”

• Click once at point J then again at Point I

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FeatureMILL2.5D Snapping and Geometry

Notice that depending on which point is picked first determines the direction of the arc.

• Click on the arc from Center, Beg, End from the arc constructor flyout
menu

• Click once at point E, then at point F and then at point D.

• Click on the arc from Center, Rad, Beg, End from the arc constructor
flyout menu

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FeatureMILL2.5D Snapping and Geometry

• Below the Assistance toolbar enter 2” for the Radius

Click once at point N next at point K and finally at point M

When the project is complete it

should look similar to the image on
the right.

Dimensioning
Below is a summary of what each item’s function is on the Dimensioning flyout menu
followed by an exercise.

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FeatureMILL2.5D Snapping and Geometry

• Click on the dimensioning flyout menu from

the geometry toolbar

Horizontal creates dimension information

based on the horizontal axis of the part.
Vertical creates dimension information based
on the vertical axis of the part.

Linear creates dimension information based on the absolute distance

between two points regardless of the angle of the dimensioned space.

Radius creates dimension information for the radius of the selected object.

Diameter creates dimension information for the diameter of the selected

object.

Angle creates dimension information for the angle between two selected
lines.

Text label creates a text label entered in the dialogue bar

Annotation places explanatory text, entered in the dialogue with an arrow of

what is being explained

Curvature samples the surface and computes the curvature in two

directions to describe how the surface behaves at the point shown in the
dialog bar. Unlike the other dimensioning tools, Curvature is a real-time
rubber-banding effect where you traverse the surface to find the point with the
smallest curvature radius. Knowing the smallest radius tells you the smallest
tool to use to manufacture the surface.

This dialog helps you extract numbers from the graphics window using
snap modes and pick filters. You can then cut and paste these values into
other dialogs.

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Dimensioning Constructor Exercise

• Open dimension_ex.fm
• Click on options then on viewing. In the Dimension text size enter 1
then press OK.

• On the snapping toolbar check snap to center and snap to object only.

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FeatureMILL2.5D Snapping and Geometry

• From the Dimensioning flyout menu on the geometry toolbar select

Horizontal Distance

• Click once on the vertical line segment, close to A, then click again on the
vertical line segment at B then click once again above the horizontal line
segment between A and B

• From the dimensioning flyout menu click on Vertical distance

• Click once on the horizontal line segment between A and B , click once
on the horizontal line segment E – F then click again to the right of the
vertical line segment B-F

• From the Dimensioning Flyout menu Click on linear distance

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FeatureMILL2.5D Snapping and Geometry

• Click once at the circle center of circle G , click again at the arc center
between D and E, then click again between the two previous points

• From the dimensioning flyout menu click Radius

• Click once on the Arc at D – E then Click again slightly above the arc

• From the dimensioning menu click on Diameter

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FeatureMILL2.5D Snapping and Geometry

• Click once on the circle located at G then click again to the left of circle G

• From the Dimension flyout menu select Angle.

• Click once on line segment F–G then click once on line segment C-G then
Click again somewhere between the two

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FeatureMILL2.5D Snapping and Geometry

• From the dimensioning flyout menu click on Text Label.

• Below the assistance bar enter the text “Watch SF closely!”

• Click once above the stock outline

• From the dimensioning flyout menu select Annotation

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FeatureMILL2.5D Snapping and Geometry

• Click once at point B then click again towards the upper right hand corner
of the stock outline

• Click again towards the upper right hand of the stock

• Below the assistance bar enter the text “Surface Finish = 12” then press
the Create button.

When the project is finished you should have results similar to those shown below.

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FeatureMILL2.5D Snapping and Geometry

Clipping
Below is a summary of what each item’s function is on the clipping flyout menu followed by
an exercise.

• Click on the clipping flyout menu from the geometry toolbar

Clip: Clip removes a region of a line, arc, circle or curve. A region is defined as a portion of an object
between two intersection points.

Trim/Extend: changes the length of a line or an arc. Trim/extend can be used to lengthen or shorten lines and
arcs as follows:

Infinite: changes the length of a line or an arc.

Clipping Exercise

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FeatureMILL2.5D Snapping and Geometry

The purpose of this exercise is to become familiar with the clipping, trim/extend and infinite
geometry modification functions. These functions will be shown once then try to make the
file clipping example look similar to the image above

• Open clipping_example.fm
• From the snapping toolbar check snap to grid and snap to point only.

• From the geometry toolbar Click on Clip.

• Locate the horizontal line segment at A then click on it once

• Locate the vertical line segment at B then click once

• From the geometry toolbar click on Trim/Extend

• Locate the Horizontal line segment to the left of C and Click once

38 FeatureMILL2.5D 2012
FeatureMILL2.5D Snapping and Geometry

Then Click again toward the vertical line and point across from C.

• Locate the horizontal line segment at D and Click once.

Then Click again between and the vertical line

• From the snapping toolbar Click on Infinite.

• Locate the Point near the vertical line segment at point E and Click once

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FeatureMILL2.5D Snapping and Geometry

• Locate the horizontal line segment at point F and Click once

When finished, you should have results similar to the image below:

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FeatureMILL2.5D Curve Creation

Curve Creation
Introduction
This module will provide an understanding of what curves are and how to create them within
FeatureCAM. By the end of the module the user will be able to construct both open and
closed curves and import curves from other objects.

What is a Curve?
Curves are paths in 2D or 3D space. You can create them in FeatureCAM or import them
from a CAD system. Curves can be open or closed. You can create curves from lines and
arcs, from other curves, from points, from CAM dimensions, from Windows fonts, or from
surfaces.

Chaining
Lines, circles and arcs typically represent the shape of a part. To use a sequence of lines and
arcs as the shape of a feature, you must chain them into a curve. To make a feature from
more than a single line, arc or circle, you must connect the geometry into a curve. Chaining is
the primary way of creating curves by connecting pieces of geometry. In many cases you do
not need to trim away pieces of geometry. Chaining will automatically prefer smooth,
tangent-continuous paths since these paths are more conducive to manufacturing.

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FeatureMILL2.5D Curve Creation

Closed Curves

Closed Curves have start and end points in the same location, and at least one other point (not
in that location) included in the curve. The closed curve clearly defines an area as the interior
of the curve and completely separates this area from the exterior of the curve. Any
ambiguities, such as overlapping curve links or intersecting curve links, cause failures and
unpredictable results in the machining routines in FeatureCAM. To chain open curves the
closed curve command may be used or by simply double-clicking the closed geometry using
the pick pieces command.

Open Curves

Open curves have end points that do not meet. You can only use open curves in Side and
Groove features. To chain open curves we use the pick pieces command. The image below
shows two open curves on a part.

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FeatureMILL2.5D Curve Creation

User Interface curve chaining

Curve chaining commands can be accessed from three different areas of the user interface:

Curve chaining commands may be accessed through the

Geometry toolbar

May be accessed from the File menu by clicking on Construct -> Curve -> Chaining

Or may be accessed by clicking on Curves from the Steps Toolbox

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FeatureMILL2.5D Curve Creation

Curve Wizard

Curve constructor commands can be accessed in four different areas of the user interface:

Curve constructor commands are available through the Steps menu:

They may also

be accessed
through the File
menu by
clicking on
Construct and
Curve:

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FeatureMILL2.5D Curve Creation

May be accessed through the curve toolbar (to show the curve toolbar, from the file menu
click on View then Toolbars then check the Curves and Surfaces checkbox and press OK)

Or may be accessed at the bottom of the Geometry toolbar(not all functions available here)

Chaining Open and Closed Curves

• Open FeatureCAM by double-clicking the FeatureCAM shortcut icon on

the desktop:

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FeatureMILL2.5D Curve Creation

• Click on Open an existing file in the New Part Document wizard window
then press Next.
• Select Curve_Chaining.fm then press the Open button.

When the file is open it should look similar to the image below:

• From the Geometry toolbar select the Chain

Menu flyout then click on Closed Curve

• Click once on the circle at “A” then press the Create button below the
graphics window.

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FeatureMILL2.5D Curve Creation

• Do the same for the circles located at B, C and D.

• From the Part View menu click on the + next to the word Curves. Four
curves should be listed. These four curves are the curves that were created in
the previous step.

• Click on the cross shape centered on “A” then press the Create button
below the graphics window

• Do the same for the cross shapes located at B, C and D

• Click on the large square with a corner radius centered around “A” then
press the Create button below the graphics window

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FeatureMILL2.5D Curve Creation

• Do the same for the large squares located at B, C and D.

• From the Geometry toolbar select the Chain Menu

flyout then click on Pick Pieces

• Click once on the horizontal line segment located at “E”

Then click once on the vertical line segment at “I”

Then click once at the vertical line segment located next to “J”

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FeatureMILL2.5D Curve Creation

Then click on the vertical line segment located at “K”

Then click on the horizontal line segment located next to “F” then press
the Create button below the graphics window.

• Following steps similar to those shown above create a zigzag curve

between “G” and “H”.

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FeatureMILL2.5D Curve Creation

In this exercise curves have been made from Geometry. These curves can be useful for
creating features, surfaces and solids.

Curve Constructors
Curve constructors are used to create/modify curves using different methods. In this section
there will be a short description of how each function works followed by an exercise.

• From the file menu click on Construct then on Curve. Let’s review these.

There are four Different methods for creating curves: From Curve, Other methods, From
Surface and Chaining:

Curve from Curve

• From the file menu click on Construct then Curve then From Curve

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FeatureMILL2.5D Curve Creation

The curve from curve menu has functions that create new curves based on existing curves.

Curve Join connects a collection of curves, arcs or lines into a single

curve.
Curve Start/Reverse changes direction and starting point of the curve

Curve Offset offsets a curve in the direction you pick by the amount
you set.

Project to UCS projects flat curve or 3D curve to current UCS

Extract Font Curve extracts curve segment from a font curve

Smooth/Reduce Curve reduces the amount of data in a curve and

smoothes out any bumps within a user specified tolerance.

Unwrap unwraps a curve that has been wrapped around a cylinder

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FeatureMILL2.5D Curve Creation

Curve from Curve Exercise #1

• From the file menu select File then Open

• Select the file named
Curve_From_Curve1.fm then press Open

• Click the “+” in the part view next to

curves

You will see that in this file there are four curves.

• From the file menu click on

Construct then Curve, From
Curve and Join.

A dialogue window for Join curve

appears.

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FeatureMILL2.5D Curve Creation

• Click on the selection arrow (black arrow with the red wavy line) icon .
Click once on the curve next to A, click again on the curve next to B and
click again on the curve next to C then press OK/Finish.

Observe the list of curves

in the Part View. A new
curve has been added
from joining the curves.

• From the file menu

click on Construct then Curve, From Curve and select Curve
Start/Reverse.

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FeatureMILL2.5D Curve Creation

By default the first curve should be highlighted. Notice there is an arrow at the end of the
curve that shows the direction of this curve.

• From the pull down

menu select crv2.
Crv2 should highlight
then press preview

The blue arrow shows the new reversed direction of the curve.

• Press OK/Finish.

Reversing of curves is useful for cutting simple grooves for milling. Simple groove toolpaths
plunge at the start of the curve and end at the end of the curve.

• From the file menu click on Construct then Curve then From Curve and
select Curve Start/Reverse. From the pull-down menu select crv4 then
activate the radio button Set start point.

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FeatureMILL2.5D Curve Creation

This will highlight the red egg-shape centered around point D. Notice that the direction of
the curve is clockwise and the start point is on the left hand side of the egg. If we were to
apply this curve to a simple groove feature the tool would plunge on the left hand side and
continue clockwise around the profile.

• Click the Pick new start point icon , then click on the right hand side
of the egg then click the Preview button.

A profile of the new curve direction and start point preview is shown.

• Press OK/Finish.
• In the Part View locate and click on the curve that was joined from the 3
separate curves at the beginning of the exercise.

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FeatureMILL2.5D Curve Creation

• From the file menu click on Construct then Curve then From Curve then
Offset.
• Enter an Offset value of 0.5, select Left then click Preview and Apply.

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FeatureMILL2.5D Curve Creation

• Using the same curve select an Offset of 0.5, select Right then Preview.

Observe the area circled in red. This is a self-intersection that could be bad for cutting as an
offset profile.

• Click on the checkbox that is labeled Eliminate self-intersections then

press Preview.

Notice that there is no longer a self intersection.

• Press OK

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FeatureMILL2.5D Curve Creation

Curve from Curve Exercise #2

• From the file menu select File then Open

• Select the file named Curve_From_Curve2.fm then press Open
• Right-click in the viewing window and press rotate.

• Rotate the part to observe the curve.

Notice that the curve is 3 dimensional. Most features from curves do not allow you to use a
3D curve for a feature. The only feature that will accept a curve that is not in the plane of the
current setup UCS is a simple groove.

• From the file menu click on Construct then Curve, select From Curve
then select Project to UCS and then press OK.

A curve is created by projecting the existing curve profile in Z to the current UCS. This
curve can now be used to create 2.5D features from a curve such as pockets and bosses.

• Click on the curve that was just created then from the file menu click on
Construct then Curve then From Curve then select Smooth/Reduce Curve
then press Preview.

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FeatureMILL2.5D Curve Creation

The Smooth/Reduce dialogue appears. When the preview button is pressed the Data
reduction% field is populated. In this example the data reduction is about 50%. The new
curve contains 50% less data but also has the ability to deviate from the original curve within
tolerance.

• Press OK and the new curve is created

Curve from Curve Exercise #3

• From the file menu select File then Open.

• Select the file named Curve_From_Curve3.fm then press Open.
• From the file menu click on View->Show->Show STOCK Axis.

The part that has been opened is a 4th axis part to be indexed about the stock x axis.

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FeatureMILL2.5D Curve Creation

• Right-click in the graphics window and press Rotate.

• Rotate the part by moving the mouse to observe the curve

Notice that the curve is 3 dimensional as in the previous example. The only feature that
would be able to use this curve would be a simple groove. So the curve needs to be
unwrapped so it lies in a plane aligned with the current UCS.

• Click on the curve so that it is highlighted then click on Construct >Curve-

>From curve-> then select Unwrap.
• In the Unwrap Curve dialog press the Preview button.

Notice that when the preview button is pressed the curve is unwrapped around the stock axis.

• Press OK

Now the curve can be used to create a 2.5D feature since it is aligned with the current UCS.

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Curve from Surface

• From the file menu click on Construct->Curve->From Surface

The Curve From Surface menu has functions that create new curves from
surfaces.

Boundary extracts the curve from a surface's boundary

Trimmed Edge extracts the trimmed edges of a surface

Intersection extracts curves from a surface-surface intersection

Isoline extracts surface row or column isolines

Project onto Surface project existing curve onto a surface

Surface Edges extracts selected surface edges

Surface Projection extracts curves from all vertical walls

Revolved Surface Boundary extracts a revolved profile about the

part’s index axis

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FeatureMILL2.5D Curve Creation

Curve From Surface Example #1

• From the file menu select File then Open

• Select the file named Curve_From_Surface1.fm then press Open

• From the file menu click on:

Construct->Curve->From Surface->Boundary

• Select Srf1 from the pulldown menu select First Row then press Apply.

In the Part View window under Curves a new curve appears. This curve is created from the
first row of srf1 boundary

• Press OK

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FeatureMILL2.5D Curve Creation

• From the file menu click on:

Construct->Curve->From Surface->Trimmed Edge.

The trimmed edge dialog appears that gives the ability to extract trimming curves used to
trim the surface.
• Click the Pick curve on surface icon with the red wavy line
• Click one of the edges of the green diamond on srf1 then press OK.

A curve is extracted from the trimmed surface

• From the file menu click on:

Construct->Curve->From Surface->Intersection

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FeatureMILL2.5D Curve Creation

The surface intersection dialog appears that enables a curve to be

constructed where the surfaces intersect.

• Locate the aqua blue and orange surfaces in the lower left hand corner.
For Surface 1 select srf2 (aqua blue surface) from the pull-down menu.
Click on the Pick surface icon and click once on the orange surface.

• Press the Preview button.

Observe that a curve is highlighted in blue in the lower left hand corner where the two
surfaces intersect. This is the curve that will be created when OK or Apply are pressed.

• Press OK

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FeatureMILL2.5D Curve Creation

• From the file menu click on:

Construct->Curve->From Surface->Isoline
• Select srf1 as the surface and in the count field enter 3

Notice the preview of the surface isolines running along surface rows in the current view.

• Then press OK/Finish.

• From the file menu click on:
Construct->Curve->From Surface->Project onto Surface.
• In the Project Onto Surface dialog select srf1 for the Surface and select
curve32 for the Curve.
• Press the Preview button.

Curve32 (DELCAM) is projected in the Negative Z direction. The resulting curve could be
useful for engraving text on a surface using a simple groove.

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FeatureMILL2.5D Curve Creation

• Press OK/Finish.

• From the file menu click on:

Construct->Curve->From Surface->Surface Edges.

• Click on the Pick curve on surface icon.

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FeatureMILL2.5D Curve Creation

• Pick the lower surface edges on the purple shape in the upper right
hand corner until all edges are selected. Be sure to pick the surface edges
consecutively.

• When all edges are pick press the red X next to the minimized surface
edges window

• Press OK/Finish.

The curve constructor from surfaces surface edges is a very useful tool for extracting curves
from surfaces or from the faces of a solid.

From the file menu click on Construct->Curve->From Surface-> then

Surface Projection.

The first dialog that appears gives you the ability to specify the draft angles and elevation
relative to the UCS where the curve is to be created.

• In the Surface Projection dialog enter 1 for the Wall Angle and 0 for the
Elevation then press Next.

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FeatureMILL2.5D Curve Creation

• In the following window select All surfaces then press Next

A preview of the geometry to chain in the viewing window appears highlighted in green.

• Check the radio button Remove after chaining then press Finish.

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FeatureMILL2.5D Curve Creation

• Chain the geometry into a Closed Curve then press Create.

The curves created from this exercise should look similar to the results shown below:

• To see the curves click on View->Hide->Hide All. Then click on View-

>Show->Show All Curves.

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FeatureMILL2.5D Curve Creation

Curve From Surface Example #2

• From the file menu select File then Open

• Select the file named Curve_From_Surface2.fm then press Open
• From the file menu click on:
Construct->Curve->From Surface->Revolved Surface Boundary.
• Select the radio button that is labeled Solid method then Preview.

• Click OK/Finish.
• Hide all solids to see the curve that has been created.
• Close the file without saving.

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FeatureMILL2.5D Curve Creation

Curve From Other Methods

• From the file menu click on Construct->Curve->Other Methods

Curve from other methods gives you the ability to create curves using other types of
constructors.

Function creates user-defined mathematical relationships to generate a

graphical figure.
Cams creates the geometric profile of various reciprocating cams or
Cylindrical cams.
Spline/Interpolation creates a continuous smooth curve between points.
Text creates text curves from any TrueType installed for windows.
Ellipse curve tool creates an elliptically-shaped curve in the plane of the
current UCS.
The Rectangle curve tool creates a rectangular shaped curve in the
plane of current UCS.
The Gear curve tool creates a 2D gear profile.

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FeatureMILL2.5D Curve Creation

Other methods Example #1 functions

The Functions method of creating a curve allows the user to define a 2D or 3D curve in terms
of a mathematical function. In this example we will create a helix.

• From the file menu click on New.

• Select a milling setup with inches then press OK.
• From the file menu click Construct>Curve>Other Methods>Functions.
• From the Function pulldown select r=F(a), z = G(a)

In this example a Helix will be constructed. The helix will have 4 revolutions with a constant
radius of 1 and a pitch of 1. F is the function for the radius of the curve and G is the
Function for the pitch. The letter “a” represents angle.

• Change the parameter F to 1 since there is a constant radius of 1”

• In the G field enter a/360. This means that every 360 degrees the helix
will rise 1 inch. If you would like to rise a half inch every 360 degrees change
the parameter to (a/360)*.5
• Select Degree.
• Enter 0 for Start.

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FeatureMILL2.5D Curve Creation

• In the End field enter 360*4. This means the helix will go around 4 times.
• Change the Increment to 5. This is how course or rough the helix will be.
Changing the value to a large value will make the helix faceted.
• Press Preview and press OK.

Other methods example #2

• From the file menu click on new

• Select a milling setup with inches
then press Finish.
• Enter the stock dimensions as 4” x 5”
x 1” then press Finish.

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FeatureMILL2.5D Curve Creation

• From the file menu click on Construct->Curve->Other Methods>Text

• In the Text field type in DELCAM then press the Preview button.

A preview of the text Delcam is shown with the default machining font.

• Click on the Font button

The available fonts are shown in the left hand window. All windows fonts are listed in this
window as well as 5 machining fonts installed with FeatureCAM. All of these fonts start
with “Machine Tool...”. These fonts are unique because they are single line engraving fonts
that are useful for engraving.

• From the available Font list select Machine Tool Gothic and press OK

*Note: it is suggested to not change the size of the font in the Font window as
undesirable results could occur. The value for all the machining fonts should be set to
72. If changes are needed to the size of the text, use the scaling option.

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FeatureMILL2.5D Curve Creation

• In the Engraving text dialog change the Location to (0.75, 0.75, 0).
Change the Angle to 30 and change the Scaling to 0.8 then press OK.

• From the file menu click on:

Construct->Curve->Other Methods>Rectangle.
• In the Rectangle dimension dialog enter the values highlighted and press
OK/Finish.

Results now should look similar to the image on

the right:

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FeatureMILL2.5D Curve Creation

• From the file menu click on Construct->Curve->Other Methods>Ellipse

• In the Ellipse dialog change the values of the fields highlighted below
then press OK/Finish.

The resulting curves can be used

for engraving by creating a simple
groove.

Other methods example #3

• From the file menu select File then Open

• Select the file named Curve_From_Other_Methods3.fm then press Open
• Enable Snap to Point from Snap Mode toolbar

• From the file menu click on:

Construct->Curve->Other Methods>Spline/Interpolation

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FeatureMILL2.5D Curve Creation

• Below the assistance bar press the Options button so that Closed
interpolation is activated.

• Click on each point sequentially then press the create button below the
assistance bar.

When finished the resulting curve should look similar to the curve below.

FeatureMILL2.5D 2012 37
FeatureMILL2.5D Basic 2.5D Features

Basic 2.5D Features

Introduction
This Module will provide an understanding of what a feature is, the feature types available
and how to create various types of 2.5D features.

What is a Feature?
Features are the intelligent core entities that a machinist would use to make a certain shape in
the material they are cutting. Shapes such as a hole, boss, slot, etc…Features are used to
make toolpaths in FeatureCAM to make these shapes. Features may consist of several
operations to create the final result or shape.

Features may consist several operations including: spot drill, center drill, drill, pre-drill, tap,
roughing, semi-finish and finish passes.

A 2.5D Feature is a Feature that in a single plane, primarily the XY plane. A more complex
Feature that will be introduced in later modules is a 3D Feature that cuts in X, Y and Z axis
simultaneously.

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FeatureMILL2.5D Basic 2.5D Features

User Interface
All features created inside of FeatureCAM are initially created using the New Feature
Wizard. The New Feature Wizard can be accessed in several different areas of the user
interface.

• Accessed through the

Advanced Toolbar.

• Accessed through the

Steps Toolbar.

• Accessed through the File Menu.

• Or the New Feature Wizard may be accessed

through the Steps Menu.

The new Feature Wizard is broken into four sections:

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FeatureMILL2.5D Basic 2.5D Features

From Dimensions: Feature From Dimensions specific dimensions for the hole,
rectangular pocket, face, etc... may be entered. No curve is required to create the
feature boundary.

From Curve: Feature From Curve defines the feature boundaries by using curves.

From Feature: Feature from Feature allows the user to create a group of features, a
pattern of features, a feature from existing toolpath or a user defined feature.

From Surface: Feature from Surface is used to create surface milling features by
either selecting part surfaces or faces.

Feature Representation

• From the desktop double-

click on the FeatureCAM
shortcut icon.

• From the New Part

Document Wizard select
New File then press Next.

FeatureMILL2.5D 2012 3
FeatureMILL2.5D Basic 2.5D Features

• Select Milling then

inches and press
Finish.

• On the Dimensions page

press Finish.

• On the
Stock
Properties
page press
OK.

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FeatureMILL2.5D Basic 2.5D Features

• Right click in the graphics window and click on Isometric.

• From the Steps Toolbox click on Features.

• Select Hole and press Finish.

• In the Hole Feature Properties window press OK.

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FeatureMILL2.5D Basic 2.5D Features

• In the Toolbox Window click on Part View.

Notice that the hole feature created is represented in three different sections of the user
interface: the feature shown in a tree structure under the part view on the left, a graphical
representation of the feature in the viewing outlined in pink and the feature listed with its
associated operations on the operation list.

• Double-click on the hole in the Part View. The Hole Feature

Properties window should appear.

It should

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FeatureMILL2.5D Basic 2.5D Features

be noted that the feature properties can be accessed by double clicking on each representation
of the feature: in the Part View in the Graphics Window or the Operations List.

Features from Dimensions

Features from Dimensions consist of Hole, Rectangular Pocket, Slot, Step Bore, Thread
Milling and Face.

Holes
There are six different types of hole features in FeatureCAM. Plain, Counter bore, Counter
drill, Counter sink, Tapped, Counter drilled tapped. Each hole type consists of different
operations to create the resulting feature. Below is a graphical representation of the available
holes in FeatureCAM

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FeatureMILL2.5D Basic 2.5D Features

Feature From Dimensions Exercise #1

• From the file menu click on Open.
• Select holes.fm then press Open.

The opened file should look similar to the image below:

• Click on Construct then New Feature.

• In the New Feature

Wizard select Hole
then press Next.

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FeatureMILL2.5D Basic 2.5D Features

• On the new feature dimensions page select Plain Hole, enter a

Depth of 1.0 and a Diameter of 0.25 then press Next.

• Click on the Pick location button.

FeatureMILL2.5D 2012 9
FeatureMILL2.5D Basic 2.5D Features

• Click once on point A (values should be identical to those listed

below once point A is clicked) then press Finish and OK.

A
plain hole is created at point A. The next step is to create the 5 different types of remaining
holes at B, C, D, E and F.

• At point B create a Counter

Bore Hole with the
dimensions shown.

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FeatureMILL2.5D Basic 2.5D Features

• At point C create a Counter

Sink Hole.

• At point D Counter Drilled

Hole.

• At point E create a Tapped

Hole

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FeatureMILL2.5D Basic 2.5D Features

• At point F create a Counter

Drilled and Tapped Hole.

When this exercise is finished you should

have results similar to the image below:

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FeatureMILL2.5D Basic 2.5D Features

Feature From Dimensions Exercise #2

• From the file menu click on Open.

• Select hole patterns.fm then press Open.

The opened file should look similar to the image below:

• Left click and drag a bounding box to enclose all six points so they are
highlighted.

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FeatureMILL2.5D Basic 2.5D Features

• With the six points still highlighted click on Construct then New
Feature.

The New Feature wizard should appear notice that hole is automatically selected and that
Make a pattern from this feature is automatically checked.

By selecting these points and then entering the New Feature Wizard FeatureCAM knows to
create a pattern of holes.
• Press Next. Select a Plain Hole.
• Press Finish

14 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

The Pattern Properties appear and a Point List for the pattern appears. The order in which
the holes are drilled depends on the order the points listed in the table.

• Press the Sorting button

• Press X-ascending then press OK then Apply.

Observe the graphics window. Notice that the order in which the holes are drilled has been
changed.

• Press OK
• From the file menu click on Edit then
Select circles

A filter dialog will appear for selecting circles of a specific diameter and tolerance.

For the Radius value enter 0.250 and enter 0.0001 for the Tolerance then press OK

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FeatureMILL2.5D Basic 2.5D Features

The circles on the upper half of the part drawing should highlight red.

• With the six circles still highlighted click on Construct then New
Feature.

• Select Hole and check Make a pattern from this feature.

16 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• Press Next.

The hole Diameter field is automatically populated because the circle diameter was
previously selected.

• Press Finish then OK and results should look similar to those shown
below.

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FeatureMILL2.5D Basic 2.5D Features

Feature From Dimensions Exercise #3

This exercise will familiarize the user with creating pockets and slots from dimensions.

• From the desktop double click on the FeatureCAM shortcut icon

• From the New Part Document Wizard select New File, press Next.
• Select Milling then inches and press Finish.
• On the dimension page enter 4 for the Width, 6 for the Length and 1
for the Thickness then press Finish and OK.

18 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• Open the New Feature wizard

from the Steps Toolbox.
Select Face then Finish.

• Press on the Features

icon to open a New
Feature from the Steps
Toolbox. Select
Rectangular Pocket then
press Next.

• Enter the dimensions of the

pocket as shown. 3 for the
Width, 1.5 for the Length and
0.625 for the Depth. The
Corner Radius should be set to
0.25 with a Bottom Radius of
0.25. Once the dimensions
have been entered press Next.

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FeatureMILL2.5D Basic 2.5D Features

• On the location tab select the

XYZ radio button and enter a
location of (.5, .5, 0) then press
Finish.

• Open the New Feature

wizard from Steps.
• Select Rectangular
Pocket then press Next.

• Enter the dimensions of the

pocket as shown below. 3 for the
Width, 1.5 for the Length and
0.625 for the Depth. The Corner
Radius should be set to 0.25 with
a Bottom Radius of 0.25. Once
the dimensions have been
entered press Next.

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FeatureMILL2.5D Basic 2.5D Features

• On the location page select the

XYZ radio button and enter a
location of (4, .5, 0) then press
Finish.

• Press on the Features icon to

open the New Feature wizard
from the Steps Toolbox. Select
Slot then press Next.

• Enter the slot dimensions as

shown below. Enter a Length of
5.0, a Width of 1.0, Depth of 0.75
,a Bottom Radius of 0.125 and
an angle of 90 degrees then
press Next.

• On the location page select the XYZ

radio button and enter a location of
(3, -0.5, 0) then press Finish.

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FeatureMILL2.5D Basic 2.5D Features

When this exercise is complete you should get feature results similar to the image shown
below:

• Right click in the graphics window and select Isometric.

• From the Steps click the Toolpaths icon, then run a 3D simulation.

22 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

Feature From Dimensions Exercise #4

• From the FeatureCAM file menu click on File then Open.

• Select the file named “ThreadmillStepbore.fm” then press Open.

Examine the features in setup 1 (Part View). Notice that a face feature and rectangular
pocket have already been created.

• Press on the New Feature Wizard icon from the Steps Toolbar.
• Select Step Bore then press Next.

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FeatureMILL2.5D Basic 2.5D Features

• Enter the values as shown for

each of the steps, press Set
then press Next.

• Press the XYZ radio button

then enter the location
dimensions as (0,0,-0.5) then
press Finish and OK.

• From the Steps Toolbox

press the Toolpaths icon
then run a 3D simulation.

Results should look similar to the image

to the right:

24 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• Eject the simulation.

• Press the New Feature Wizard icon from the steps toolbar.
• Select Thread Milling then press Next.

• Select Get the thread dimensions from a standard thread.

• Select ID then from the

Designation pull-down menu
select 1.1250-12 UNF then
press Next.

• In the Thread Length field

enter 1 then press Next.

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FeatureMILL2.5D Basic 2.5D Features

• Pick the XYZ radio button then

enter a Z location of -0.5 then
press Finish and OK.

• Press the New Feature Wizard icon from the steps menu.
• Select Thread Milling then press Next.

• Select Get the thread

dimensions from a
standard thread.

• Select OD then from the

Designation Pull-down menu
select 3.0000-4 UNC then press
Next.

26 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• In the Thread Length field enter

1.5 then press Next. Select the
XYZ radio button enter all 0’s in
the X, Y, and Z fields.

• Finish and OK.

• Run a 3D simulation.

You should have results similar to the image below:

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FeatureMILL2.5D Basic 2.5D Features

Features from Curves Exercise #1

• Open the file named ChamferFillet.fm.

Examine the features in setup 1. Notice that a face feature has already been created.

• Press on the New Feature Wizard icon from the steps menu.
• Select Boss and press Next.

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FeatureMILL2.5D Basic 2.5D Features

• Use the Pick curve or geometry arrow to select the curve in blue that
goes around the outer profile of the part. The curve name should be
curve1 then press Next

• For the Offset from curve Z

location value enter 0.25, then
press Next.

• On the New Feature -

Dimensions page enter a
Height of 1.5 then press
Finish and OK.

FeatureMILL2.5D 2012 29
FeatureMILL2.5D Basic 2.5D Features

• Open the New Feature Wizard

select Chamfer then press
Next.

• Use the selection arrow to select the curve in blue that goes around the
outer profile of the part. The curve name should be curve1 then press
Next twice.

• For the Offset from curve Z

location value enter 0.25, then
press Next.

30 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• Select 2D Chamfer.

• For the Depth and Width

dimensions for the chamfer enter
0.25 then press Finish and OK.

• Run a 3D simulation.

You should see results similar to the image below

• Press the Eject button on the simulation toolbar to clear simulation

results
• Enter the New Feature and select a Pocket then Press Next.

• Use the Pick curve or geometry

arrow to select the curve in blue
that goes around the outer profile
of the pocket in the solid. The
curve name should be curve2
then press Next.

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FeatureMILL2.5D Basic 2.5D Features

• For the Offset from curve Z

location value enter 0.25 then
press Next.

• On the Dimensions page enter

the Depth of 1.0 then press
Finish and OK.

• Click on the New Feature

Wizard icon select Round then
press Next.

• Use the selection arrow to select

the curve in blue that goes around

32 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

the outer profile of the pocket. The curve name should be curve2 then
press Next twice.

• For the Offset from curve Z

location enter 0.25 then press
Finish and OK.

• Run a 3D simulation of the part.

Results for the 3D simulation should be similar to the image shown below.

Features From Curves Exercise #2

• Open SideWheel.fm.

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FeatureMILL2.5D Basic 2.5D Features

• Open the New Feature

Wizard.

• Select Side then press Next.

• Left click and drag a

bounding box so all curves
are selected in red then press
the green plus sign to add all
selected curves to the list then
press Next three times.

• On the Dimensions page enter the Depth of 1.0 then press Finish.

34 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• Run a 3D simulation.
The simulation results should look similar to those shown below

Feature from Feature Exercise #1

FeatureMILL2.5D 2012 35
FeatureMILL2.5D Basic 2.5D Features

• From the file menu click on File then Open and select the file named
PatternGroup.fm then press Open

Examine the features in setup 1. Currently there is a single hole and a rectangular pocket.
Say for example you would like to create a pattern of the hole/ rectangular pocket
combination. You could create a pattern of a hole, then a pattern of the pocket or you could
group the hole and the pocket together and create a pattern of the group that would be more
effective.

• Open the New Feature Wizard in the From Feature group select
Group then press Next.

• Add the hole and rectangular

pocket to Group Members
then press Finish.

36 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• Open the New Feature

Wizard select pattern and
press Next.

• Select the newly created group

then press Next.

• Select Rectangular then press Next.

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FeatureMILL2.5D Basic 2.5D Features

• Enter 2 for both the number of Rows and Columns and enter 2 for the
Row Spacing and Column Spacing, then press Finish.

• From the simulation toolbar select 3D simulation then press Play.

38 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

Feature from Feature Exercise #2

• From the file menu select File then Open select ToolpathEdit.fm in the
examples folder then press Open.

Notice there is only a single face feature in this example located at Z=0

• Run a Centerline simulation of the current toolpath. To do this press

the centerline simulation button on the toolbar then press the play
button

On this facing toolpath there are four undesirable areas where we would like to change the
toolpath. For the toolpath representation there are both feed moves and rapid moves. Black
toolpath segments represent the feed moves while the green segments represent rapid moves.
Currently circled in red are feed moves for the stepover between facing passes. Since the
stepover of the facing tool is off the stock it is safe for us to change these to rapid moves.

FeatureMILL2.5D 2012 39
FeatureMILL2.5D Basic 2.5D Features

• Press Eject on the simulation toolbar

• Open the New Feature Wizard

and select Toolpath in the
From Feature section then
press Next.

• Press the Operation radio

button select face1, finish then
press Next.

• Select the first Y

feed move from the
list, then press the
Edit segment
button.

40 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• Check the Rapid checkbox then press OK.

• Locate the remaining y stepover feed moves and change them to Rapid
also then press Finish.

Observe the Features in the part view. Now there should be a Facing Feature and a toolpath
feature. The toolpath feature is simply a copy of the original features toolpaths with the
edited move.

• Uncheck face 1 in the part view (so there are not two facing operations)
• Press Play on the Centerline simulation and observe the toolpath.

Now notice that the stepover moves have been converted to rapid moves that will reduce the
cutting time of the part.

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FeatureMILL2.5D Basic 2.5D Features

Feature from Feature Exercise #3

Often when creating NC programs it may be desirable to insert G code between operations or
to add comments. In this example we will explore the “User Defined Feature” that will give
us the ability to add code or comments to their program.

• Click on File then Open and select CodeComment.fm then press

Open.

In the file the should be a hole and rectangular pocket feature. Observe the operation list.
There is a Spotdrill->Drill->Rough Pass 1-> and Finish. Between the rough pass 1 the finish
pass we want to put in an optional stop (M01) so the roughing chips can be cleared out for the
finish pass.

• Click on Options then Add-Ins.

• Click on the Browse button.

• Browse to the Code-Comment operation.bas in the examples folder

then press OK and OK again.

• Open the New Feature Wizard

and select User then press
Next.

42 FeatureMILL2.5D 2012
FeatureMILL2.5D Basic 2.5D Features

• Select Insert Code/Comments (Milling) then press Next.

• Click on Line 1 Code and in the New Value field type in “M01” then
press the Set button. Click on the word comment below Line 1 and in
the New Value field type in optional stop then press set then press
Finish.

FeatureMILL2.5D 2012 43
FeatureMILL2.5D Basic 2.5D Features

In the operations list in the results window notice there is a new operation called code/text.
This is the code comment operation that was just created

• Left click and drag the code/text feature so that it occurs right after
rough pass 1 (a warning message may appear depending on your
configuration press OK if it appears)

Now an M01 should appear in the G-Code.

Note: Some posts may not be configured for this functionality to ensure G-Code is properly
output check to see that there is {N<SEQ> }{<UDF-TEXT> }{( <UDF-COMMENT>
)}<EOB> in Formats/Move/UDF Text.

UDF’s (User Defined Features) are not only available for inserting text into the G-code but
can also be configured to create your own customized features. To discover the capabilities
of FeatureCAM’s UDFs contact your local salesperson or support representative.

44 FeatureMILL2.5D 2012
2.5D Milling 2.5D Advanced Milling

2.5D Advanced Milling

Introduction
In 2.5D Milling there are more advanced features than milling and drilling, such as 4axis,
multiple fixtures, cross section, multiple islands, bosses and side features, etc. The user will
learn how tapered walls and other shapes can be machined to emulate 3D milling surfaces
using a ball end mill, but are still 2.5D features.

Multiple Curves in One Feature

Boss and Side features begin cutting the feature at the stock boundary. If your part contains
more than one boss you must select all of the feature curves for the bosses in one feature. If
they are separate features, each will start cutting at the stock boundary thereby removing all
of the material instead of leaving the individual shapes of each boss. Side features are the
same. A pocket with one or more islands (a shape that the tool cuts around and leaves that
shape inside the boundary of the pocket) has an island button to select the curves for the
island, or islands, and then the tool will cut both the pocket shape and the island.

Multiple Bosses

• Open a new Milling

document, select Inches.

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2.5D Milling 2.5D Advanced Milling

• Establish the stock size and Block shape (4 x 4 x 2) or use Sample:

Boss-Side-Pocket.fm.

• Draw the circles for the multiple Bosses (.500 radius Circles as a triangle
as illustrated). These are the multiple shapes you intend to leave on the
top of the stock after machining.

Shape curves do not have to be round but they cannot touch, be inside each other or be higher
than the stock, they will have a common bottom depth although they can be at different
heights. If they are different heights draft angles may not be selected, chamfers will have to
be separate chamfer features but bottom radiuses will be common to all.

• Select New Feature>Boss from

Curve.
• ALL curves must be included in
this one feature
• Enter the height to be 0.500.

• Click Finish
and run a 3D
simulation.

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2.5D Milling 2.5D Advanced Milling

Pocket with Islands

• Open a new Milling

document and select Inches.
Establish the block stock size
(4 x 4 x 2) alternatively you
may open the Sample: Boss-
Side-Pocket.fm.

• Draw geometry to create a

triangular pocket shape with
.500 radius corners, roughly
as shown.

• Chain a closed curve from

the triangular shape. Add two
.250 radius circles, roughly as
shown, inside the pocket.

The islands can be any shape and have a common depth. They can have tops at different
heights, but may not be above the top of the pocket. If they are different heights, draft angles
may not be selected. Also, in the case of different heights, chamfers need to be applied to the
pocket, and each island, as separate chamfer operations. If you add bottom radiuses they will
be common to all.

• Click on New
Feature > Pocket
From Curve >select
the triangular curve
(.500 depth) Finish,
then on the Pocket
Properties page,
Dimensions tab,
select Islands and
include the two circles
whose shape will be
left in the pocket after
machining.

• Click OK and Apply.

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2.5D Milling 2.5D Advanced Milling

All island curves or circles must be included in the feature.

• Click OK and 3D simulation.

Multiple side features

• Open a new Milling document and

select Inches. Establish the stock
size and block shape (4 x 4 x 2) or
you may open the Sample: Boss-
Side-Pocket.fm.
• Draw a “U” shape with a 2.000
opening and .250 corner radiuses,
roughly as shown, and chain it as
an open curve. Add a .250 radius
half circle, centered in the
opening, and clip the left side.
Click New feature > Side From
Curve and select both the “U” shaped curve and the half circle.

Side features can cut on either side of the curve so it is important that the machining side tab
in the properties is checked to make sure the arrow (which indicates the side to be cut for
each shape) is pointing toward the other side curve. The arrows do not have to point at each

2.5D Advanced Milling 2012 4

2.5D Milling 2.5D Advanced Milling

other but they must point at the other side feature. Although there is no island, so to speak, in
a side feature, multiple sides will have the same effect.

• Click Finish.

• Set the depth at .250 and

run a 3D Simulation.

Multiple Plunge Point Curve

When machining a part, it is usually more desirable to plunge the tool to depth off of the
material, wherever possible. For example, a part with four bosses that needs to have the
stock removed all the way to the center. A Boss feature is designed to plunge off the part, but
somewhere in the tool path it may also plunge into the material to reduce the travel distance.
However, center cutting end mills, though designed to cut to the center, may find this
difficult. Because of this, Featurecam defaults to using 50% of feed rate when plunging.

In the Boss feature, under the Milling tab, there is a selection called Plunge Points.

• Open the Plunge Point Curve.fm file.

Hide all Curves and Geometry. Double
click on one of the Bosses in the
graphics window to open the Boss
Properties.

• Click on the Rough operation and the

Milling tab. Select Plunge Point and
Unset. Now run a 3D simulation.

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2.5D Milling 2.5D Advanced Milling

Using a 1.5 diameter end mill, notice how the tool plunges once in the
middle of the Stock. We can use a curve to force the tool to plunge in
certain locations instead of the stock.

• To create this type of curve,

pick Point from the geometry
toolbar. Place multiple point
locations in the graphics
window at locations where you
desire the tool to plunge, as
shown to the right. These
multiple points force the tool to
plunge only at these four
locations, not in the stock.

• Connect the dots with geometry

using Connected Lines and then
chain as an open curve.

Note: When you create the curve, be sure to

notice exactly how it is named. For
example: curve1.

• Open the Boss

Properties>
rough>Milling
tab, and select
Plunge Points
then in the New
Value field type in
the exact name
of your curve.
Example:
“curve1”.

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2.5D Milling 2.5D Advanced Milling

• Click Set, Apply, and OK.

• Run a 3D simulation and notice

that the rough tool feeds to the
center, but does not plunge in the
center.

Note: The curve you create for use in Plunge

Points must have sharp corners at the desired
plunge point locations. As seen in the
exercise, the easiest way to create such a
curve is to use Connected Lines.

Cross Section (X section); Side, Pocket and Boss

Features.
When creating Boss, Pocket and Side features there is an option of selecting X section. This
allows you to apply a shape, other than an angle, to the walls. FeatureCAM will even select a
ball end mill where necessary. Surface or solid models are NOT required, although the end
result is similar to a 3D finished surface.

Cross Section (X section)

• Create a new document, Milling,
and Inches. Select Block and use
Stock Dimensions (6 x 6 x 6).
Alternately, you may open the file:
Cross X Section.fm

• Create a Pocket by drawing a 2.0

radius circle, centered on top, XY
plane of the stock. Click New
Feature>Pocket From Curve, a 1.0
Depth and Finish.

• For use in Cross (X Section), draw a

2.0 radius circle, using Center,
Radius from the Geometry toolbar.
Enter X=-2.0 and Y=0, Z=0. Using
geometry, draw a horizontal and

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2.5D Milling 2.5D Advanced Milling

vertical line through the center of this new circle. These lines will be
used for trimming. Trim the geometry until you have the lower right
quadrant of the circle remaining as shown to the right.

This arc could be used as the wall shape of the pocket.

Rules for an X-Section Curve

• When using geometry for your

cross section shape it does not
have to be round. It can be other
shapes as well.

• Once you start drawing away from

XYZ=0 you may not draw back
toward the start point in the X or Y
direction. This would create an
undercut.

• A straight line in the X or Y is ok

as long as the end point continues
away from XY=0. It must also
remain planar (Z elevation must
stay at Z = 0).

• By drawing the shape, starting in the illustrated position (XYZ=0), it will

attach to the top of the pocket and form the pocket walls identical to the
X-section curve.

• A Boss X-Section is the same, but if there are multiple bosses, and the
bosses are NOT the same height, X Section can NOT be used.

• Open the file Cross (X)

Section.fm. You should only see

2.5D Advanced Milling 2012 8

2.5D Milling 2.5D Advanced Milling

this line and circle, as shown to the right.

• Create a point located at X=3, Y=-3, Z=0.

Using the Geometry toolbar and the Arc menu, create a 3 inch radius arc
from 2 points, Radius. Click once at XYZ=0
and click a second time at the point location
(point that was just created). This will create a 3
inch arc as illustrated below.

• Click New Feature > Side From Curve.

• Click the line across the middle of the stock

and add it to the Curves list (depth is not
important). Finish.

• Click the X-Section button and add the arc. Change the machining side if
necessary from the Side Control tab.

• Run a 3D simulation.

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2.5D Milling 2.5D Advanced Milling

Note: It may be necessary to add a short straight extension on the bottom

end of the X section curve so as to carry the ball end mill flush with the
stock face.

2.5D Plunge Milling

Open a new Milling document. Set the stock as Block, Enter 10 inches for
Length and Width, and 4” for Thickness. Finish and OK.

Now we will need to create two curves in our new milling document.

With the UCS and Setup on the Top and Lower Left of the part create a
point at (X.5, Y0, Z0), and a second point at (X9.5, Y0, Z0). Draw a 4.5 inch
radius, from Geometry by selecting arc from 2 points, Radius and attach
to the two points.

Important: select the point we created first, then the second point to
create the arc properly. Chain the arc as an open curve.

This curve is the finish curve, the finished shape, or profile that you desire.

• Open the Curve Wizard. Select

Curve from curve, Offset. Next.

• Set the Offset value to .500, and to

the Left. This represents the radius
of the tool (1.000 dia.) to be used for
plunging. Finish.

You can add to the offset value, any

finish allowance if you desire, for an
additional finish pass. You can do
this to remove the scallops left by the
plunge mill tool stepover.

The new curve (the offset curve) is

going to be the center of the plunge milling cutter and the milling cutter
will follow this curve.

Note: The Curves created can have any number in their name.

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2.5D Milling 2.5D Advanced Milling

In order to get the tool to plunge on the curve in an equal stepover amount we have to use
SCL Code to achieve this. The following instructions will introduce you to this concept.

• Hold the Control key and Right Click your mouse on the Status Bar at
the bottom of the FeatureCAM user interface and check the option to
Enable SCL dialog.

• Click on Edit > SCL Code > Check the All Defines checkbox.

• Copy the bolded code below (minus quotations):

“curve1 = crvsamples( curve2, 0.1, 0.001 )” and paste into the Edit
SCL Code top field.

Note: If you fail to check All Defines first you will have to close and reopen
SCL. Also know YOUR curve numbers before doing SCL.

What does this Code Mean?

• Curve 1 in the code is finish curve number, change to whatever YOUR

finish curve name is.

• Curve 2 in the code is offset curve number (toolpath), change to whatever

YOUR curve (offset curve) name is.

• 0.1 is stepover for plunges (You may change).

• .001 is tolerance for following Curve 2 (You may change).

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2.5D Milling 2.5D Advanced Milling

Click Evaluate and then Close.

Important: You may have noticed when you clicked evaluation that the finish curve moved
to the toolpath curve and became the same size, both curves are now in the second or offset
position, it kept the original curve number from the first position and that is the curve number
that must be selected, it may already be in the curve selection window when you click the
curve button.

• Create New Feature > Hole and Make

a pattern from this feature (Points
Pattern). Next.

• Set Depth 2.0, check Through, and

Diameter 1.0. Next.

• Select Points list pattern in the setup

XY plane. Click Finish

• Click on the
Curves… button in
the Pattern
Properties dialog
and select the
curve you offset
earlier.

• OK and Apply.

• Uncheck Spot Drill

in the Strategy tab.

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2.5D Milling 2.5D Advanced Milling

• Change the tool (matching the offset curve radius) to the appropriate
milling cutter: Tool Group, pick End Mill, then for Diameter select 1.00
inch.

• In the Strategy tab of the Hole Feature Properties, check “Combine with
similar holes into a canned cycle”.

• Apply and OK.

Note: The canned cycle setting helps reduces the retract distance. It
will now retract to the plunge clearance value on each plunge cut.

Grooving
The Groove Feature provides the ability to
apply grooves to the face with a flat or ball end
mill, to the side using a side cutting milling
tool or to perform engraving using a flat end
mill, ball end mill or a Bevel/pointed tool.

• Create a New File. Stock

dimensions (6” X 6”, Length and
Width X 2” Thick). Finish and OK.

• Create a Point (X 1.0, Y 0.0, and Z

0.0) and another Point at (5.0, 0, 0).

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• Create an Arc from Radius, 2 Pts.

Enter a 2 inch radius and select the first point you created, then the
second.

• Create a New Feature > Groove > From Curve and select the circle. Next
3 times.

• In the Dimensions dialog, enter the Width .25, Depth 0.2, and check
Face and Simple (Engrave). Finish and OK. FeatureCAM picks a tool the
same diameter as the groove width and plunges to the bottom, cuts around
the circle once, then retracts.

Note: There may be more passes, depending on depth, but there is no

radial movement of the tool. The walls are cut to size.
In a Face Simple (Engrave) groove the cutting tool is the same width as the groove and
makes one pass. When Simple (Engrave) is unchecked a tool smaller than the width of the
groove is used, and makes a rough and finish pass. This method is usually used when
tolerance and finish are more critical.

Simple checked Simple unchecked

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An Inside/Outside groove may be created on the outside of the part, or the inside of
vertical walls using a side-cutting tool. When the tool is the same width as the groove,
one rough and one finish pass is made. A single finish pass may also be used.

When the tool is smaller than the width of the groove, the first pass places the center of
the tool width on the curve, next makes a pass using the top of the cutter to cut the top of the
groove and next pass using the bottom of the cutter to cut the bottom of the groove, this
method is usually used when width tolerance and finish is critical. The geometry and curve
for the groove must be on vertical walls, outside or inside and the curve may be at the top or
bottom (radially), remember the opening of the groove is facing out (or in) so when it says
curve at bottom it means radially of the tool (check box) because that is the depth of the
groove now and the depth is not measured in the Z direction.

Inside/Outside groove

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4th Axis Indexing and Wrapping:

Introduction
In 2.5D milling, 4th axis indexing is standard, and can be accessed when opening a new
document. The stock wizard allows you to choose 4th Axis, as multi-axis positioning. It can
be accessed any time in the stock properties under the indexing tab. Your machine must
have four axis capabilities, and a rotary table, or indexer. Also a 4th axis post processor must
be loaded in FeatureCAM.
The part can be indexed around the X,Y or Z axis. The desired axis you wish to index around
must be selected in the stock wizard (illustrated) while selecting the shape and size of your
stock.

• The Stock Axis is different from UCS or Setup Axes. It corresponds to

machine zero, along with the axis of rotation for an indexer or rotary table.

• The Stock Axis is not normally displayed but to view the stock axis
click View and select Show/stock axis from the Show menu. It is
displayed as two vectors (blue). One shows the axis of rotation (X or Y)
and the other indicates the orientation of a 0 deg rotation (pointing at the
spindle). You must align your part center of rotation to the rotation
axis of the STOCK AXIS.

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If the Stock Axis is not centered, any features that you will be adding to the part will be out
of place. When a block stock is being used the UCS and Stock Axis are many times together
but not always centered.

The Stock axis CANNOT be moved, the stock must be positioned around
it.

• Click on Options then Addins.

• Check the box in front of the Macro called “Center Indexed

Stock.bas” and a little tool bar appears, usually by the Part View.

• Drag the toolbar to dock it to an

area next to the one of the other
toolbars. Click this new button.

• This macro will move and center

the stock with the Stock Axis.

Stock Axis
When a new document is opened, and round is selected,
the UCS and Stock Axis will be merged and centered on
the stock. Now the features can be placed around the
indexing axis. The UCS may be moved for Feature creation, if desired.

Stock Axis is
Light Blue in
color.

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Caution: When indexing a part that is not round, FeatureCAM calculates the corners of
the Stock rotation and retracts a little extra to clear the corners of the stock. DO NOT use
Retract to plunge clearance whenever there is a corner present on the part that will rotate
under the tool, when indexed. An example of this is when there is a circular bolt pattern on
more than one face of a block stock. In this case you will index to another face using the
same tool. After drilling the last hole there must be a retraction to the Z Rapid Plane to clear
the corners. If Retract to plunge clearance is set the part will hit and break the drill, or worse.

Once you have completed the prior steps, you may begin creating and placing
features on your part. All 2.5D, and 3D, features may be programmed on an
indexed part. FeatureCAM can index from face to face and cut features, or
machine a continuously wrapping feature. Geometry, curves and features are
applied in the same manner as in any 2.5D part programs. They are placed in
relationship to the UCS the same way as non-indexed parts.

Wherever the UCS is located, for example the center of the part, the feature
may be created at Z 0, but must be moved up to the desired Z elevation to
place it in the proper location.

Features MAY NOT be transformed/rotated/copied around an INDEXING

AXIS but geometry and curves can. You may also create patterns around
an indexing axis. On block stock, the part is indexed to the desired face, and
the features are applied to each face.

On the indexing tab you may choose Tool Dominant or Setup Dominant. Tool Dominant
does all of the machining on every feature that uses that particular tool before it changes the
tool, more indexing, less tool changes. Tool dominant can have just one setup for all of the
part features.
Setup Dominant requires a separate setup for each face to be programmed and it completes
all features for each setup before indexing to the next setup, more tool changes, less
indexing.

• Open a New Document

and, using one Setup,
create a Stock (Block) with
the dimensions, 6 inch
Length,Width and
Thickness. Place the UCS
in the Lower Left corner,
and material as Aluminum.

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• Click on the Indexing tab and select

4th axis positioning, Index Around the
Stock X axis and Tool Dominant. OK.

• Create a New Feature, select hole

from dimension and Make a pattern
from this feature. Next.

• Enter Plain Hole, Diameter and Depth of 1.0 and check Through.
Click Next

• Pick Radial in the Setup XY plane.

• Diameter 4, Number 6, Spacing

Angle 60, Angle 0. This creates
a pattern on one face and will be
used to create the same pattern
on the other 3 faces, a pattern
within a pattern. Next

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• Location X 3.0, Y3.0, Z 0. Finish

• Create a New Feature. Pattern. Next.

• Use the pattern just created. Next

• Select Radial Around the index axis.

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• Number 4, Spacing Angle 90.

• Finish.

This places the (6) hole pattern on

four faces positioned the same as the original pattern.

When you choose to put a different feature on each face this is not a pattern around the
indexing axis. There are several ways to accomplish this.

Note: Remember you CAN’T transform/rotate/copy features around the indexing axis.

An alternate way is to create a Setup on each face. For example, on the 6 inch cube stock
place a Setup on lower left corner of the stock on each face to match Setup1. When creating
a new Setup you want the X axis to point in the same direction on ALL setups. If you need to,
rotate the Setup around the Z axis so the X is pointing the same direction as the Stock Axis
X.

Let’s create 4 setups, top, front, bottom and back of the part.

• Open a New File with the

Stock dimensions 6” X 6” x 6”,
and align the UCS and Setup
on the Top and Lower Left of
the part.

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• Click the Setups icon on the Advanced Toolbar.

• Click New and Next.

• Select Align to Stock

Face.

• Next.

• Select Front for the

Stock Face and the little
hand at LL (lower left).

• Next

Note: If necessary use Z Rotate to align X with Stock Axis X.

• Finish.
• Repeat the steps for two other faces on the Back and Bottom of the
part.
You can now create the feature, or features, as you would normally, (UCS – XY plane) on
each face.

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Hint: Keep Setup1 in the isometric view as you create each Setup. All faces relate to the first
Setup as to which is Top, Front, Bottom and Back. This helps to keep the orientation straight
in your mind. Also, remember that you must have a
Setup on each face to use Setup Dominant.

• Before creating the feature, select the

Setup first (Setup2 – Front Face) in Part
View window that belongs to the face that
you want to apply the feature to.

• Select the Top view, then create the

features for that setup.

• Select next setup, top view, until all

features are on all faces.

Another way is using one setup and creating new features, from dimensions, on multiple the
faces. There is the ability to specify the Location around the part when Radial about the X
axis is chosen on the Location dialog.

• Create a New Feature, select Hole

from dimensions, Plain Hole,
Diameter and Depth 1.0. Next.

• On the location page check Radial

about X axis.

The Radius value is the top of the

feature. It is measured from the center of
the Stock Axis in the Z direction and will
place the top of the feature at the
specified radius which would be the stock
face.

• Enter 3 for the Radius, Angle 270.

This places the top of the feature to the desired face around the Indexing Axis.

• Enter 3 in the X Location.

This will position the feature on the face measured from the UCS in the X
direction.

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• Enter 0 for the Y shift.

This will position the feature on the face in the Y direction, in this case no shift.

• Finish.

Another way is when creating new features from a curve using one setup. You need to view
the XZ plane (Front), so geometry and curves created on the front face can be transformed to
the back side using the Y direction. This also applies to curves created in the XY plane, top of
the part that can then be transformed to the bottom using the Z direction. Once the geometry
and curves are in place the New Feature can be created and you need only to select the curve
on any face and FeatureCAM knowing the position around the indexing axis to machine the
part.

Another way, using one setup, is to create ALL geometry and curves in the XY plane and
Transform/rotate them around the center point and X axis. Each feature needs to be
rotated to the correct face, individually, then create the new features from curves.

Remember you CAN’T rotate FEATURES around an index axis but you can rotate
geometry and curves).

The last way using one setup is when you create a hole pattern in the XY plane (for example
a bolt circle) and then you need to place it on one other face. In this case, you don’t use a
pattern from a pattern, because you only need it on one other face, and you can’t
Transform/Rotate features around the indexing axis.

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• Open a New File and create 6” X 6” X

6” Block of Stock.

• New Feature. Hole from dimension

and Make a Pattern from this
Feature. Next.

• Create a Plain hole, Diameter and

Depth 1.0. Next.

• Radial in the XY plane. Next.

• Diameter 4, Number 6, Spacing

Angle 60. Next.

• In the Location window select Radial about the X axis, Y Shift 0, Radius
3.0, Angle 270, X Location 3.0. Finish.

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Round Stock
The Stock Axis is in the center of the part and so is the Setup. However, the Setup and UCS
may be moved for programming purposes. The same rules apply to round parts as those of
the block stock parts. Features CAN’T be Transformed/rotate/copied around the Stock
Axis. One setup is commonly used, but other setups may be added if needed. You may also
wrap pocket and groove features, including engraving, around the Stock Axis.

To wrap a pocket you must first create the pocket, and if the UCS is at the center of the part,
you must translate the feature in the Z direction to put the top of the feature at the outer radius
of the stock.

On a round part the feature can be applied as normal and then wrapped which is selected
from within the feature. The “Wrap feature around X axis” check box becomes visible on the
dimension tab when 4th axis is turned on. If it is not visible usually two things happen, either
4th axis is turned off (stock, indexing tab) or the feature was created at the center of the part
and you failed to move it up to the desired radius on the part, it cannot wrap around the
center.

Wrapping a Groove

• Open a New Milling

Document, Inch, Round
Stock, X axis, OD 12.0,
Length 12.0 and ID 0.

• On the Indexing Tab select

4th

• Axis Positioning, and Index

around the STOCK X Axis.

• Click on View from the top Menu

bar. Show > Show Stock Axis.

The Stock Axis and the Setup/UCS are

together in the center of the part.

The stock and length of the stock are

aligned with the X axis. Alternatively,
open the 4axis wrapping.fm example.

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Note: When wrapping a groove you must first create the geometry for the grooving feature,
and it must lie in the XY Plane.

Wrapping a groove is like wrapping a label around a soup can. The values entered as
indicated below will start the groove with the center of the tool being on X 0.0 and end on X
0.0 with no movement in the X direction. The Y is Pi*12 determines the length of the
geometry and the part will rotate 360 degrees. The Z 6.0 puts the top of the groove on the
outside radius of the stock. The geometry is the path for the groove but does not create the
groove.

• From Geometry draw a line from 2 points to the dimensions below.

Disregard length and angle.

XYZ 1 sets the start point of the groove tool at the top or radius of the stock centered on the
end where the Setup X 0.0 is located. Y 0.0 means it starts on 0 in the Y direction. Z 6.0
means it starts at a 6.0 elevation in the Z direction above the center on the 6 inch radius of the
stock.

XYZ 2 is the end of the groove geometry and also determines whether it travels in the X and
how many times it wraps around. X 0.0 - Means the tool will not travel in the X direction. If
there is a different value in X then the tool will move to that distance in the X direction as the
part rotates. Y pi*12 - Means the part will rotate once around the part. Notice that the value
is pi*12, this means pi times the diameter which is the circumference of the 12 inch diameter
stock and FeatureCAM understands what pi means and its value and the *(asterisk) is
multiplication. Z 6.0 - Means the tool ends at the same Z elevation as when it started.
• Select New Feature, Groove From Curve and select the line.

• Groove Width .250, Depth .200, Simple (Engrave) and Face. Finish.

• Double click the groove feature in the Part View window. Check the
“Wrap feature around the X axis”box at the bottom of the dimensions
tab. Click OK and run a 3D simulation.

The tool plunges to depth, rotates 360 degrees, retracts, and finishes.

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• Right click on the groove feature in the Part View

and pick Hide
Selected.

• Select the Line just

created to change the
dimensions.

• Change only the end point (XYZ2) in the X to

12.0, click Modify, run a 3D simulation.

Now the tool plunges to depth, part rotates once

around but travels the full length of the part, retract and finished.

• Select the Line again.

• Change the end point (XYZ2) Y to 4*pi*12,

Modify, and run a 3D simulation.

Now the tool plunges to depth, part rotates 4 (4 x

360 degrees) times around the full length,
retracts and finished.

• Select the Line once more.

• Change only the end point (XYZ2) X to 0 and Y to 270/360*pi*12, run a 3D

simulation.

Now the tool plunges to depth, part rotates

270 degrees or ¾ of the way around,
retracts and is finished.

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Wrapping a Pocket
The Pocket may be created by drawing, or importing geometry, or from dimensions as you
would normally create this feature. It can be created at the center of the stock and given a
value in the Location Z direction, while creating the feature so as to place the top of the
feature on the radius of the stock.

The feature, when completed, may be Transformed/Translated in the Z direction to locate the
top at the radius of the stock.

The UCS can be translated in the Z direction, to the radius of the stock, and then the feature
can be created. The feature remains at 0. in the Z Location.

Remember, if the 4th axis is not checked, on the Stock properties Indexing tab, or the
feature is located down on the center of the part, the “Wrap feature around the indexing
axis” on the dimension tab will not be visible.

• Open a New Milling Document, Inch, Stock as Round, and X axis.

• Set the Diameter 12.0, Length 12.0, ID 0.

• Next twice, 4th Axis Positioning, and Index around the Stock X axis.

• Next twice. Rename the Setup, if you choose. Next.

• Use the current location for alignment. Finish and OK.

• Create a New Feature, Rectangular Pocket from Dimensions.

• Next.

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• Enter Length 3.0, Width 5.0, Corner Radius .250, Depth .250.

• Next.

• In the Location window enter X4, Y-

2.5, Z6. Finish.

This centers the pocket and places the top of the feature at the outside radius
of the stock.

• Double click the rectangular pocket feature in the Part View window. On
the Dimension tab check the box “Wrap Feature around X axis”.

Note: If it’s not visible, either the 4th axis is off, or the feature is at the
center of the stock.

• Click Apply and OK. Run a 3D simulation.

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Wrapping a drilled hole pattern

• Open a New Milling Document, Inch, Stock as Round, X axis.

• Enter Diameter 12.0, Length 12.0, ID 0. Next twice.

• 4th axis Positioning, and Around STOCK X axis. Next. Set it to Tool
Dominant. Next twice, Use current location. Finish.

• Create a New Feature, Hole

From Dimensions and Make a
pattern from this feature. Next.

• Plain Hole, Diameter 1.0, Depth

1.0.

• Next.

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• Radial in the setup XY plane.

• Next.

• Diameter 10.0, Number 9, Spacing

Angle 40, Angle 0. Next.

• Set the Locations at X 6.0, Y 0, Z

6.0.

• Finish.

• Double click the hole

feature under the Pattern
from the Part View window
and check “Wrap Feature
around X axis” OK.

• Run a 3D simulation.

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The wrapping keeps the point of the drill lined up with the centerline of the part.

Wrapped Engraving
Engraving around a cylinder can be accomplished, by first creating the text, and then
applying a grooving feature to the text curve.

• Open a New Milling

Document. Inch, Round
Stock, X axis.

• Diameter 12.0, Length

12.0, ID 0.

• Next twice.

• 4th axis Positioning,

and Around STOCK X
axis.

• Click on View from the Menu bar at the top. Show, Show STOCK
Axis to make sure the Stock Axis and the Setup are aligned and
centered on the part.

Change to a Top view, Select

Construct, Curve, Curve
Wizard.

• Select Other Methods and

Text. Next.

• In the Text field type DELCAM, click the Font button, select Machine Tool
San Serif from the list, and Size 72. OK.

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• Select Linear, Location of X 3, Y0, Z 6, Angle -90 and Justification

Center. Finish.

This will move the text to the outside radius of the

Stock. It will also rotate and center it to the proper
alignment position.

• Create a New Feature,

Groove From Curve.

• Next.

• Select the text curve (all

letters are one curve).

• Next twice.

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• Enter Width .0625, Depth .02,

Simple (Engrave), and Face.

• Finish.

• Double click the groove from

the Part View window.

• On the Dimension Tab, check

“Wrap feature around X
axis”. Apply and OK.

• Run 3D simulation.

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Form Tools
Introduction
In this module the user will learn how to create Form Tools for milling with end mills and
side cutting milling cutters and also for drilling. These tools may be used in Milling and
Turn/MILL. At the end of the module the user will be able to draw the geometry for the
shape of the tool and chain a curve to that shape for FeatureCAM to use to create a new tool
in the tool crib and save it in a Tool Group called Form Tools that can be recalled anytime.

Create a Dovetail Milling Form Tool

• Open a New Milling Document, inch or

Dovetail Form Tool.fm for reference.
• Create Stock size 6x6x6, any material,
no 4th axis. Viewing from the top,
Locate the UCS in Lower Left Hand
corner of stock.
• Right Click in graphics window and
View from the front. The XZ plane.

It is very important that the STOCK AXIS is

located at XYZ 0. If this is omitted, the curve will
not be accessible when creating the form tool.

• To view the STOCK AXIS Click View in top toolbar>Show>Show STOCK

AXIS.
Another set of arrows (blue) will show up in the graphics window merged with the UCS.

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The Z0 will be the bottom of the Dovetail tool. The X0 is the

center of the tool and only half (radius) of the tool will be created
(+ side of X). The finish curve will be an open curve.

• Using the Geometry constructors Draw this shape

and chain an open curve. (no centerline)

UCS = XYZ 0 and STOCK AXIS 0

• Click on Manufacturing on top toolbar and Select Tool Manager.

• Select “From Crib”

Tools.
• ”Tool Group” End
Mill.
• “Current Crib”
Tools.
• “Sort by” Diameter.
• “Show only”
Diameter.
• “= 2” Press Enter.
This takes you to
the 2 inch diameter
end mills. OK.
• Double Click on a
2 inch tool in the
current list.

The 2” inch diameter end mill was

chosen because our Dovetail tool is 2
inches.

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

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operations. The diameter is still used for calculating stepovers and generating the paths.

• Change the Name to “Dovetail

2.0 x 45”
• Check “Use curve to describe
tool shape” and Click on the
curve in the drop down list.
OK.

Remember if the curve is not in the

drop down then you either do not have
the STOCK AXIS at the XYZ0 or the
curve does not start at XYZ0.

The New Tool shape appears in the window. Be sure to make any necessary changes such as
“Cutting type”, “Material”, etc.

This only creates the tool; you must now create geometry and a groove feature.

• Viewing from the top, draw

a line across the center of
stock. Extend the line 1.100
inches beyond each side of
the stock so the tool will
plunge off the material and
retract when it’s clear at the
end of the cut.

• Click on New Feature and Select

“Groove from curve”, Select geometry
line and Enter Width 2 inches. Simple
(engrave). Depth of .75. Finish and
edit properties.

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• Click on slot
operation and
Tools tab and
from Tool
Group Select
Form Tools.
Check the box
in front of
Dovetail. OK.

• Run 3D Simulation

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Create a Side Milling Form Tool

• Open a New Milling Document, inch or Side
Milling Form Tool.fm for reference.
• Create Stock size 6x6x6, any material, no 4th
axis. Viewing from the top, Locate the UCS in
Lower Left Hand corner of stock.
• Right Click in graphics window and View
from the front. The XZ plane.
• Using the Geometry constructors Draw this
shape and chain an open curve. (no
centerline)

UCS = XYZ 0 and STOCK AXIS 0

• Viewing from the front

draw a line from 2 points at
X0, Y0, Z -.4375 across the
front face for the groove.
• Repeat the Groove from
curve feature but instead
select Inside/Outside with a
Depth of .125 and a Width
of .625. Finish.
• Click on Rough operation
and Tool tab. From the list
of Side Mills Select a
KEYSEAT cutter then Click
on the new tool button .
• Change the name to Side
Milling Form Tool 2.25D x
(2).125r.
• Change Diameter to 2.250.
Change the Cutter width to .625.
Check “Use curve to describe tool
shape” and Click on this new
curve in the drop down list as
before. OK.
• Click on Finish and Tool tab and
Tool Group Form Tools. Check
the same tool as for the rougher.
OK and Run 3D Simulation.

The Tool makes a Rough and Finish pass.

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Create a Drilling Form Tool

• Open a New Milling Document, inch or Drilling Form Tool.fm for
reference.
• Create Stock size 6x6x6, any material, no 4th axis. Viewing from the top,
Locate the UCS in Lower Left Hand corner of stock.
• Right Click in graphics window and View from the front. The XZ plane.
• Using the Geometry constructors Draw shape from the dimensions shown
on the next page and chain an open curve. (no centerline)
• Click on New Feature Wizard and Select Hole from Dimensions. Next.
• Select Plain Hole. 2.0 Diameter. 2.25 Depth. No Chamfer. Uncheck
Through. Next.
• Enter X3, Y0, Z0 for Location. Next.
• Uncheck Spot Drill. Next and Next.
• Default Tool Select “I want to Search for another tool or make new one”.
Next.
• Tool Group Select Twist Drill and Diameter 2.0. Click “Create New Tool
button” and Change Cutter Length to 3.0, Overall Length to 5.0 and
Exposed Length to 4.0. Check “Use curve to describe tool shape” then
Select the curve. Re-Name “Drill Form Tool 2.0” and Apply.
• Check Create New Tool when asked in Rename Tool popup. OK and
accept as override. Finish.
• Run 3D Simulation. You can see the cross section.

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FeatureCAM Milling Multiple Fixture Documents

Multiple Fixture Documents

Introduction
FeatureCAM allows the user to program multiple parts or multiple instances of the same part
within a single part called a Multiple Fixture (mf) document. These documents are for
milling parts that have already been created and saved in individual fm files. The parts can
be arranged relative to a single Setup, or they can each have their own individual fixture
positions. They can also be machined from a single stock model or from individual stock
pieces.

Since complete parts are loaded into Multiple Fixture documents, they cannot be edited
within the Multiple Fixture environment. They must be changed in the fm files and then
manually reloaded into the mf file.

This chapter will describe the process for loading parts into Multiple Fixture documents.

Getting Started
In order to begin programming a part, the Multiple Fixture option must be selected from the
New Part Document wizard.

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Multiple Fixture Interface

The user interface for Multiple Fixtures is slightly different from the typical fm file. You will
notice that many functions are dimmed or completely unavailable. Again, this is because the
purpose of the Multiple Fixture document is to collect and arrange multiple parts into a single
file – it is not for creating features of any type or making changes to existing parts. So, any
functions related to creating toolpath will not be available.

Steps
The Steps mode of the Toolbox is open by default (Part View is not available at any time),
and it is quite simple. The only entries that are unique to the mf file are Fixture ID and Parts.
The rest of the options operate exactly as they do in any other FeatureCAM file.

Fixture ID
The Fixture ID step allows the user to define and locate established fixture locations. Those
locations can later be used to anchor single or multiple parts.

Parts
The Parts step is the Wizard that is used to build and edit the part layout. It allows the user to
add, delete, and edit all of the part configurations in the file. Remember, the parts themselves
cannot be edited in the Multiple Fixture environment. We will discuss making changes later
on in this chapter.

The following examples will examine how Multiple Fixture files can be programmed:

Example 1 - Multiple Parts as Separate Blocks

For this example, we will use the Caliper part that is found in the FeatureCAM Examples
folder. This part has two setups – a top setup and a bottom setup. We will use this to create a
row of tops and a row of bottoms. This will depict a scenario where you have parts that you
are rotating through fixtures on the machine. For each cycle, you will be adding a set of
material blanks and removing a set of complete parts.

The first step for creating a Multiple Fixture file is to add parts that you want to machine to
the Parts List.

• Make sure the

Parts step is
active, and select
Parts List from the
buttons along the
right edge of the
dialog box

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• When the
Part Files
window
opens, click
Browse and
navigate to
the Data
folder
• Open
Caliper.fm.

• Click OK and
Add

As stated earlier, the

Caliper part has two setups,
and we will be machining
both in this example. First,
we will start with a row of
Top setup parts.

• Click the top setup

Notice that there is also a

field where you can name
the Multiple Fixture file.
This is the name that will
appear in the NC code, if
desired.

The next screen allows the

user to select a starting
offset for the parts. Since
we will be cutting our parts
from separate fixture offsets
in this example, this dialog
will determine the beginning
offset, and other offsets will
be added incrementally as
we add parts.

• Accept 54 as the
initial offset by
clicking Next

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The next screen in the wizard defines how this part will be arranged. The XYZ location is
the position of the first setup, and the other boxes determine the number and spacing of the
repeats. Since these are repeats, a value of 3 will give us 4 instances. FeatureCAM fills in
the spacing automatically by adding a set distance to the part’s stock size, but this can be
overridden to any value the user wants. Note: When using separate blocks of stock, the
spacing is for simulation purposes only. The actual offset positions will have to be
determined at the machine and entered into the control registers.

• Fill out the

Configuration
dialog box as
shown
• Click Next

• Select
Individual
Blocks and
click Next

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At this point, we have completed the layout of the first set of parts. The Preview dialog
appears. You can drag this window aside to inspect the part placement. If you want to make
any changes, click Back to revisit the wizard screens.

• Click Finish

Once you have clicked Finish, the Multiple Fixture screen reappears showing you all of the
parts and offsets in the file.

The parts in the Multiple Fixture file can be machined two different ways:
Tool Dominant – Each tool cuts all of the part instances before changing to the next
tool.
Part Dominant – Each part is cut completely before proceeding to the next part.

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• Click OK to exit the Multiple Fixtures window

• Run a simulation

Next, we will add another set of parts to the file.

• Clear the Simulation Results

• Click on the Parts step to reopen the Multiple Fixtures window
• Click Add

This time, we will add some Bottom setups to our layout.

• Select the
CALIPER/bottom
setup
• Click Next

Notice how the Fixture IDs have picked up where we left off at G58. Of course, this can be
overridden, but we will keep the default value

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• Click Next

On the configuration screen we have an opportunity to locate our next setup and determine
the repeats and the spacing of the new part.

• Enter X0, Y6,

Z0 as the
position of the
next setup
• Enter 3 X
Repeats with
a spacing of 8
inches
• Click Next

• On the Layout
screen, select
Individual
Blocks

• Click Next

• Examine the Preview and click Finish

Again, we see the summary of our efforts detailed on the Multiple Fixture screen. The setup
IDs are based on the available registers in the post processor.

• Click OK to exit

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• Run a Simulation

• Close the part

Example 2 - Multiple Parts out of a Single Block of Material

In this exercise, we will create an array of parts that are cut out of a single block of material.

• Open a new Multiple Fixture file

• In the Multiple Fixture window (Parts Step) click on the Parts List button
• Browse to the Caliper.fm part in the Data folder
• Click OK to accept the Caliper and return to the Multiple Fixtures window
• Click Add
• Choose CALIPER/top from the available setups and click Next

Since we are going to machine all of these parts from a single block of material, there will
only be one fixture offset used.

• Accept the default Fixture ID by clicking Next

We are going to lay out two rows of parts in this example. To do this, we will enter values
for both the X and Y repeats. In this situation, spacing will also be critical since we must
allow room for the tooling to move between parts without gouging.

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• Fill out the

Configuration
screen exactly
as shown
• Click Next

• Select Single
Block on the
Layout page

When you chose a

single block,
FeatureCAM gives
you an opportunity to
nest the parts by
inverting alternating
instances of the part.

• Check the
Nested box
and click Next

Now, the stock size

must be determined.
The user has a choice
to enter the stock size
manually or let
FeatureCAM
automatically
calculate the required
stock size.

• Click Auto to
let
FeatureCAM
calculate the
stock size

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• Click Next to advance to the Preview page

• Click Finish to exit the wizard
• Click OK to close the Multiple Fixtures window and view the results

As you can see from the results, the spacing of our nesting is incorrect. This was visible from
the preview page, but this will demonstrate how Multiple Fixture layouts can be edited after
the fact.

• Click on Parts in the Steps window to reopen the Multiple Fixtures window
• Highlight the setup and click Edit

The Edit function will open the properties of our layout and give us access to all of its
parameters.

• Click on the
Layout tab
• Change the
spacing of
the nest as
shown
• Click OK to
exit
• Run a
simulation to
see the
results

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• Close the part

Example 3 - Multiple Parts Located on Predefined Fixture IDs

The next example will demonstrate how to create predefined Fixture IDs and locate parts on
them. Keep in mind that the locations for the setups do not automatically translate to the
machine tool. Each fixture ID location must be determined at the machine and entered into
the control.

• Open a new Multiple Fixture file

• Click the Fixtures button in the Multiple Fixtures box (Note: This is the
same as clicking Fixtures in the Steps view)

• Click the
Add button
to begin
defining a
new fixture
location

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• Accept 54 as
the first fixture
location by
clicking Next

• Accept 0,0,0 as
the location for
offset 54 by
clicking Finish

Below, you see that Fixture ID 54 has now been defined and is ready to be used. Before we
start adding parts to this file, we will create a second setup location.

• Click Add to
create
another
Fixture ID

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• Accept 55 as the next Fixture ID by clicking Next

• Enter the
location of this
Fixture ID as
shown and click
Finish

• Click OK to exit the Fixture Offset Locations screen and return to the
Multiple Fixtures window
• Click on the Parts List button an Browse to the Caliper.fm file in the Data
folder
• Click OK
• Click Add
• On the Setup screen, select the CALIPER/top setup and click Next

Now that we have predefined fixture locations, we are given the opportunity to select them as
locations for out parts.

• On the Fixtures
screen, select
Add the new
setups to a
predefined
fixture and
verify that 54 is
selected
• Click Next

Notice on the Configurations screen that you still have the opportunity to offset the part
origin from the Fixture ID, and you are able to create both X and Y repeats from that
location.

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• Accept the default offset (0,0,0) and make sure the there are 0 X repeats
and 0 Y repeats
• Click Next
• Click Finish to accept the single part located at Fixture ID 54 and return to
the Multiple Fixtures window

For the next step, we will bring an entirely different part to locate at Fixture ID 55.

• Click Parts List

• Click Browse
• Select the plate.fm file located in the Data folder and click Open
• Click OK to return to the Multiple Fixtures window
• Click Add

• Select
plate/WORLD
from the
Part/Setup list
• Click Next

• On the Fixtures screen, select Add the new setups to a predefined

fixture and select 55 from the drop-down list
• Click Next

• Accept the default offset (0,0,0) and make sure the there are 0 X repeats
and 0 Y repeats
• Click Next

• Click Finish to accept the single part located at Fixture ID 54 and return to
the Multiple Fixtures window

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• Click OK and run a simulation

• Keep this part open for the next section!!!

Example 4 – Making Changes

As mentioned earlier, there are very few changes that can be made to files programmed in a
Multiple Fixture document. As we have seen, layouts can be modified by accessing the Parts
step, but many of the other functions normally available in an fm file are dimmed. This final
example will show how modified parts are handled in a Multiple Fixture file.

For this example, we will modify the plate.fm file.

• Making sure not to close the mf file, click File > Open, and open the
plate.fm file located in the Data folder

We will make a very simple change and see how the mf document is affected.

• Turn off the pocket feature by unchecking the

pp1_pocket feature in the Part View
• Save and Close the file
• Once back in the mf document, run a simulation

Nothing has appeared to have changed, has it? There is one more
step that must be performed in order for the part to be updated in the
Multiple Fixture document.

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• Clear the simulation

• Click on the Parts step in the Steps view to open the Multiple Fixtures
window
• Click the
Parts List
button
• Highlight
the
plate.fm
file and
click the
Reload
button

• Click OK to return to the Multiple Fixtures window

• Click OK to exit
• Run a simulation

This is the procedure that will be required every time a change is made to how the individual
part is machined. None of the parameters controlling Attributes, Tooling, etc. can be edited
from the Multiple Fixture document, so the original part file must be opened, edited, and
reloaded into the mf file.

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FeatureRECOGNITION for
Milling
Introduction
This Module will provide an introduction to FeatureCAM’s Feature Recognition capabilities.
When this module is complete you will know how to perform Automatic Feature
Recognition, Interactive Feature Recognition and Feature Re-recognition.

What is a Feature?
Features are the intelligent core entities that a machinist would use to make a certain shape in
the material they are cutting. Shapes such as a hole, boss, slot, etc…Features are used to
make toolpaths in FeatureCAM to create these shapes. Features may consist of several
operations to create the final result or shape. These may consist of several operations
including; spot drill, center drill, drill, pre-drill, tap, roughing, semi-finish and finish passes.
FeatureCAM takes, for example, a tapped hole and combines the operations like the center
drill, drill and tap and automatically selects the necessary tooling, feeds, speeds, etc.

What is Feature Recognition. Why is it necessary?

Feature Recognition is the ability to extract manufacturing features and associated operations
from an existing Solid or Surface model. Geometry, curves, and dimensional input are not
required as this information is automatically extracted out of the design model.

Feature Recognition is necessary for several reasons, the first being that the CAD data
available is just a collection of surfaces and faces. The CAD data (surfaces and faces) needs
to be interpreted by the CAM software so useful features and subsequent operations may be

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collected from this data to manufacture a part. For example holes in a solid are just cylinders
and a pocket in a solid is just a collection of faces.

The second reason Feature Recognition is necessary is that in modern manufacturing a

majority of the design software used for part design is solid or surface based. The valuable
information contained in the model file has already been entered by the CAD engineer, why
should the machinist re-enter information that is already available in the model? A review of
the manual process is listed below, which can show the process to be quite lengthy:

1. Create Geometry
2. Create Curves
3. Select Feature Type
4. Select Curve
5. Specify Depth
6. Enter manufacturing information
7. Obtain wireframe visual display
8. Obtain F/S, tools, toolpaths and NC code

The third reason FeatureRECOGNITION is necessary is that re-entering the model data by
the machinist is error prone as the model information needs to be completely re-entered.

How does FeatureRECOGNITION Work?

There are two different types of FR: Automatic Feature Recognition (AFR) and Interactive
Feature Recognition (IFR). Both tools search the CAD data (cylinders, surfaces, and faces)
and matches them to FeatureCAM’s features so manufacturing operations may be generated.
These two techniques use different algorithms for identifying features. Descriptions of the
algorithms used will be described below.

Requirements for FR

In order to use Feature Recognition a surface or Solid Model is required. There is a wide
variety of Import formats supported:

• Iges, Acis, Parasolid, SolidWorks, Inventor, SolidEdge

• Optional import plugins: Catia V4 & V5, Step, Unigraphics and ProE

There are several ways that the model can be imported directly into FeatureCAM:
• Click on File then Open.
• Click on File then Import.
• Locate the file, left click on the file to import, hold the left mouse
button down then drag and drop the file into FeatureCAM’s Graphics
Window from any folder where the model resides (except a zip folder).

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FeatureCAM 2012 FeatureRECOGNITION for Milling

Import Wizard

When you import a file, FeatureCAM steps you through its import wizard. The import
wizard pops up automatically and assists you in importing the file into FeatureCAM. This
wizard helps to:
1. Import the file into FeatureCAM
2. Size the stock
3. Orient the stock
4. Position the part program zero
5. Set up a milling part for indexing
6. For some solid file formats, it even helps you recognize and suppress some part
features

AFR Example #1

• Click on File then

Open. Under Files of
type at the bottom of
the screen select
ParaSolid (*.x_t, *.x_b).
Find the file in the
FeatureRECOGNITION
Data folder named
ex02ex02.x_t then
press the open button.

• If asked, select Scale the imported

geometry into the document’s
units.

• Select Milling Setup and select the

Unit of Measure to be Inch then press
OK.

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• Select the button “Use the wizard to

establish the initial setup location
and stock size” then check the
“Launch AFR after finish” checkbox.
Next

To aid in aligning the model, when the model is

first brought into the Graphics Window, right
click and view Top or Isometric and Shade the
model so you can see how it is positioned in the
window. (Shade-upper tool bar-button with two
little red barrels)

Because the CAD model may have been saved

in a position that is not aligned with your Z and
X axis, FeatureCAM in the “Pick Initial setup
Z Direction” form provides five tools to assist
in aligning the model to your document in the Z
direction, which in turn aligns to the machine
spindle, table and axis.

• 1) Pick two
points to define Z
direction. Click
on arrow then
click twice on a
vertical surface
edge starting low,
then the second
click above will
point to the spindle.

• 2) Align Z perpendicular to a horizontal surface. Click on any known face

that is flat and horizontal that you wish to be perpendicular to the spindle.

• 3) Align with center of a revolved surface such as a hole by selecting the

arrow and clicking on the round surface.

• 4&5) can be used even when geometry alone is imported by clicking on

the defined geometry. Next.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

“Pick Initial Setup X Orientation”

offers assistance to align the setups X
direction. The instructions below does
not rotate the part, you must do a top
or isometric view for the model to
move.

1) Pick two points to define X direction

works the same as the Z, except the
edge you click on will be parallel to the
table.

2) Rotate X direction 90 degrees

around Z axis will rotate the model 90
degrees for each click, three times will
rotate 270 degrees. Next.

Stock type gives you the choice of Block, Round or N-Sided such as hex stock.

• On the Stock Dimensions

page check the radio button,
“Compute stock size from the
dimensions of the part”. Enter
0 in all dimension boxes.
Additional stock may be added
on all sides. Next.

• On the “Pick Initial Setup XYZ

Location” form (Part program 0) select
LL (lower left from top view). You can
also use the pick arrow and click on a
location, use the center of a revolved
surface or enter the XYZ location
measured from the UCS. Next.

• No 4 axis Indexing. Finish.

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Because the “Launch

AFR after finish” box
was checked on the
initial Import form, the
Automatic Feature
Recognition pops up.

It identifies the solid just

imported.

• Click the Verify

button to assure
you have a good
Solid Model.
(AFR does not work with Surface Models)

• Click the Options button.

o Create a facing feature.
o Combine like holes into a
pattern.
o When checked, Bottom
radius suppression will
recognize bottom radiuses
and when unchecked it
skips them and leaves
material there instead.
o Maximum Hole diameter
value is the largest hole
AFR will create with a drill,
anything larger uses an
endmill.

(Disregard 3D for now)

• Click OK for Options. Next.

• Setups can recognize multiple setups. Next.
• Select features will allow you to accept all or pick and
choose. Finish.
• Run the 3D simulation.

ALL features, tooling, feeds, speeds, coolant, depth of cut and

stepovers, etc, have been created for the entire part in this setup and
looks like the finished part illustrated.

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• Click on File then Save as and name the file ex02ex02.fm

Types of FR Available
There are four types of FR available:
1. Fully automatic – “AFR” as in the previous example,
2. IFR Automatic by feature type,
3. IFR using surfaces or faces
4. IFR chaining.

Each of these is a different tool used increase the programming options available to you.
Each technique has its own benefits and disadvantages.

AFR (Automatic Feature Recognition)

• Open the file saved previously ex02ex02.fm.
• In the Part View right-click on and delete the
single face feature and all of the holes in
setup1.

The reason all the face features and holes are deleted is so
we can easily see all the side features that AFR created to
cut the part. In order to completely cut the part (excluding
face feature and holes) AFR uses side features. For
Bosses, pockets and sides, AFR always uses side
features.

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• On the top tool bar, if the model is not already shaded, shade the part

by clicking on the shading icon (two little red barrels).

• Right-click in the Graphics Window and select isometric.

• Click on each of
the side features in
part view one by
one

o Notice that it creates a set of features that will completely cut the solid, but it may
create more features than you might create if you have modeled the features yourself.

o The way AFR works is that it examines the model and looks for any flats on the part.
It creates features by dividing the model into horizontal slices at these flats and
automatically determines side control. Any features (excluding holes) remaining will
be cut using surface milling.

o The advantage of this method is that a part may be programmed quickly as it requires
minimal user input. This method could be useful for quickly programming
prototypes, or to help users new to programming in FeatureCAM. It can also be used
by experienced users to create curves or to help get a better idea on how to cut the
part.

o The disadvantage of this method is that the most efficient toolpath may not be created
and the features created may not be exactly the way the programmer is used to cutting
the part.

o One last note is that a solid is required to run AFR. The reason for this is so that AFR
is able to properly recognize side control and will cut on the correct side of the part.

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AFR Example #2
• Browse to the
FeatureRECOGNITION Data
folder, locate the file named
EndPlate.x_t then left-click
and drag into FeatureCAM.

• Select Milling Setup and

Inch Units then press OK.

• Select the top radio button

then check “Launch AFR
after finish” then follow the
same import procedure as
the previous part.

• On the AFR Options page

the Maximum hole diameter
is set at 1 inch so the through
hole in the part will be
machined with an endmill. If
you also check the Create 3D
feature check box
FeatureCAM will apply a ball
endmill to the chamfers. (FR
does not do chamfers and you
must be licensed for 3D
surface milling). Do NOT
select 3D now. Click OK.

• Run the 3D simulation.

The chamfers on this model are standard 2.5D features and first require a curve, three in all.
A curve can easily be created by projecting (ALL surfaces) geometry in the Z direction, this
will include the shape required and will be located at the proper Z elevation you choose.
During this process a curve can quickly be chained on only the geometry you need then all
geometry is automatically deleted when curve chaining is complete leaving only the curve
required for the feature. Multiple curves may be created by clicking the create button after
each curve. If all curves are created at the same elevation in Z, any curve when selected may
be transformed to the correct elevation.

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• Click on Curves from

the Steps Toolbox, Click
“Chain projections of
vertical surfaces into
curves using mouse
clicks”.

• The wall angle can be acquired by clicking on the Blue Words “Wall
Angle” and then click twice on an isoline along the vertical edge of a
surface as illustrated.

• Click on the “Blue Word” Elevation and then click once on any surface or
edge that is the Z Elevation or height you desire. Chamfer curves must be
at the top of the chamfer. Next.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

• Select “All
Surfaces” and
check the box
“Remove
hidden lines
on solids”.
Next.

• Select “Remove
after Chaining”.
Finish.

The cursor now changes to

the mode for chaining
curves. Chain the desired
geometry for the shape
and elevation required for
the chamfer curve.
Geometry is deleted when
the select arrow is clicked
canceling curve chaining.
A Chamfer Feature can
now be created for each
curve.

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• To determine the size of the chamfer from the model, view from the front
then use Interrogation. The Interrogation button may be obtained by
clicking on View>Toolbars>Command tab>Geometry. Left click on the
little icon with the yellow question mark then drag it and place in the tool
bar docking area.

• With Distance, Z, and

UCS selected use the
arrow button and click
on the top edge of the
surface and the
bottom edge to
measure the distance
in Z, this dimension is
used for the height in
the chamfer feature.

• To determine the width, view from the top and using Distance, 2D, and
UCS click on each end of any isoline on the chamfer faces as shown for
the width of the chamfer. If they are equal you of course have a 45 degree
angle but if they are not remember this is a formed chamfer with a tapered
tool and your tool crib may not have that angle tool, it will have to be
created and purchased or ground to the taper.

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• Create a 2.5D chamfer, no Recognition and use the .0394 dimensions for
both the height and width for each of the three chamfers.

AFR Example #3 (Feature Re-recognition)

• From the file menu click on File

then Open. From the files of type
pull down menu select ParaSolids
(*.x_t,*.x_b). Select the file named
“Original file - before.x_t” then
press the Open button.

• In the New Part Document window

select milling setup, inches then
press OK.

• On the Import Results screen

select the top radio button and
check the Launch AFR after finish
checkbox then press Next four
times.

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• On the Stock Dimensions

page check Compute stock
size from the size of the
part then press Finish.

• On the Automatic
Feature Recognition press Next then
Finish.

Feature recognition completes

the part by identifying all the
features in the setup.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

The next step is to

import the similar
solid model that has
been revised into
the same document
as the first and
perform Feature
Re-Recognition.

• From the file

menu click on
File then
Import.
Select the file
named
“Original file - after.x_t” then press Open.

Upon closer examination there should be a noticeable difference between the two solids.
Some holes are removed and in a different location, as well as the depth and dimensions of
the side and pocket features recognized using AFR.

• On the Import Results window

select the top radio button,
Uncheck Launch AFR after
finish and Check “Use the
same alignment as last
import”.
Finish.
They merge together.

• In the Part View on the left hand side

under Solids click the plus sign to
expand if necessary then toggle between
each solid that is highlighted. When the
solid name is clicked in the part view the
solid will be highlighted in red.

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• Click on Construct from above then select Re-Recognition Wizard at the

bottom of the menu.

• From the solid pull down

menu select the second, last
imported, solid in the list then
press Next twice.

The Re-Recognition wizard will show

what has changed. This is very useful
so the programmer is not required to
completely reprogram the part upon
design changes.

Note: This method is only

effective for features that
have been programmed
using AFR or IFR.
Features created using
curves will not be Re-
Recognized upon changes
to the model.

• Press Finish then

run a 3D simulation.

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• Open or drag and drop EndPlate.x_t into a new milling document, inch.
Repeat the Import Wizard process including “Launch AFR after finish”.
Click Next four times.

• Compute stock size from the size of the part then Finish. This will
establish the Stock and Setup the same as before and then execute AFR
but first in AFR Options, Uncheck 3D. This completes the initial Setup.

• Import or drag the model EndPlate Changes.x_t located in the

FeatureRECOGNITION folder and click YES to Import into the same
document.

• Uncheck “Launch AFR after finish”. Check “Use same alignment as last
import”. Next.

• Select “Accept the imported data as is and exit the Wizard”. Finish.
The revised model, EndPlate Changes.x_t is merged with the first.

Note: The “Use same

alignment as last import”
button will disappear. This
is expected.

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• Click Construct
and Click on the
Re-Recognition
Wizard and drop the
menu down and
select the second
model.

• Click Options. Check

“Create 3D feature” and
Select “Multiple feature”.
This will apply the 3D tool
path to the three chamfers
and a new 3D (only if
licensed) addition in the
revised model. The three
chamfers can be Unchecked
in the Part View under Setup
1 to execute only the new 3D
surface features.

Notice the numerous

changes in the holes,
pocket depths, islands
and even 3D.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

• Run a 3D
simulation.

IFR (Interactive Feature Recognition)

o IFR has three types of strategies available IFR Automatic by feature type, IFR using
surfaces or faces and IFR chaining.

o IFR Automatic examines the model for a particular feature such as a side, pocket,
face, slot, hole and boss. Side, pocket and boss features are not created using AFR
side features but separate side, pocket and boss entities.

o IFR using surfaces or faces extracts information about the highlighted entities
extracting depth and feature contour.

o The IFR using chaining method takes a horizontal slice of the model then the slice
profile may be chained into a curve.

o Depending on the geometry of the feature to be extracted one technique may be more
advantageous than others. Usually when programming a part using a solid model a
combination of these techniques is used.

IFR Example #1
• Click on File then Open.
Under Files of type at
the bottom of the screen
select ParaSolids
(*.x_t, *.x_b). Find the
file named
ex02ex02.x_t then
press the Open button.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

• Select Milling Setup and

select the Unit of Measure to
be Inch then press OK.

On the Import Results page select the

top radio button and Uncheck “Launch
AFR after finish” then press Next four
times.

• On the Stock Dimensions page

check the lower radio button
Compute stock size from the
size of the part. Finish.

• Start the New Feature Wizard

select Face then check “Extract
with FeatureRECOGNITION”.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

• Left click on the top most horizontal face of the part then click the green
“+” to add it to the list. Then press the Finish button.
• In the Properties, Click the finish operation and Milling Tab and change
the Zig-zag Angle to 90.

Open the New Feature wizard and

select Side and check Extract with
FeatureRECOGNITION. Next.

• Select side surfaces. Next.

• Using the arrow, select this vertical face and press the green + to enter.
Next.

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Observe the arrow, it points to the side that is cut. Reverse if pointing to the wrong side
of the curve by using the button on the right of the machining side window.
• Next.

• Because the side selected for the feature descends into the pockets you
must Click on the Bottom arrow and Click on the horizontal face to control
the depth. Both the Top and Bottom can be controlled here. Next.

• Select Boss with Recognition from New Feature. Next.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

• Select “Use horizontal surface”.

Next.

• Rotate the part and select

the bottom horizontal face for
the shape and one vertical
face to determine top and
bottom and Click the green +
to enter.
Finish.

• Select New Feature Wizard and Select Side with Recognition. Next.
• Automatic, then select only the side feature that goes through. Finish.

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• In New Feature select Pocket and

Extract with
FeatureRECOGNITION. Next.

• Select Automatic recognition.

Next.

FeatureCAM using IFR Automatic

recognition will identify all pocket features.

• Press the “Select All” button to

select all identified features and
then unselect the two similar
small pockets which the top of
these features are too high, these
two should be at a lower Z
elevation. This happened
because a face in the pockets goes higher than the tops of the pockets.
Unselect the round also.
• All selected pockets turn red when
selected and all you need to do to
unselect them is to click on each
and they will become blue again
and are not included.

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• Repeat the Automatic pocket process again with New Feature except
Check “Force same Z height”, Click on the Blue word Elevation then Click
on the horizontal surface to set the height (Top) of all three remaining
pockets. Click on the three remaining pockets turning only those red.

• Open the New Feature wizard and

select Hole and check Extract with
FeatureRECOGNITION. Next.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

• Select the Recognize and

construct multiple holes radio
button and check the Exclude
holes with a diameter greater
than checkbox and enter a value
of 1 inch. Next.

• Select All. Finish.

• Run 3D simulation

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FeatureCAM 2012 FeatureRECOGNITION for Milling

IFR Example #2
• From the file menu open 2.5D
pocket with open groove.fm
from the examples folder and
shade it.

• New Feature Wizard and select

Side from Curve and check
Extract with
FeatureRECOGNITION. Next.

• Select “Use horizontal

section” and “Elevation” of 0
(top). Next.

• Use “Slice location” arrow and

Click on the edge of the first
horizontal surface to establish the bottom of the feature. Next.

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The cursor is now in the Mode to create curves and you can readily see the outline of the two
side features that will require open curves.

• Chain both Open geometry shapes separately. Click on Create at the

bottom in the geometry dialog area after each curve is complete. Be
certain not to go around the outside of the part with the curve, both should
be open curves and end at the openings on each side. This geometry will
be deleted and only the curves will remain. Next.

Remember these are TWO open curves in One side feature and both Machining Side arrows
must point inside and each must point at the opposite curve. This will machine everything in
between.

Chain this
geometry

• Repeat the same steps except use the bottom of the previous feature as
the “Elevation” (top) of the next Horizontal Section and the first face
stepping down as the second “Slice location” (bottom).

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FeatureCAM 2012 FeatureRECOGNITION for Milling

The third and final feature is a pocket.

• Open New Feature wizard, select Pocket and Extract with

FeatureRECOGNITION. Next.
• Select Use horizontal surfaces. Next.
• Select the bottom horizontal face of the pocket. Next.

• Using the Top arrow select the top edge of the pocket. Finish and 3D
simulation.

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IFR Example #3 (4 Axis)

All previous FeatureRECOGNITION examples have been stationary 3 Axis parts but
FeatureCAM gives extraordinary results on solid models mounted on a 4 Axis indexer or
rotary table. The part you will create is a special boring tool with pockets that will use
carbide indexable inserts when finished. You will begin by importing TWO solid models.
One is the Part and the other represents the Stock. The Stock material would logically be
turned on a lathe to the size and shape of the finished holder and that is the state of the Stock
when it comes to the mill for these secondary features.

• Open a new milling document in inch. Click on File then Import and
select from the Data folder model 2.5D Cutter horizontal slide-PART.x_t.
• In the Import Results Select “Use the wizard to establish the initial setup
location and stock size” and select an Isometric View by right clicking in
the graphics window. Uncheck “Launch AFR after finish. Next.

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The part centerline must be aligned with the rotary table in the X Axis and perpendicular to
the spindle.

• Shade the part. Select the Arrow to “Align Z perpendicular to a

horizontal surface” and Click on the horizontal face then Top view. If
your selected surface is upside down Click on the “Reverse Z” button and
Top view again. Next.

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The center line is now perpendicular to the spindle

but the part must be rotated around the Z Axis
to align with the X Axis.

• Click three times on the “Rotate X direction 90 degrees around Z Axis

and Top View again. Pockets to the left as shown below. Next.

• In Stock Type, Click Round, X

Axis.
Next.

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• View from Left View to check if

stock is on center. Next.

• From Stock Dimensions Click on the

“Blue” letters “OD” and then click on
the largest OD of the model then type the Length 7.000 dimension in the
box and Preview. Next.

• From the “Pick Initial Setup XYZ Location” Click on the Left Hand to set
the XYZ Zero Location. Next.

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• In “Is Part Indexed?” Select 4th Axis Positioning and Index around the
STOCK X Axis. Finish.

When using 4th Axis the Part must be aligned with the “STOCK AXIS”. This is the
Center of the Indexing and equally important is the Reference for ALL features created or
recognized to be placed around.

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• To view the “STOCK AXIS” Click on View, upper menu bar and Select
Show then Show Stock Axis. You will see another set of arrows merge
with the UCS (light blue in color). The Z points up in the Z direction
toward the spindle and is “0” degrees, the starting point of indexing angles.
The X is parallel to the X Axis and will index around this axis

• Repeat the Import process for the STOCK model 2.5D Cutter horizontal
slide-STOCK.x_t. Import the STOCK into the same document that the
PART is in, the STOCK model initially appears as below. Click Yes.
• In the Import Results select the top radio button to Use the Wizard and
check “Use the same alignment as last import”.

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When Finish is clicked the STOCK model will align to the PART model in the same
relationship as when they were exported from Cad but will not be merged, see below. For
the two models to merge together at this point they must be created in the Cad system
aligned and merged together although they can be Imported into FeatureCAM together or
separately. You may be able to control how models are created in house but models from
customers can be created in various positions.

The two models now need to be merged and that means you will have to Transform the
STOCK model by Rotating and Translating it to the PART model

Having a STOCK model in addition to the PART model is very helpful in as much as the
STOCK model actually represents the state of the stock material presented to the 4 Axis
operations plus FeatureCAM now uses the STOCK model as the STOCK boundary instead of
bar stock.

• To finish the alignment or the merging of these two parts, change to a

Right View and shade the part.
• Using Curves from the Steps Toolbox then curve wizard select Curve
from Surface and Trimmed Edges. Next.
• Using the Surface arrow select the End Face on the STOCK model. The
face will show select color. Around the outside edge a curve is created and
that is what the purpose for doing this is, you will need this curve. Finish.
End Face

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FeatureCAM 2012 FeatureRECOGNITION for Milling

• Click on the curve you just created and then click on Construct from top
menu bar, Select Curve and from the sub menu select “To Geometry”.
This changes the curve into geometry but keeps the curve.

The Geometry circle gives you an exact center point of the model and can be used as an
anchor to click on whereas the curve didn’t provide this. These two tools are very helpful
throughout FeatureCAM when working with curves and models. You are simply extracting
engineering information from the model.

Circle Center

• Now change to Isometric View then place your cursor on the STOCK
model, Right Click and Select Solid. You will need to see the circle
center and the red select color covers it. Click the shade button if you need
to unshade (2 little red barrels on top tool bar) and this will reveal the circle
but the select color must remain on the model in order to open Transform,
so be sure not to click on the graphics window or you will un-select and
have to do it over again. You must always select first or the Transform
button will not be accessible (grayed out).

Circle Center

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• Click on the Transform button (little arrow with pigtail next to the Select
arrow) on upper tool bar. Select Translate and use the From: arrow click
on the circle center. Enter 0 in all three boxes next to the To: and Click
preview and you will see the STOCK model shift to the UCS at the end of
the PART model. OK.

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• Select the STOCK model as before and return to Transform and Select
Rotate. Angle of 180 and Select Center Point and Z Axis and Enter 0 in
both boxes. The STOCK model will rotate and merge with the PART
model. Preview and OK. If unshaded, shade the part.

Summary: The purpose of “Use same alignment as last import” is to take advantage of
assemblies and multiple models that are created and aligned or merged together when created
in Cad. If the parts are not aligned when created, it does not matter because FeatureCAM
provides all of the necessary tools to align the parts. So you use the Import wizard to Align
completely or as close as possible and finish off with these tools.

The PART model is now ready to apply the Features using FeatureRECOGNITION.

• You first must change the Stock. Double-Click on the wire frame of the
stock in the graphics window. Click on “User defined” and check the box
for the solid of the STOCK model. Click OK and Apply.

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• From the Part View Click Solid in the list and Right Click on the STOCK
model and Hide Selected. This is necessary to see the PART model and
even with the STOCK model hidden it will still be visible when running 3D
Simulation.

• Switch to Isometric view. Click New Feature Wizard and Select Side
From Curve and check Extract with FeatureRECOGNITION. Next.

• Select Around the index

axis and Specify angles.

• Click on the “Blue” words

“Index Angle”.

• Click on any vertical surface

edge, starting low on the line
with the first click and above
the first with the second Click.
Next.

The second click is pointing in the

direction that you want the spindle to
come from and at the same time you
are establish the index angle for setting
the features.

• Select side surfaces. Next.

• Check the arrow direction for
Machining side. Next.

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FeatureCAM 2012 FeatureRECOGNITION for Milling

When selecting vertical surfaces, the Top and

Bottom are already established but if you
desire to change either the arrows can be used
by clicking on a surface edge or you may
enter the dimensions

• Click Finish and OK. Run 3D

Simulation.

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There are the same side features opposite the side features just completed. You can repeat
the same steps for them. Remember when selecting the index angle the second click is
always pointing to the spindle so if you select the surfaces when upside down the second
click has to be lower because when the part indexes the vertical surfaces rotate and must be
aligned with the spindle.
The other choice is making a pattern from the previous feature but should only be used
when you are absolutely certain they are identical and symmetrical.

• To make a pattern first Select the existing feature and then the New
Feature Wizard and select Pattern From Feature. Next.
• The previous Side feature must be selected. Next.

• Select Radial around index

axis. Next.

• Select Number 2 and Spacing

Angle 180. Finish and OK.

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When milling cylindrical parts the side feature has to extend outside of the Stock far enough
to satisfy the bottom of the feature but at the top, because of the shape of the material the tool
is cutting air on some passes.
• To eliminate this, under the strategy tab in the milling feature select
Individual levels, Apply and OK.
This creates control at each Z increment depth of cut and follows more closely to the shape of
the material on each level. Higher passes start their passes closer to the material and move
out as the tool descends. FeatureCAM has also selected three tools now, the first pass is the
shortest tool and each pass changes to a longer tool. You may override this by selecting the
same tool for all three cuts.
This will also make the part index on each level but can be eliminated by selecting “Cut
higher operations first” from the results window (right side of graphics window), click on
Automatic ordering options button at top. This works only if the features are individual
not a pattern.

• Rotate the View so you can see the horizontal surface of the feature
between the previous features just completed. Continue with Side Feature
using Recognition and select the arrow “Normal to surface”. Click on
the horizontal surface that you rotated to. The vertical surfaces that
FeatureCAM is looking for are Normal to this horizontal surface.
FeatureCAM uses the horizontal to index to and looks for any vertical
surfaces with Recognition at this angle.

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• Select Automatic
recognition. Next.

• Uncheck “Exclude features smaller than’ and Click only on the vertical
surface (red preview in graphics window as shown below) connected to the
horizontal surface you selected. Finish and OK.

This Feature

You can extend the lead on the feature if it fails to remove all the material on the short end of
the feature.

• In the feature Click on the finish operation and the Stepovers Tab and in
the “Lead moves for cuts with open ends” Enter .250 in the Extension
dist: box. Apply and OK.

You will do the Pockets for the inserts next.

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• Isometric view back to 0 or the first feature.

• Open New Feature Wizard and Select Side and Recognition. Next.

Follow the same

procedure for finding the
angle of index using the
edge of a vertical face. It
will be the area where the
inserts will sit. These will
be side features.

Side Features

• Select Use horizontal section.

Click on the “Blue Word”
Elevation and Click on the Top
edge of the vertical face for the
feature, this sets the top of the
feature. Next.

• Click on Slice location arrow and

Click on the bottom of the same
vertical face and this sets the
Bottom of the feature. Next.

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• Click on Switch to Top View

and the part moves to a top view.
The geometry is readily visible
and must be chained with an
open curve. Chain them with two
open curves, not connected.
Click on Create at the bottom in
the geometry dialog area after
each open curve. Next.

Remember this geometry goes all the way

around the part; be sure the curve doesn’t
go there.

• Check the Machining Side arrows, they must point in. Use the reverse
button to the right if necessary. Next.

• Confirm the Top and Bottom and change using the Top and Bottom
arrows if necessary and extend the leads as before if necessary. Click
Finish.

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Complete all of the remaining side features.

o For hole features, if Automatic is used, FeatureCAM recognizes ALL of the holes at
All of the angles. When the holes have a bottom (blind) FeatureCAM knows from
what direction to come with the spindle.
o When the holes are around the indexing axis and are on the centerline, whether they
are blind or through like in tubing it also knows from what direction to drill the holes.
o When the holes are not on the centerline and are through like this model, Feature
CAM basically has to guess from what direction. To avoid this you will use the
isoline in one hole to give the indexing angle and remembering the second click on
the line tells FeatureCAM the direction you want the drill to come from. It does ALL
holes in Recognition but only at that angle and will not drill any of the others from the
wrong direction. You will have to do the various indexing angles for the holes for
Recognition until all of the holes are complete.
• Open New Feature Wizard and Select Hole and Extract with
Recognition. Next.
• Select Specify angles and click on the “Blue Words” Index Angle and
Zoom in on the hole you choose. If you un-shade it temporarily it exposes
the line very clearly for easy picking.
Next.

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• Select Recognize and construct

multiple holes. Next.

All holes have been selected at your chosen

angle, even those on the other side that you don’t want and that is because they are an open
cylinder and could be drilled from this Z direction.

• You simple choose only the ones you want. Click on them and they then
turn red as selected. The others remain blue and are not selected.

Continue repeating these steps

until all holes are completed then
your PART is finished.

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FeatureCAM Milling Part Library

Part Library
Introduction
The Part Library is a function of FeatureCAM that enables users to save items that they use
repeatedly. Rather than having to recreate the same entities, the user can just recall them
from the Part Library. In addition to saving specific features, the Part Library can store
processes. For example, if a user machines pockets the same way all the time, one pocket can
be stored, and then it’s parameters and attributes can be applied to future pockets, saving the
user from having to change the same settings over and over.

Creating a Part Library Feature

Any feature can be stored in the Part Library to be recalled later. This exercise will
demonstrate how to save a feature to the Part Library, and it will offer some tips on how to do
this most effectively.

• Open a New milling file

• Fill out the Dimensions page

of the Stock Wizard as shown
• Click Next 4 times to get to
the first Setup – Part
Program Zero page
• Select Align to Stock face
and click Next

• Designate the setup location as

the center of the part
• Click Finish
• Click OK to exit the Stock
Properties

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In this next step, we are going to create a ½-

13 tapped hole to be stored in the Part
Library.

• Launch the New Feature wizard,

and select Hole
• Click Next
• Fill out the Dimensions page as
shown
• Click Next, and verify that the hole
will be located at 0,0,0
• Click Finish
• Click OK to exit the Hole
Properties

Hint: If possible, it is best to locate Part Library features at the origin. This makes it easier to
locate the features accurately when they are loaded into another file. If a Part Library feature
is not located at the origin, its original location has to be known and compensated for in the
new document.

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Next, we are going to rename the feature so that it has a more descriptive name.

• Right-click the hole feature in the

Part View
• Select Rename
• Rename tapped hole as shown
• Click OK to accept the new name
• Select the tapped_hole_500_13
from the Part View

• Open Part Library by selecting Part

Library under the Construct pull-down
menu

• Save the tapped hole by

clicking Add selected

This will save the tapped hole to the

“root” of the Part Library. In future
examples, we will create sub folders so
that the Part Library stays neat and
organized.

• Click OK to close the Part

Library
• Close the file without saving

Now that the hole is in the Part Library,

we do not need to save the file that
defined it. Its definition is contained
entirely in the Part Library directory.

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Using Part Library Features

Now that a feature has been saved away, it can easily be installed in another part.

• Start a new milling file

• Use the Stock wizard to create a 4 x 6 x 1 block
• Locate setup on lower left-hand corner
• Finish the Stock Wizard and exit the Stock Properties by clicking OK

• Start a new feature by clicking

the New Feature wizard icon
• Select a User defined feature

This is one way to access existing features

in the Part Library. We will explore other
methods later in this chapter. User-defined
features include features that can be created
by macros and features that are stored in
the Part Library.

• Select the tapped_hole_500_13

from the dialog box and click
Next

To complete this process, we have to

determine the location of the Part Library
feature. Since we created our original
feature at 0,0,0, we will be able to enter the
coordinates without having to adjust for
any offset.

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• Enter the value 1 for both X and Y

You will notice that our tapped hole is now located in the proper position and is now ready to
complete.

• Click Finish to complete the feature wizard.

If you open the new feature, you will see that it came in exactly as it was originally defined.
This feature can now be edited, if desired, without affecting the Part Library feature - the
installed feature is no longer associated to the original.

• Close the file without saving

Saving Patterns and Groups to the Part Library

Oftentimes it is not a single feature, but a combination of features that needs to be saved for
future use. This exercise will show you how to combine multiple features into groups and
then save the group into the Part Library.

• Open Gauge Mount.fm from the Data folder

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• Run a Simulation

• Clear Simulation results

As you can see from the simulation and from the Part View, we have a pocket feature and a
hole pattern that we want to always machine as a set. We would like to be able to store them
together so that they could be brought in as a single Part Library item. In order for these two
features to be stored together as a set in the Part Library, they have to be combined into a
Group first.

• Start the New Feature wizard

• Select Group from the From
Features section
• Add both features them to the
Group Members list
• Click Finish
• Exit the group properties by
clicking OK

As with the original tapped hole we created

in this chapter, we are going to rename our
group to a more descriptive name. This is
especially useful if we are going to have
several similar features stored in the Part
Library.

• Right-click on the group in the Part

View
• Select Rename
• Rename the group as shown

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From here, the process is exactly the same. For this part, though, we will create a new folder
in the Part Library. You can create folders to organize your features and keep the Part
Library from getting too cluttered.

• Highlight the Group in

the Part View
• Open Part Library
• Click Add Folder
• Select the folder and click
Rename
• Rename folder to
instrument-mounts
• Click Add Selected to
save group to new folder

You will see that gauge_mount_1

is added to the Part Library as a
child of the instrument_mounts
folder.

• Exit the Part Library by

clicking OK
• Close the file without
saving

Patterning Part Library Features

If a user wants to install multiple instances of a Part Library item into a file, this can be done
by utilizing Patterns. All of the pattern types such as Linear, Radial, and Rectangular are
available. If the positions of the Library features are laid out in advance, the process can be
made very quick and easy by creating a Points Pattern.

• Open Instrument Panel.fm from the Data folder

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This file simply contains the locations at which we will locate our Library features. If the
features are created correctly, they will come in perfectly positioned at each one of these
points.

• Start by selecting all of the points

by dragging a selection box around
the entire part.
• Start a New Feature
• Select User
• Make a pattern from this feature
should already be checked since
we preselected more than one
point
• Click Next

• Select the gauge_mount_1 group

from Part Library
• Click Next

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The Points Pattern is the style of pattern already selected because of our collection of points.

• Click Next
• On the Dimensions tab, you can alter the sorting order, if desired
• Click Finish to complete the wizard
• Click OK to close the Feature Properties
• Run a simulation to see the results

• Close the file

Saving Solids to the Part Library

Solid models that are brought into FeatureCAM can also be stored in the Part Library for later
use. This capability is especially handy for using solids as fixtures and clamps. The
following example will demonstrate saving a solid to the Part Library and then loading it into
a FeatureCAM document.

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FeatureCAM Milling Part Library

• Open a new Milling file

• Cancel the Stock Wizard
• Import Toe Clamp.sldprt from
the Data folder
• When the Import Results
screen appears, choose to
Accept the imported data
“as is” and exit the wizard
• Click Finish

The clamp comes in located at 0,0,0.

Now we will save it to the Part Library
so that it can be easily loaded – and even
patterned – in future files.

• Expand the Solids folder in

the Part View and right-click
the solid

• Rename the solid toe_clamp_1

Again, it is good practice to rename entities that are going to be used at a later date with
descriptive names.

• Make sure the solid is still selected and open the Part Library
• Click Add Folder
• Rename the new folder clamps_and_fixtures
• Highlight the clamps_and_fixtures folder and click Add Selected to add
the toe clamp to the Part Library
• Click OK
• Exit the file without saving

Now that the toe clamp is stored and ready to use, we will bring it into a finished version of
the Instrument Panel that we worked on earlier. Since the clamp is not a feature, we will not
do this through the New Feature wizard. Instead, we will copy the toe clamp directly from
the Part Library.

• Open Instrument Panel – Finished.fm from the Data folder

• Click Construct > Part Library
• Select toe_clamp_1 from the clamps_and_fixtures folder
• Click Paste

This exercise will introduce us briefly to the Paste Special function. We will study Paste
Special in further detail later in the chapter.

10 Issue FeatureCAM 2012

FeatureCAM Milling Part Library

We want to paste the toe clamp

into our part, but we want to be
able to designate where it is
located. For this, we need to
use the second choice of the
Paste Special options.

• Select the second

option as shown

Before we give our feature

location dimensions, we need to
define a reference point. This is
a nice tool because you do not
have to locate the entity relative
to an origin. If you would
rather locate the clamp 3 inches
from a specific point, you could
select that point as your
reference point. In this
example, however, we will use
the origin as our reference.

• Make sure the

reference point is 0,0,0
and click Next

Now that the reference point is defined, enter the position of the clamp.

• Enter position for clamp as shown below

Issue FeatureCAM 2012 11

FeatureCAM Milling Part Library

• Click Preview to confirm the location

• Click Finish to place the solid

• Click OK to close the Part Library

Solids that are brought into FeatureCAM files can be used to represent fixturing during
simulation. However, this requires a few more steps. If you were to run a 3D simulation
now, the clamp would not appear.

• Right-click on the
toe_clamp_1 solid in the
part view
• Select Use Solid As
Clamp

Now that the solid has been

designated as a clamp, it will
show up in our simulation. It will
even detect gouges if a tool or tool
holder contacts it.

12 Issue FeatureCAM 2012

FeatureCAM Milling Part Library

• Run a 3D simulation

• Close the file without saving.

Paste Special
We have already seen how Paste Special can be used to position a Part Library item in a
FeatureCAM file. Paste Special has a couple other functions that help to load a feature or its
parameters into a file.

• Open the file Paste Special.fm from the Data folder

• Make sure the basic tool crib is active

This file contains two pocket features that have different settings, depths, and parameters.
We will use Paste Special to create and modify features based on the settings of a Part
Library feature. First, we will save Pocket1 to the Part Library.

• Click on pocket1 to highlight it

• Open the Part Library
• Add a New Folder
• Rename the folder pockets
• Select the pockets folder and click Add Selected to save the pocket to the
Part Library

We will use this pocket as the templates for other pockets in the part file. First, we will
create an entirely new pocket with all the parameters of pocket1. This strategy is very useful
if you want to apply dimensions and attributes of one feature to different curves.

• Click on pocket1 in the Part Library to highlight it

• Click Paste

Issue FeatureCAM 2012 13

FeatureCAM Milling Part Library

The Paste Special dialog box appears. We will paste the feature “as-is” into our part file.

• Select “Paste the selected objects into the current setup”

• Click Finish
• Click OK to exit the Part Library

You will notice that there is a new feature in the Part View, but it is not visible in the
graphics. This is because we have two identical features in the part file. Next, we will
modify the new feature be selecting a different boundary curve.

• Double-click pocket1_1 to access its properties

• Click on the Boundaries button
• Clear the current curve selection and select Curve2
• Click OK and Apply
• Click OK to exit the Feature Properties

We now have a new feature attached to Curve2. This feature has the exact same parameters
and dimensions as the original feature.

14 Issue FeatureCAM 2012

FeatureCAM Milling Part Library

Hint: When you create a feature to be stored in the Part Library, avoid overriding any tools
unless you want to designate specific tools to the feature. By keeping default tools in place,
you allow FeatureCAM to change the tool selection based on the geometric conditions, and
you create a more flexible Part Library feature. If you compare pocket1 and pocket1_1, you
see different tools are selected because of the different radius values of the corners.

Another way to use Paste Special is to apply the Machining Attributes of the library feature to
another feature. In this example, we will apply the attributes of pocket1 to pocket2. First,
open the properties of pocket2 and examine the Strategy tab.

Pay attention to which attributes are checked, and exit the properties.

• Open the Part Library

• Click on pocket1 in the Part Library to highlight it
• Click Paste
• Select “Copy the machining attributes from the selected feature to another
feature”

Issue FeatureCAM 2012 15

FeatureCAM Milling Part Library

• Click Next
• Check the Machining Attributes

You have a choice of applying all of

the machining attributes of the
library feature, or only the attributes
that were overridden in the library
feature.

• Choose to copy all of the attributes as shown

• Click Apply and Finish
• Close the Part Library

Now take a look at the Strategy tab of pocket2.

Options such as Individual Levels and Cutter Comp, which were characteristics of pocket1
are now installed in pocket2. This strategy is useful when you want to machine features of
different dimensions in a very consistent manner. All of the attributes get applied without
altering the geometry of the feature.

Another note about Paste Special: Paste Special is not limited to being used in conjunction
with the part library. You can use Paste Special more “locally” by copying a feature from the
part view and then using Paste Special. The Paste Special can occur within the same part, or
in a different part.

16 Issue FeatureCAM 2012

FeatureCAM Milling Part Library

Streams
Entities other than features and solids can also be stored in the Part Library. Curves,
geometry, and machine functions can also be saved and recalled. These items show up as
Streams in the Part Library.

Oftentimes, geometry is reused from one part to another. For example, there might be a
fixture that has specific layout geometry. In that case, the layout geometry can be stored
away in the Part Library and used repeatedly as a template.

• Open the file Layout.fm from the Data folder

The lines and circles in this file represent a bolt hole pattern in a fixture. We would like to
save this pattern to the Part Library so that it can be transferred to a new document.

• Select the geometry by dragging a selection box around the entire part
• Open the Part Library
• Add a new folder
• Rename the folder layout_geometry
• Select the layout_geometry folder and click Add Selected

• Exit the Part Library

• Close the part

Each geometry entity is stored under the Stream1 heading. The Stream1 heading can now be
renamed to something more descriptive. This new geometry stream can now be added to new
files using the Paste Special function.

Issue FeatureCAM 2012 17

FeatureCAM Milling Part Library

Streams can also be used to store other types of features. This sample will construct a stream
of lathe functions that will be very similar to the Grouping method that we have already seen.

• Open the file Turn Part Transfer.fm from the Data folder

This file contains Subspindle features that carry out a part transfer on a lathe. It would be
quite time consuming to create each one of these steps manually for every turning file, so the
entire set of steps can be stored in the Part Library as a Stream.

• Select all of the features by dragging a selection box around the entire part
• Open the Part Library
• Add a new folder
• Rename the folder transfers
• Select the transfers folder and click Add Selected

Each subspindle feature is stored under the Stream1 heading. The Stream1 heading can now
be renamed to something more descriptive. This new feature stream can now be added to
new files using the Paste Special function.

18 Issue FeatureCAM 2012

Creating Set Ups FeatureMILL

Creating Machining Set-Ups

Introduction
Before starting any machining operation, it is necessary to set a Datum position
from which to work from. In FeatureCAM these positions are called Set ups and
these can be defined using a number of techniques.

Creating SetUps from the Stock

The Stock represents the material which is to be machined. The most common
places that are used when defining the Set Up on a standard Block are the Centre
of a Face or one of the Corners as shown below.

When FeatureCAM opens a new part a Stock is automatically displayed on

the screen.
• Double click on the stock either in the Part View Toolbox or in the main
Graphics area.
• Fill in the Form as shown below, Length=200, Width= 200 and
Thickness=100

FeatureCAM 2012 1
Creating Set Ups FeatureMILL

The X, Y, Z input fields at the bottom of the form are the position of the top
face bottom left corner in the World Co Ordinate System as shown in the
image below

Change the figures in the input fields and watch how the Stock moves around.

• Reset the figures to X0 Y0 Z0.

To place the Set Up in the centre of the Block, it is simply a case of moving
the Set UP to the centre of a Stock face and this is achieved by changing the
position, using the Part View Toolbox

• At the left of the screen are the Toolboxes and depending upon which
Toolbox is selected, it will either show the Part View or the Steps
Toolbox,

If you can only see the Part View Toolbox and not
the Steps options as shown....Try looking at the
bottom of the screen. (When it is not in use, the Steps
Toolbox drops down to the bottom, just click on the
tab to reactivate the toolbox.)

2 FeatureCAM 2012
Creating Set Ups FeatureMILL

• Right click on the

Setup in the Part
View and then select
Properties from the
menu that appears as
shown.

• This will open the

Set- Ups form,

On this form, the user can

choose whether to create a
New Setup or to Edit /
Change an existing one.

• Click on Edit, followed by Next

• Select Align to Stock Face

FeatureCAM 2012 3
Creating Set Ups FeatureMILL

The form is divided into two areas and these are Stock Face and XYZ location

Stock Face is used to

tell FeatureCAM on
which Face to place the
Setup.

XYZ Location is
used to position the
Setup on that Face

• Select Top followed by Centre. Click Finish and then Close.

The screen should now look as shown below.

Using the same method, create a new set up on the Front Face at the Upper
Right Corner.

4 FeatureCAM 2012
Creating Set Ups FeatureMILL

Creating Setups Using Geometry

It is also possible to create Setups which are aligned to existing Geometry. Draw the

wireframe shown below, using the Geometry Step.

• Go to the Setups icon on the Advanced Toolbar at the top of the screen.

If it’s not there, then the advanced toolbar needs to be switched on. To do this,
right click on the grey area around the edge of the graphics area, and choose
Advanced from the drop down list.

FeatureCAM 2012 5
Creating Set Ups FeatureMILL

After selecting the Setups Icon, Select Setup1 from the drop down menu and click on
Edit

This will open the Setup Definitions form

Here it is possible to change / set key details of the

Setup. To rename the setups so that they are easier to

manage,

• Enter the name Datum Point into the Setup Name field. This name
will appear in the Part View Toolbox.

The Fixture ID field is

where the user tells
FeatureCAM which
machine offset to use.

For example: If the

machine uses G54, G55
then enter 54. If the
machine tool uses P1, P2
etc then enter 1.
FeatureCAM will
automatically insert the
correct Fixture ID for
the next new Setup.

It can be useful for the

Part / Product name to
appear in the NC output
file, This can be inserted
in the Part Name field.

6 FeatureCAM 2012
Creating Set Ups FeatureMILL

• Click Next and on the following page, select the Align to Part Geometry
option.

By selecting the Align to Part Geometry option, FeatureCAM now knows

that it has to provide the user with some tools to help them set up or align the
Setup.
There are five options on the following page and depending on the geometry
available; the user can choose one of these to align the Z axis .

FeatureCAM 2012 7
Creating Set Ups FeatureMILL

• Select Pick two points to define initial Z direction.

The form will shrink to one side of the screen to allow access to the geometry.

Two mouse clicks are used to define the Z Axis direction. To define the Z Axis,

• Select the 1st point as shown, followed by the 2nd point. The position of
the second click in relation to the first is what controls the direction of
the axis.

• When the form returns, click Next

8 FeatureCAM 2012
Creating Set Ups FeatureMILL

• Set the X Axis in exactly the same way as the B. Choose the left
baseline as shown.

• This has aligned the X Axis along the short edge. Click Next.

FeatureCAM 2012 9
Creating Set Ups FeatureMILL

• To reposition the Setup. Use one of the two pick buttons or enter the exact
co- ordinates into the X,Y,Z fields on the form.

The two pick buttons

are suited to different
applications.

Pick Location allows

the user to define
positions, by picking
points, directly from
the screen.

Centre of revolved
surface is used when
there are surfaces that
might represent a
dowel hole for
example

• Using any one of the methods, move the Setup until it is in the middle of
the top line.

10 FeatureCAM 2012
Creating Set Ups FeatureMILL

To create a new setup aligned to the angled face

• Create a new Setup by going to the Advanced Toolbar again

• Select New followed by Next and then Align to part geometry.

• This time on the Initial Setup Z direction form, select the option to
Align Z perpendicular to a plane defined by two lines as shown.

• Select two
lines that
are
perpendicu
lar to one
another.

FeatureCAM 2012 11
Creating Set Ups FeatureMILL

• If the Z axis is pointing the wrong way, then use the Reverse Z
button to correct.

• Click Next twice and reposition the setup as shown below by using the
Pick Location button.

12 FeatureCAM 2012
FeatureCAM Milling Creating Tool Libraries

Creating Tool Libraries (Cribs)

Introduction
It is possible to create Tool libraries or Cribs in FeatureCAM. The main reason for
creating Tool Cribs is because in any machine shop there is normally a finite amount of
tooling available and by creating a custom Tool Crib, FeatureCAM will know what
tooling is available to choose from.
• Open a new FeatureCAM part by selecting File, New.
The following will appear. Select Turn/Mill Set-up and click OK

• Go up to the
Manufacturing Menu and
down to Tool Manager.
This will open the
following form.

• There are three tool Cribs

loaded as standard. (Basic,
Basicmetric and Tools)
and these can be used as a
starting point when the user
first starts to look at setting
up their own Cribs

Issue FeatureCAM 2012 1

FeatureCAM Milling Creating Tool Libraries

• The window is divided into separate areas and at first glance can
look a little intimidating, but by applying some simple rules it
becomes much easier to work with.

If the user divides the form in two down the middle of the form. The left side is
used to select which Crib to copy from whereas the right hand side of the Form
relates to the Crib that is current or the working Crib

Tool Group …..The tools can be grouped together

depending upon their type or use.

2 Issue FeatureCAM 2012

FeatureCAM Milling Creating Tool Libraries

• Also listed down the right hand side of the form are a
number of options. Among these options are New
Tool, New Crib, Delete Crib and Copy Crib.

These options do exactly what they say on the tin.

New tool is used to create a new tool type.

New Crib will create a new crib, ready for the user to insert their own
selection of tools.

Delete Crib will delete an existing crib and Copy Crib will
produce a copy of an existing Crib

Tool Grades is used to apply scaling to feeds/speeds to similar tool types that
use different speeds/feeds

Import / Export allows the user, to either import or export tool cribs from one
computer to another computer containing a copy of FeatureCAM.

• By selecting the New Tool Crib

option, the following form will
appear. Enter the name as
Training, and then click OK.

• The New Tool Crib will now be listed in the Tool Manager on the
left hand side

• The new Crib is empty so it is possible to copy tools from existing Cribs,

• Select the Basicmetric Crib in the From Crib Menu and the
Training Crib from the Current Crib Menu. In the Tool Group
select End Mill

Issue FeatureCAM 2012 3

FeatureCAM Milling Creating Tool Libraries

• Click on the Select All Button and then on the Add button to transfer the
selected tools over to Training Crib.

• Repeat this procedure for the different tool groups and add some 4, 5, 8, 10
& 12mm Twist Drills and some Spotting and Centre Drills.
• Click on the OK button and the following will appear.

• Select Yes and the Crib is complete for now. More tools can be added at a
later date just by selecting them from the Tools Crib or defining New Tools
based on Catalogue data and adding the tools as needed.
• To set the Tool Crib so that it is used when calculating the tool path, go to
Manufacturing, Set tool crib and select the crib from the list. Alternatively go
to the bottom left of the screen and click on the area indicated

• Select the Crib required as shown.

FeatureCam will now use the selected crib for any future operations
If the wrong tool is being selected, for example using a finishing tool to
rough out, it could be that the tool needs to be set for a particular operation
type.

4 Issue FeatureCAM 2012

FeatureCAM Milling Creating Tool Libraries

Setting a Tools Operation type

1. Open the Tool Manager as described above.

2. Double click the Tool that the user needs to edit as shown

3. This will open the

Issue FeatureCAM 2012 5

FeatureCAM Milling Creating Tool Libraries

4. Click on the Overrides tab and then go to the Operations drop

down menu and select the operation type as shown.

5. Check that the Finishing tools are set to Finishing by following the
same procedure.
6. Click OK and then re-simulate the toolpath, the correct tool should
now be used.

6 Issue FeatureCAM 2012

Milling Machining Configurations/Attributes

Machining
Configurations / Attributes
Introduction
This module will provide the user with an understanding of what attributes are,
(characteristics and features) and where they reside Also covering when an attribute is
chosen, where it shows up in FeatureCAM, and how it affects the feature.
By the end of the module the user will be able to select, prior to creating the program, the
machining configuration of attributes, as the defaults for the material and/or machine to be
used. This saves time in programming by not having to make the same repetitive entries for
the choices you wish to be defaults when that particular material, or machine, is chosen. It
also eliminates having to remember the different settings.

Machining Configurations

• The Machining Configurations can be

accessed from the Manufacturing
drop down menu.

• Machining Configurations are

predetermined default functions that
are selected, and used in all features
that are created in the document.

• A Machining Configuration contains

approximately 150 settings.

• An unlimited number of Machining

Configurations may be created.

The user can name a Configuration to

reference the material and/or machine to be
used.

• “Initial Configuration for

new documents”, is in the
drop down menu at bottom.

Machining Configurations/Attributes 2012 1

Milling Machining Configurations/Attributes

When a Machining Configuration is selected prior to programming, the attributes, so to

speak, rain down into the new document just opened. These are used as the default settings.
They are divorced from the Machining Configurations and become Machining Attributes,
assigned to, and a permanent part of the new document.

These settings may be changed in the

document. You can click
Manufacturing and Machining
Attributes at any time. Changing any
attributes will assign them to this
document only, but does not affect the
original, or default, Machining
Configuration.

In other words, these changes do not

become the defaults and when a new
document is opened the old defaults are
active. These settings stay with the
document and are active anytime this
same .fm document is opened.

What are Machining Attributes?

When an option in the Machining

Attribute is selected, a box is checked
or a value is entered, it becomes a
default. This means that FeatureCAM
uses this setting every time a feature
requiring that particular setting is
selected in a program. There is no
input required from the user during
programming, as it is now
automatically set. However, it may be
overridden and changed in the feature
as needed.

Tabs are used to categorize the

different operation types and
necessary attribute settings.

Some selections are check boxes, some are numerical values, and some are specific functions.
The majority of these show up in the feature that they affect, but some settings do not. These
settings may only be changed in the attributes. This is the reason it is so important to know
where these settings reside, what their function is, and where they are located in the features.

2
Machining Configurations/Attributes 2012
Milling Machining Configurations/Attributes

To apply the changes you have made, in the Attributes for the document, to become the
defaults for any new documents they must also be changed in the Machining Configuration
that opened with the file. Once set, and the next time a new document is opened, those
changes will then take effect as the default settings.

• Open a New Document and click Manufacturing on the top menu and
select Machining Configurations.

• Select the document you just opened. Usually there is only one
document open but multiple documents may be opened. In this case, you
would see multiple documents in the list.

• Click Copy and select the desired configuration from drop down menu.
These defaults load into the new document.

To copy the changes from the document’s configuration into another configuration to be set
as the defaults:

• Select the desired

Configuration in the window.
This is the configuration you
want to copy the attributes
to.

• Click Copy and select the

document from drop down
menu in the Copy
Configuration dialog.

• OK.

This reverses the copy and places the changes from the document
Attributes into the configuration selected in the window of the Machining
Configurations dialog.

Machining Configurations/Attributes 2012 3

Milling Machining Configurations/Attributes

Creating Machining Configurations

• Open a New Milling Document. Click Manufacturing on Menu bar then

Machining Configurations.

• Click on New and type the word Aluminum in the field. OK

• Repeat these steps to create a Stainless configuration. OK.

• Double click on Stainless in the

window. Select the Stepover Tab in
the Machining Attributes dialog.
Change the Rough Pass depth to
25%.

The Rough pass depth for milling was

100% of the .500 diameter of the cutter. It
is now 25%, so for a 1 inch endmill the
rough pass depth is set to take cuts at a
depth of .250.

Note: You now have three separate Machining Configurations. Each has
approximately 150 settings.

• Select the Document you have open in the Machining Configurations

dialog at the top of the window.

• Copy and select

Aluminum from the Copy
Configuration dialog.

• OK twice. These
settings will be used in the
new document.

Open an existing file named Milling Attributes.fm, from the 2.5D

Advanced Data folder, and run a 3D simulation.

4
Machining Configurations/Attributes 2012
Milling Machining Configurations/Attributes

The .500 diameter milling cutter cuts to the bottom of the .500 deep pocket in
one pass because the default attribute specifies the depth of roughing passes
is to be 100% of the diameter of the cutter.

• Click Manufacturing then Machining Configurations. Select the

document in the window on the left named Milling Attributes.fm.

• Press the Copy button. Select Stainless from the drop down list in the
Copy Configuration dialog. Press OK twice.

Using the same feature and by

only changing the Machining
Configuration the Attributes
automatically change to the
Stainless settings.

• Run a 3D simulation.

The setting for Stainless is 25%

of the diameter of the cutter so
now the tool makes four passes
at .125 depth of cut instead of
one at .500 with no further input
from the user.

Machining Attributes Explained

The rest of this document will be used to explain the attributes found in each
of the tabs inside the Machining Attributes dialog. To follow along and
compare, click Manufacturing then Machining Attributes to open the dialog.

Drilling Tab
Spot drill: All holes that are drilled will receive a spot or center drill operation before the
hole is drilled.

Attempt chamfer w/spot: When a chamfer is entered in a hole feature, a spot drilling tool is
selected that is large enough to cut the chamfer as it center drills for the hole feature. If the
hole is too large, it will still be spot drilled but will give a warning that it was not able to
achieve the chamfer and use a chamfer tool in addition to the center drill.

Use L/D Compensation: As a hole is drilled deeper the feed and speed is adjusted to
compensate for the additional depth. This is true for holes that have a ratio of hole depth (L)
to hole diameter (D) of greater than 2.5. The greater this ratio, the greater the speed/feed
reduction becomes.

Machining Configurations/Attributes 2012 5

Milling Machining Configurations/Attributes

Combine with similar holes into canned cycle: This Attribute serves two functions. First it
creates more efficient NC code by entering canned cycle mode only once. It also causes the
tool to retract to the lower Plunge Clearance plane after drilling each hole, typically .100
above the hole instead of the Z Rapid Plane which is usually set much higher to clear clamps,
etc. Retracting to the higher plane when necessary is possible on a per hole bases in the
Results Window Op List by clicking on the green arrow of the selected hole.
Drill large counterdrill first: A counter drill hole has a second, larger hole drilled on top of
a smaller hole. You may select to drill the larger hole first to avoid drilling the same material
with the smaller tool that will be removed with the larger tool. The smaller tool will then
rapid to the plunge clearance above where the first drill stopped drilling.
Ream before Chamfer: Allows you to ream a hole before the chamfer to avoid pushing any
kind of a burr or edge back up onto the chamfer in the event the chamfer is a sealing surface.
Pilot drill diameter: Set the diameter for a frequently used pilot drill size as a default.
Spot drill edge break: If 0 chamfer is entered in a hole feature, this setting will cause the
center drill to break the edge by this amount, typically .005.
Spot drill diameter: This percentage is used to select a spot drilling tool. A value of 100
specifies that the spotdrill should be the same diameter as the hole. A smaller value will
create only a starter hole.
Dwell: The spot drill will dwell for this many seconds.
Max tap spindle RPM: Sets the maximum spindle speed that FeatureCAM will select when
tapping regardless of the size of the tap.
(Cycles)
Drill cycle: Deep hole will peck and retract to the plunge clearance and return to previous
depth and chip break only stops feeding in order to break the chip, both perform their
function until hole is to depth.
Tap Cycle: Floating (floating & tension-compression holders), Rigid which is most
commonly available on today’s machine tools being sold, Deep hole and Chip break is the
same as drilling.
Ream Cycle: Ream cycle affects how a ream operation is performed. The choices are Ream
FDF (feed-dwell-feed), Ream FF (feed-feed), and Ream FSR (feed-stop spindle-retract).
If you select Ream FF, the cycle is posted using the Bore (F-F) format in XBUILD. Ream
FDF will use the Bore (F-D-F) format, and Ream FSR uses the Bore (F-S-R) format.
FDF, feed down-dwell-feed up, FF, feed down-feed up, FSR, feed-stop-retract.
Bore cycle: FDF, feed down-dwell-feed up, FF, feed down-feed up, FSR, feed-stop-retract
and No Drag shifts a designated amount in No drag X and Y shift so as not to touch the
finished wall upon retract.

6
Machining Configurations/Attributes 2012
Milling Machining Configurations/Attributes

Pecking Tab
Drilling: Depth of the First, Second and Minimum peck may be entered by the % of the drill
diameter.

Tapping: Depth of the First, Second and Minimum peck may be entered by the % of the tap
diameter.

Milling Tab
Climb mill: With the milling cutter rotating clockwise if you follow behind the cutter in the
direction of the travel of the tool and the cutter is on the left side of the curve it is climb
milling and if it is on the right side it is conventional milling.

Bi-directional rough: The rough passes alternate between climb milling and conventional
milling. When cutting a Boss feature on a square block, the cutter cuts across the corners
first. When climb milling is selected in the strategies, the first pass is a climb cut, and then
the tool alternates with conventional milling until the corners are finished. The cutter finishes
the roughing cuts using climb milling.

Use finish tool: When rough and finish milling, FeatureCAM uses the same cutter to rough
and finish. When Use finish tool is checked FeatureCAM will always add a second tool to do
the finish operation.

Cutter Comp: Whether cutter comp is selected or not FeatureCAM offsets the tool by the
radius of the tool. By selecting Cutter comp, it adds the necessary G40, G41and G42 to the
NC code so the tool size for holding tolerances may be adjusted with the tool offset in the
control by the user.

Part line program: Instead of the cutter center being offset by FeatureCAM the program
aligns the center of the tool on the curve. The NC code reflects this with the print dimensions.
All of the offsetting is done by the machine control.

Minimize tool retract: For use when it is more desirable to feed the tool to another region
of a feature instead of retracting and plunging. For example: in a pocket with islands,
minimize tool retract will keep the tool from retracting and plunging.

Individual rough levels: Many roughing cuts are performed at multiple Z levels due to the
depth of the feature. If you select Individual levels on the Strategy page, you will be able to
customize the manufacturing attributes of each level. If you have a feature that is roughed in
four levels there will be four z-levels listed in the feature instead of one. Note that each pass
is listed underneath the rough operation. By clicking any of the passes, you can set attributes
in the Milling tab. If Individual level is not selected, then only the rough pass is listed in the
tree view and you can only make changes to Milling tab attributes that will apply to all
levels. Individual levels also controls clipping of boss and side features against the stock
model including both STL and solid stock models. With this attribute selected, the toolpaths
are clipped against the stock boundary at each Z level.

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Milling Machining Configurations/Attributes

Depth-first machining: Selecting the Depth first option will cut each region of the feature
completely before moving on to another region. The toolpaths descend in Z. If this option is
deselected, then all regions of a feature are cut at one Z level before descending to a deeper
Z-level. If you are using multiple roughing tools or multiple finishing tools, to efficiently
rough out tight corners, Depth first is also useful. The second tool that roughs the corners
only will cut each corner to depth before retracting and moving to the next corner.
Reorder: (Surface Milling) 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. Use this if it 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.

Side roughing bottom up: A 2.5D feature with a Draft Angle may be roughed from the
bottom up instead of the normal top down.

Side finishing bottom up: A 2.5D feature with a Draft Angle may be finished from the
bottom up instead of the normal top down.

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Milling Machining Configurations/Attributes

Toolpath corner (%): This attribute rounds the corners of milled roughing passes. It is
specified as a percentage of the tool diameter. Rounding the sharp corners of the toolpaths
provides a more constant tool velocity and reduces the tool load.
It applies to all 2.5D milling features. The left figure shows a pocket without Toolpath
corner % set and the right is set with Toolpath corner set to 98%:

Hi speed machining technique. The first rough Tool path corner at 500% flattens the tool
path, usually faster feeds and speeds. The second rough Tool path corner at 25%, cleans up
only what the first rougher left. The 25% value helps smooth out some of the sharp corners,
but must not be too large, or there might be an excessive amount for the finishing tool.

First rough passes 500%

Second rough passes 25%

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Milling Machining Configurations/Attributes

(Trochoidal slotting)
Trochoidal cut: Simple grooves have an option of using a trochoidal toolpath. Instead of a
simple slotting cut, the tool uses a series of circles to clear away the metal, as shown. This
toolpath has the advantage of maintaining a constant radial depth of cut which produces the
same load on the tool at all times.

Stepover Tab

(Rough Pass)
Do rough pass creates a rough operation for ALL milling features.

Depth in the Z direction is a % of the diameter of the cutting tool for each pass.

Spiral is the Tool motion offset from the curve shape and the tool steps over as it moves
radially toward the curve, this step over is a % of the tool diameter. (33% or less is
recommended)

Zig-zag is how the tool travels parallel to X or Y or at an angle, the radial step over is a % of
the diameter of cutter. (Up to 55% is recommended)

(Semi-finish Pass)
Do semi-finish pass is selected if an additional finish pass is needed before the final finish
pass and will be applied to all milling features.

Allowance is the amount of material left for the finish pass.

Bottom Allowance, if required, is the amount left on the bottom for the finisher to remove.

(Finish Pass)
Do finish pass is selected if a finish pass is desired and will be applied to all milling features.

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Milling Machining Configurations/Attributes

Allowance is the amount left by the rougher for finishing.

No. of Passes made by the finish tool, additional passes may be added, they are considered
spring passes the tool does not move in any further then the finish curve.

Overlap is the amount from where the tool ramps on for the finish cut and where it ramps off
when complete.
Finish bottom is selected if fishing the bottom of the feature is desired and Wall pass is
checked if it is to be included.

Spiral is the type of finish toolpath with a % of the tool diameter, radial step over.

Zig-zag is the type of finish toolpath with a % of the tool diameter, radial step over.

Bottom allowance is the amount of material left by the rougher when finish bottom is
selected.

Lead/Ramp Tab

(Horizontal lead/ramp)
Extension distance pertains to Lead moves for cuts with open ends. In the milling feature on
the stepover tab, there are settings to extend the lead onto the feature without having to
extend or change the feature. An arc ramp may be added and a 90 degree approach that is
perpendicular to the arc may also be included.

Lead distance is the distance the tool plunges from the end of the curve and is measured in a
% of the tool diameter.

Lead in angle is the angle to the curve that the tool approaches the feature after plunging. A
90 degree Lead in is perpendicular to the curve.

Lead out angle is the angle to the curve when the tool exits the feature before retracting. A
90 degree Lead out would be perpendicular to the curve.

All Stepover applies the Lead in and Lead out to every step over.

Ramp type is the shape of the transition move when the tool steps over radially. They
include Direct (90 degrees) Arc, Line and S-shape. S-shape provides very smooth transition,
good for hi-speed machining.

Ramp diameter is measured as % of tool diameter and determines the arc size for the radial
step over.

Minimum ramp distance controls the length of the ramp.

Wind fan finish plunges and retracts the finish tool in the same place and ramps on and off
the finish curve in the same place with no overlap. The arc size for ramping may be entered
along with the angle move to the arc. To watch this in centerline simulation, it looks like a
fan you would hold in your hand.

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Milling Machining Configurations/Attributes

(Vertical ramp)
Minimum Z ramp dist is the allowable minimum distance (radially) when ramping has been
selected. It may be 0 and if the tool doesn’t fit when ramping FeatureCAM will plunge
straight down with no ramping to attempt to make it fit.

Max ramp angle is the maximum vertical angle the tool is allowed to plunge (rough op)

Max finish ramp angle is the maximum vertical angle the tool plunges (finish op)

Helical Ramping is a technique that plunges the tool into the material in a helical (circular,
like a screw) motion and may be CW or CCW.

Linear Approx may be used when helical is not applicable. It uses short linear moves for
the helical motions instead of arcs. (also thd milling)

Ramp diameter is the radial size of the helical arc that is used. (thd. milling)

(Arc lead)
Arc lead, Use 90-deg Comp on/off and Distance are associated with Extension distance and
pertains to Lead moves for cuts with open ends.

Misc. Tab
Z rapid plane is the distance measured in the Z positive direction that the tool retracts to
when either moving to the next hole for drilling or moving to another region to continue
milling and usually considered a safe height for clearance of clamps, etc.

Plunge clearance is the distance in the Z direction above the part that a tool will rapid to and
then go into feed rate to plunge or drill to depth.

Tap plunge clearance has the same purpose in a tap operation as for drilling and milling.

Z ramp clearance is the distance above the part in the Z direction that a milling tool feeds
straight down to after plunging to the plunge clearance when ramping is being used so it
doesn’t ramp above the part.

Spline Tolerance parameter controls the maximum deviation of the generated tool path from
the theoretical spline contour.

Z index clearance is applicable on 4 axis indexing parts. When for example a square part is
indexed on a 4th axis table FeatureCAM takes into account the corners being higher than the
flats during index and retracts the tool to the Z index clearance height above the corners
which is safe for the corner to index under any tool.

Wrap tolerance also applicable to 4th axis parts. Certain features can be created flat as
normal and then wrapped around a cylinder on a 4 axis rotary table and this tolerance setting
determines how close.

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Milling Machining Configurations/Attributes

Chamfer depth is how far the point of the chamfer tool goes past the bottom of the chamfer
on the part. This is to make sure the point of the tool uses the full length of the cutting edge
and not give a burr along the bottom edge because the point of the tool is possibly not sharp
to the end.

Deburr radius is automatically applied to a sharp outside corner to remove the burr, for
example on a boss feature where there is no radius on the corner. It can be any size and if
there is any radius whatsoever on the curve of the feature then FeatureCAM ignores the
Deburr radius and the curve radius is applied instead.
Minimize corner radius is used to restrict the maximum size tool that FeatureCAM will pick
when there is a square inside corner with no radius.

Minimum rapid distance is the distance determined by a percentage of the tool diameter as
to whether the tool will feed or retract and rapid to the next region to machined. The smaller
the setting the more retracting, the greater the number the it will feed to the next area to be
machined.

Speed is the percentage of programmed spindle speed that the spindle will run in the
program.

Feed is the percentage of programmed feed rate the tool will feed in the program.

Plunge feed is the percentage of the programmed feed rate that the tool will feed when
plunging.

Use IPR/IPT will use inches per revolution or per tooth instead of inches per minute (IPM).

Proportional plunge feed when selected determines the milling plunge feed rate according
to the angle of ramping while plunging. The steeper the angle the slower the feed rate and
the more shallow the angle the higher the feed rate.

Peripheral Feed has various settings for inside and outside corners during milling to slow or
increase the feed rates to help maintain a more consistent tool load and obtaining the
optimum feed rate.

Post Variables provides the opportunity to pass data directly to the NC code in designated
locations as laid out by the post variables built into the post processor.

Operations Tab

(Ordering)
Automatic Options has four functions:
1) Minimize tool changes attempts to optimize tooling to do all the work for that tool on
the entire part before changing tools, especially helpful when one tool can be used on
several functions or features including 4th axis, more indexing and less tool changes.
2) Do finish cuts last allows all of the roughing of milling features to be completed first
and then does the finish cuts to avoid any possible movement of the part after a finish
cut has been completed.

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Milling Machining Configurations/Attributes

3) Cut higher operations first completes for example a pocket with drilled holes in the
bottom, pocket first then the drilled holes.
4) Minimize rapid distance helps to find the most efficient path for the tooling by
examining the distance of each move and then picking the shortest distance.

Base Priority is when 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 and 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.
Time estimation has six settings including indexing speed of the 4th axis rotary table. If care
is taken to enter accurate figures, a very close estimation of the actual time it will take to run
your part, excluding any operator intervention can be achieved. A stop watch may have to be
used instead of accepting speeds from manuals.

Facing
Do rough pass when roughing passes are desired.

Do finish pass when a finish pass is desired. May be used without rougher.

Finish allowance is the amount of material left by the roughing operation.

Facing stepover is the radial step over perpendicular to the cut direction measured by a % of
the cutter diameter.

Lateral overcut is how far, measured by a % of the cutter diameter, that the tool goes off the
end of the part parallel to the direction of the cut.

Last pass overcut is how far by a % of the cutter diameter, that the tool goes off the part
radially perpendicular to the cut direction on the final pass.

Max depth of cut is the maximum Z increment depth the cutter will take in one pass.

Connect stepovers with arc provides a very smooth transition by changing the direct 90
degree stepover to an arc or loop. This is also a high speed machining technique.

Zigzag angle is the angle that FeatureCAM uses to cut Face features.

Tool Selection

(Counter bore)

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Milling Machining Configurations/Attributes

Use counter bore will select a specific diameter counter bore tool. An inventory of various
sizes of counter bores is usually maintained.

Use endmill will select a milling cutter to cut the counter bore. Eliminates an inventory of
counter bore tools and can cut any size.

Automatic selects and endmill when counter bore tools are being used and the desired
counter bore size is not available.

(Spot drill)
Prefer spot drill is used to cover a wider variety of hole sizes because it has one diameter
and comes to a point.

Prefer center drill is usually selected for spotting a hole to be drilled, short and makes the
initial plunge into the material with no wandering or movement.

Preferred spot drill diameter allows a specific size spot drill to be selected on ALL holes.
Size may be changed when needed.

Optimize spot drill tool selection will attempt to use a tool that will satisfy All holes when
there is a variety of sizes to be drilled. If attempting to chamfer holes when spot drilling one
tool may not satisfy and an additional tool may be selected.

Optimize chamfer tool selection will attempt to use a chamfer tool that will satisfy All holes
when there is a variety of sizes to be chamfered.
Tool diameter tolerance is a value not to exceed when selecting tools, for example, if the
tolerance is set to .002 then if FeatureCAM doesn’t find a tool plus or minus .002 of the
needed size it will show a red flag next to the operation indicating it doesn’t have a tool
within the tolerance.

Drill % of ream/bore determines the size of the drill to be used for a ream or bore operation.

Thread % for tap drill (cut) determines the size of the drill to be used for the tapping
operation to obtain a specific % of thread (example 77%)

Thread % for tap drill (rolled) determines the size of the drill to be used for the tapping
operation to obtain a specific % of thread (example 65%). Rolled threads drilled hole size is
very important because the thread is formed and material is pushed down into the root of the
tap and if the hole is to small it will break the tap and if too large there is not enough to form
an accurate thread.

Tap type lets you select the type of tapping you do most.

Tool % of arc radius (also Toolpath corner % in milling tab) is set to 100 then a tool
equal to the smallest corner radius is selected for a feature such as a pocket. With Toolpath
corner% set to 100 the tool dwells in the corners as it changes direction. This can sometimes
nick the part. To avoid this problem, set Toolpath corner % to a slightly smaller number,
such as 98.

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Milling Machining Configurations/Attributes

Multiple Roughing Tools gives you the opportunity to allow FeatureCAM to select
additional roughing tools when, for example, you have a pocket with small radius corners and
FeatureCAM chooses to rough the entire pocket with the small cutter. When selecting Use
multiple roughing tools from largest to smallest, stopping when the material is gone, you
enter tools that you want FeatureCAM to select from when multiple cutters are necessary to
make the operation efficient. Starting with the largest tool and adding smaller tools separated
by a comma, FeatureCAM will start with the largest tool that will fit. It will also select a
rougher that fits the corner so there will be the same amount of leave allowance in the corners
as there is along the straights. You may also restrict the minimum size tool to use as a
rougher. Remember though that if you are running small parts with small tools you may have
a tool needed in your tool crib for a specific operation but it will never select it for roughing
if it is smaller than the minimum tool diameter.

Surface Leadin
Stepover type is the transition move the tool makes radially to make the next pass (usually
bi-directional) this is perpendicular to the tool path direction.
1) Direct is two 90 degree turns, stopping twice to
change direction of 180 degrees.

2) Loop is a smooth rounding transition which does not

stop to change direction. Good hi-speed technique.

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Milling Machining Configurations/Attributes

(Lead-in/out parameters)
Use lead-in/out:
Never provides no leads, it uses plunge clearance and
plunges to depth.

On all plunges/retracts or On first plunge/last retract

applies the lead type, line or arc, to every plunge and
retract or the first and last only.

On all stepovers, plunges & retracts applies the lead type

to every transition move the tool makes.

Surface normal applies the leads normal to the surface whether horizontal or vertical.

Use arc ramp-in/out allows you to choose the ramp diameter and the ramp in/out
angle.

Use linear lead-in/out allows you to choose the lead-in/out angle and the lead-in/out
length.

Machining Configurations/Attributes 2012 17

Milling Machining Configurations/Attributes

Surface Mill Tab

Tolerance (Rough .005) ( Finish .001) 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.
Scallop height stepovers is the height between passes of a
Ball End Mill 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. The scallop height and
stepover default values may also be entered but can be entered
or changed in individual features also.
Parallel angle refers to parallel tool path strategies. The value of 0 causes the tool to travel
parallel to the X or to the Y axis.
Tool diameter allows a default tool diameter to be selected for Surface Milling
Tool end radius provides the opportunity to select the default for the cutter end, Ball, Flat or
Bull Nose and also the diameter.
Finish allowance is the amount of material left by the rougher for the finisher to remove.
Check allowance is how far away you wish the tool to stay away from selected surfaces or
faces.
(Slope limitation angles)
Horizontal only cuts horizontal surfaces up to a desired slope angle.
Vertical only cuts vertical surfaces above a desired slope angle.
Swarf axial tolerance is for a relatively rare number of geometries where 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.
Edges contains four choices as to how you want the tool to react when it comes to the edge of
a surface or face at the stock.
1) Automatic, depending on the toolpath strategy being used, does much like Don’t roll
over the edges at all and therefore calculates a boundary but if a different boundary is
used such as a curve, FeatureCAM won’t calculate for both.
2) Don’t roll over the edge at all cuts 100 percent cleanly to the edge but does not roll
over the edge.
3) Cut top edge: Just roll over the top edge allows the ball only to roll over the edge.

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4) Cut to bottom: Roll over the top edge and cut to bottom of stock/part basically
turning off all boundaries and letting the tool cut until it runs out of part or stock.

Thread Mill

(Wind Fan)
Wind fan is the same as a milling feature, it can plunge and retract and feed on and off in
same location plus the angle of approach and the ramping radius.

Linear ramping may also be applied using ramp distance, diameter and angle offset.

Feed direction can be either Negative Z or Positive Z.

Feed overrides for ramp in and ramp out.

Passes for Rough and Finish with Rough Stepover, Finish allowance and Spring passes.
Starts may be multiple if desired.
Start angle can be entered if necessary.
Tooth overlap attribute controls the amount that one revolution of a multi-thread tool will
overlap the previous revolution. It is an integer that represents the number of threads. We
recommend that you overlap at least one thread.
Tooth outside is the number of teeth that will be above (if feeding in negative Z) or below (if
feeding in positive Z) the thread mill feature for the first pass.
Taper approx. angle is for tapered threads. The toolpath is increasing in diameter as well
as moving in Z. These moves are approximated with 3D arcs. The Taper approx angle is the
angle around the thread that will be approximated by a single arc. A 360 must be evenly
divisible by the Taper approx angle. For example, if set to 90, a single revolution of the tool
will be broken into 4 arcs.
Feed to depth override may be set to a desired feed rate.
Linear Approx. attribute is associated with Helical ramping and Thread mill features. If
Linear approx is selected, then the arc moves are approximated by linear moves. Helix linear
approx tolerance controls how accurate the approximation is relative to the theoretical spiral.
Set this tolerance to a smaller number to more accurately approximate the spiral.
Cutter comp to apply G40, G41 and G42 to the NC code so the control can adjust size with
tool offset.
Part line program puts the center of the tool on the finish curve and the NC code reads to
print dimensions and all offsetting is done by the control.
Through for thread milling is set if there is no material on the bottom of the thread. If
Through is not set, the toolpaths will be generated to ensure that the tool will not cut past the
end of the thread.

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Milling Machining Configurations/Attributes

Use Finish Tool allows a separate tool to be used as a finisher.

Plunge to center plunges the tool on the center of the hole to assure clearance.

This concludes Machining Configuration/Attributes.

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Machining Configurations/Attributes 2012
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