VisualCAMc is the first full-cloud production ready CAM solution that allows you to perform CAM programming from anywhere and on any computer from your Onshape account. VisualCAMc is currently in a FREE Beta program and is available now from the Onshape App Store. Watch the video below to see how to get VisualCAMc for Onshape. This release from MecSoft Corporation builds upon years of product innovation development of its flagship desktop product, VisualCAM. 

Scroll down this post to find a comprehensive walkthrough of the VisualCAMc beta Production CAM for Onshape app!

https://youtu.be/of7zGwg7VF8

Manufacturers, furniture designers, prototypers, makers and machining enthusiasts all say they use MecSoft’s CAM products for one very simple reason – it’s fast and easy to use! We hear this every time we sit down and talk with our users. To illustrate this point, we have programmed the following 2½ Axis Onshape part in just minutes using the intuitive VisualCAMc User Interface.

What’s New in the VisualCAMc Beta

We’ve added a lot of new functionality to VisualCAMc for this exciting new phase of the beta program. If you’re an existing VisualCAMc beta program user, here’s a quick list of some of the new features and enhancements that you will see. If you’re an existing user from MecSoft’s VisualCAM desktop products, you’re gonna feel right at home with VisualCAMc. And if you’re completely new to VisualCAMc then be prepared to be amazed by amount of production-ready CAM you can now do on the cloud!

Add your Custom Posts

This new release allows you to upload your custom post definition files to use in VisualCAMc. If you’re familiar with or are a current user of our VisualCAM desktop products then you know that these enhancements are key to getting your production CAM jobs done quickly and out to your CNC machine tools without a hassle. 

Even more Toolpath Strategies!

This release adds even more toolpath strategies to choose from. Here are the 2-1/2 Axis, 3 Axis and Holes menus now available in the latest VisualCAMc beta release:

2-1/2 Axis, 3 Axis and Holes toolpath strategy menus

Even More Control Parameters & Options!

Every VisualCAMc toolpath strategy has been enhanced with an even more extensive array of control parameters to choose from. Below we see just a portion of the 3 Axis Z Level Roughing and 2-1/2 Axis Pocketing parameters menus. Additional tabs are now available to hold all of the options and control parameters available. 

3 Axis Z Level Roughing Parameter Tabs

2-1/2 Axis Pocketing Parameter Tabs

2-1/2 Axis Walkthrough

In the following section we take you on a VisualCAMc test-drive to program a simple Fixture Plate using 2½ Axis machining strategies. You quickly realize that the wizard-driven machining browser in VisualCAMc makes programming easy and painless. Each of the Parameters tabs contains default values that work well for most cases but can be adjusted to suit your machining needs. We begin with a review of the Part & Setup procedure, then move on to selecting and generating the toolpaths strategies needed to cut this part. We then wrap up with creating the posted g-code file that will be sent to the CNC machine to cut the part. For a 3 Axis Walkthrough, see our previous blog article How to Generate G-Code For Onshape Models From Anywhere in Minutes.

If you’re ready let’s get started!

The Part & Setup

In the illustration below we see our Fixture Plate part being setup in VisualCAMc. This process includes defining the Machine, Post, Stock and Work Zero definition. The Machine defines the orientation of the part on the table of the machine tool. The Post defines the post-processor that matches the controller on the CNC machine. You can choose from over 300 available posts supporting the most popular machine controllers. The stock defines the length, width and height of the material you are cutting and the Work Zero defines the machine home position on the stock. The VisualCAMc Toolbar located across the top of the screen provides easy access to each of these tools.

Defining the Machine, Post, Stock and Work Zero in VisualCAMc

Your Machining Job tree will now look like this

The Machining STRATEGY

VisualCAMc offers a complete set of 2½ and 3 Axis machining strategies. For this part we will be using the 2½ Axis Facing, Pocketing, Slotting, Drilling and Profiling strategies. Our Fixture Plate is ⅜” thick with pockets, slots and holes. We will be cutting these features in two levels of 0.188” deep for each cut level. The holes will be drilled through. For a sample 3 Axis part we invite you to visit our previous blog post titled: How to Generate G-Code For Onshape Models From Anywhere in Minutes. The animations below illustrate how easy it is to program each of these toolpaths strategies using VisualCAMc.

Selecting Machining Regions

Machining Regions for an operation can be selected at any time while the operation dialog is displayed but before you select the Generate Toolpath button. You can select an Onshape sketch or surface edges of the part. You will notice that right-clicking on an edge will automatically select the entire chain of edges. In the future, if you do not want to chain-select, just select using a left-click and only one edge will be selected at a time.

Selecting Machining Regions in VisualCAMc

2½ Axis Facing

The Facing strategy is used to machine the top of the FixturePlate to ensuring that it is nice an flat. A ½” diameter flat End Mill is used for this cut that is contained to the outer perimeter of the part. For facing larger parts you can also use Face Mill cutting tools. In the General Parameters section we can set Global Parameters such as Tolerance and Stock allowance. Here we can also set the Cut Pattern, Cut Direction and Stepover Distance among other parameters. 

The Cut Levels tab is used to control where the cut begins and its Z depth values. The Entry/Exit tab controls how you want the cutting tool to approach and engage at the start of the cut and how it should depart and retract at the end of the cut. Linear, radial and ramp motions are supported. On the Advanced tab, we will use the Cut Corner Rounding option. This will eliminate any sharp corners in the toolpath, extending the life of your cutting tool and also reducing vibration during cutting which in turn helps to extend the life of the mechanical components of your CNC machine!

2½ Axis Facining clears the top of the part to the selected perimeter region

Your Machining Job tree will now look like this

2½ Axis Pocketing

Pocketing is used to machine the large center cut out on the Fixture Plate using a ¾” diameter End Mill. With the High Speed Cut Pattern, 60% stepover and Cleanup Passes at each cut level, this strategy makes clean and fast work of cutting this pocket. Like the plate, the pocket depth is ⅜” passing through the part and will be cut using two levels each 0.188” deep. 

Here is a look at each of the six available Pocketing cut patterns in VisualCAMc. The Offset Spiral, Linear and High Speed patterns are shown with a perimeter clean up pass.

Pocketing Cut Patterns in VisualCAMc

2½ Axis Pocketing with the High Speed Cut Pattern

Your Machining Job tree will now look like this

2½ Axis Slotting

The Slotting toolpath strategy is used to cut the two slot cut-outs on the front end of the Fixture Plate. The width of the slots is 0.61” and we will use 0.61 diameter” End Mill to cut them. Similar to the Pocketing toolpath operation shown above we will cut ⅜” deep at two cut levels each at 0.188” deep. Notice the option to Determine open/closed ends using 3D Model. This allows you to machine many slot configurations even if they pass completely through the end of the part (referred to as an open slot).

2½ Axis Slotting, single pass, multi-level using a Flat End Mill

Your Machining Job tree will now look like this

2½ Axis Drilling

For the two holes located at the back of the Fixture Plate we will use the Drilling operation and a ⅜” diameter drill. VisualCAMc now supports Standard Drill, Deep Drill, Countersink Drill, Breakchip Drill and four User Defined Drill cycles! To demonstrate, we will use the Breakchip Drill option with a ⅛” peck step increment. We will cut ⅜” deep and automatically add the drill tip thickness to the depth of cut ensuring a complete through hole is machined.

Drill Types supported in VisualCAMc

Breakchip Drilling ⅜” diameter through holes with a peck increment of ⅛”

Your Machining Job tree will now look like this

2½ Axis Profiling

Now let’s Profile cut the outer perimeter of the Fixture Plate using a ⅜” diameter Flat End Mill. We will set our Stock value to zero and set Compensation to AUTO/ON. With Compensation enabled, the posted g-code will enable the Haas controller’s cutter compensation register. Again we will cut two levels at 0.188” each using linear entry exit motions.

More about Cutter Compensation

Cutter Compensation is used to compensate for the difference in the dimensions of the actual cutter used in machining and the cutter used for programming in VisualCAMc. You will notice that the cutter we use in VisualCAMc is a 0.500 inch diameter end mill. Let’s say for example, that due to tool wear, the actual cutter on your CNC machine is only 0.495 inches in diameter. The offset difference of 0.005” for this tool can be compensated for in your CNC controller rather than you having to program the operation again in VisualCAMc. 

Cutter Compensation offsets on CNC controllers is often used in volume production machining when tool wear affects critical part dimensions. In production, the CNC operator will check (with a calliper, micrometer or other calibrated measuring device) critical part dimensions. This is done after the initial setup AND after every tool change. It is referred to as a first-piece-inspection. If the machined part dimension measures outside of the allowable tolerance range, the operator will adjust the offset value for that tool on the controller, machine another part and check the measurement again before continuing with production. The procedure is also typically performed after every 100 parts machined. 

What you should know before enabling Cutter Compensation Here are some additional things you should know before enabling Cutter Compensation in your toolpaths: Make sure your controller supports the following codes: (G40) Compensation OFF (G41) Tool Radius Compensation Left and (G42): Tool Radius Compensation Right. Cutter Compensation only makes sense in 2½ axis toolpath operations. If you are using roughing (pocketing and facing) the compensation will be turned on only during the final pass. Make sure you are not using a Zig-Zag cut traversal (also referred to as a Mixed Cut Direction) in any of the methods that you want to turn compensation on. See our blog article titled Understanding Climb vs. Conventional Milling for more information about Cut Direction. Make sure you begin with a linear motion whose length is at least equal to the diameter of the cutting tool you are using. If your first motion is an arc, the controller will not be able to turn on the compensation. Thus, in 2½ axis profiling, make sure there is a linear entry motion.

Your Machining Job tree will now look like this

Toolpath Simulation

Now that all of the required toolpaths are complete its time to perform a toolpath simulation. During the simulation, each tool motion type is listed along with the GOTO coordinates used.

Post Processing

Once the toolpaths are generated and simulated and we are happy with the toolpaths we programmed, we’re ready to post g-code for our Haas controller. Once post processing is complete, the g-code file is downloaded to my local computer and displayed in notepad where I can review it prior to running it on the CNC machine.

Let’s Review:

1. The Setup procedure is the machine environment unique to the part you are machining. It defines the Machine, Post, Stock and Work Zero.
2. The machining strategies used for this Fixture Plate were Facing, Pocketing, Slotting, Drilling and Profiling. The Pocketing, Slotting and Profiling were machined in two cut levels each. The Drilling was performed using a Breakchip method at ⅛” Peck Increments.
3. Each toolpath was simulated and the entire Setup was posted to a g-code file for the Haas controller, downloaded to my computer and displayed in notepad for my final review.

For More Information

If you want to learn more about the VisualCAMc Milling plugin for Onshape, check out our Products Page, Tech Blog and YouTube Channel playlist for what’s new, specifications, videos, tutorials and more! To join the VisualCAMc Beta program, go to the Onshape App store and add VisualCAMc to your Onshape account. Enjoy!

MecSoft Corporation joined Onshape for The Pacific Design & Manufacturing Expo February 6-8, 2018 at the Anaheim Convention Center, Anaheim, CA where VisualCAMc for Onshape was on full display. VisualCAMc is currently in a free beta program and is available now in the Onshape App Store. 

Onshape attracts attention from attendees at the PDES show in Anaheim, Feb 6-8, 2018

Jon Hirschtick, one of the founders of Onshape, talking cloud CAD and CAM with Uday, MecSoft’s Technical Support Manager and some attendees at the PDES show, Feb 6-8, 2018 in Anaheim, CA.

What is VisualCAMc

VisualCAMc is the first full-cloud, production-ready CAM solution that allows you to perform CAM programming from anywhere and on any computer from your Onshape account. VisualCAMc is currently in a free beta program and is available now in the Onshape App Store. 

This release from MecSoft Corporation builds upon years of product innovation development of our flagship desktop product, VisualCAM. Manufacturers, furniture designers, prototypers, makers and machining enthusiasts all say they use MecSoft’s CAM products for one very simple reason – they are fast and easy to use.
 

Read what a VisualCAMc subscriber has to say about VisualCAMc below:

“I’ve been really happy with the continued support that I am receiving from MecSoft as the VisualCAMc Beta is being further developed. I have worked a wide range of aviation and aerospace jobs over the past 30 years from Aerospace Engineer to Aircraft Mechanic. This is my first real venture into the Computer Aided Manufacturing (CAM) field. The integration with OnShape has been intuitive and relatively easy to learn. Within a couple hours I was able to import parts and being routing sheet metal on our Industrial CNC 203 unit.”

Chris Shearer, PhD

Veth Research Associates, LLC

www.vethresearch.com

Try VisualCAMc Yourself

If you want to learn more about the VisualCAMc Milling plugin for Onshape, check out our Products Page and YouTube Channel for what’s new, specifications, videos, tutorials and more. To join the free VisualCAMc Beta program, go to the Onshape App store and add VisualCAMc to your Onshape account. Watch the video below to learn how to add VisualCAMc to your Onshape document. Enjoy!

Irvine, CA, Feb 22, 2018: MecSoft Corporation, the developer of industry leading CAM software solutions, has announced the availability of RhinoCAM 2018 for the newly released Rhinoceros 6 product. 

Users have the option now to choose RhinoCAM 2018 to either run inside Rhinoceros 5 or the newly released Rhinoceros 6. Each of these versions of RhinoCAM 2018, RhinoCAM 2018 for Rhino 6 and RhinoCAM 2018 for Rhino 5 are separate products and can be bought and licensed individually. Alternatively, users have the choice of purchasing a bridge license that will allow them to run both versions.

“Rhino 6 from McNeel & Associates is one of the most anticipated version upgrades to this popular CAD and Design Modeling platform to date. As their longtime partner, MecSoft is proud to announce that our latest CAM plug-in RhinoCAM 2018 now runs inside Rhino 6.0.,” stated Joe Anand, President and CEO of MecSoft Corporation.

Free demo software of RhinoCAM 2018 for Rhino 6.0 can be downloaded here

About MecSoft Corporation

Headquartered in Irvine, California, MecSoft Corporation is a worldwide leader in providing Computer Aided Manufacturing (CAM) software solutions for the small to mid-market segments. These solutions include products VisualCAD/CAM®, RhinoCAM, VisualCAM for SOLIDWORKS® and AlibreCAM®. These software products deliver powerful, easy-to-use and affordable solutions for users in the custom manufacturing, rapid prototyping, rapid tooling, mold making, aerospace, automotive, tool & die, woodworking, and education industries.

For the latest news and information, visit mecsoft.com or call (949) 654-8163.

Many of you have asked and now the wait is over! RhinoCAM 2018 now supports Rhino 6 for Windows! You can download and evaluate RhinoCAM 2018 here. Rhino 6 is one of the most anticipated and long-awaited version upgrades to the popular Rhinoceros CAD and Design Modeling platform to date. Rhino 6 includes many new features and thousands of usability enhancements. Grasshopper is now a part of Rhino! You will find many enhancements in the areas of Presentation, Display, Documentation, Licensing & Administration, Make2D, Refinements, Development Platform and Serengeti.

RhinoCAM 2018, with its impressive array of new features and enhancements, now fully supports Rhino 6. By far the most exciting new RhinoCAM 2018 enhancement is Automatic Feature Machining (AFM) that allows you to completely automate your machining tasks. AFM unlocks the feature-rich information hidden within 3D solid models and allows you to apply the CAM knowledge rules that are unique to your machining processes. 

Here are some recent posts that tell you more about Feature Machining in RhinoCAM 2018:

• New Feature Machining in 2018!
• Automatic Feature-Machining (AFM) Walk-Through
• Automatic Feature Detection (AFD) Walk-Through

RhinoCAM 2018 running inside Rhino 6 showing Cut Material Simulation of Center, Deep and Chamfer Drilling, 2½ Axis Pocketing & Chamfering, 3 Axis Horizontal Roughing and 3 Axis Parallel Finishing.
Watch the video version here!

More about this RhinoCAM Part

Here are some CAM programming details about the cut material simulation shown above created in RhinoCAM 2018 and Rhino 6. Enjoy!

Part Geometry: NURB Surfaces, Containment Geometry: 2D Curves, Stock definition 42” x 35” x 2.625”	Hole Machining, 0.125” dia. spot drill, 1” dia. deep drill, 0.1 peck increments, 1.25” dia. countersink drill, directional sort, 4 holes total
2½ Axis Pocketing, 0.500” dia. End Mill, Offset pattern, 25% Stepover, Climb cut, Cleanup Pass, 2.125” deep at 0.5” cut levels, Zero Stock, Ramp entry and Linear exit	3 Axis Z-Level Roughing, 0.5” End Mill, Mixed cut, Facing/Offset pattern, 25% Stepover, 50% Stepdown, 0.1” Stock, shown in Z Level Display
3 Axis Parallel Finishing, 3 degree C-Radius Taper Mill, Mixed cut, 25% Stepover, Linear entry/exit, with cut containment	2½ Axis Chamfering, 45 degree V-Mill, 0.25 deep, 0.125” cutting width and 0.0625” Stepover

More about RhinoCAM 2018

If you’re new to RhinoCAM, have a look at our RhinoCAM Product Page, RhinoCAM Data Sheet and What’s New in RhinoCAM 2018 documents. Want more? Have a look at the following RhinoCAM 2018 videos or visit our RhinoCAM 2018 video playlist here. RhinoCAM 2018 now includes our RhinoCAM-NEST and RhinoCAM-ART modules at no additional cost!

What’s New in 2018 Webinar Replay

RhinoCAM 2018 (AFM) Quick Start

More about RhinoCAM Configurations

RhinoCAM – MILL is available in 5 different configurations (Express, Standard, Expert, Professional and Premium). The parts shown here were programmed using the Expert configuration. Here are some additional details about each of the available configurations. For the complete features list, visit the RhinoCAM Product Page.

• RhinoCAM MILL Express: This is a general purpose program tailored for hobbyists, makers and students. Ideal for getting started with CAM programming. Includes 2 & 3 axis machining methods. Includes ART & NEST modules as well!
• RhinoCAM MILL Standard: This configuration includes everything that is in the Express configuration and additional 2-1/2 Axis, 3 Axis & Drilling machining methods.
• RhinoCAM MILL Expert: Suitable for 4 Axis rotary machining. Includes the Standard configuration plus 4 Axis machining strategies, advanced cut material simulation and tool holder collision detection.
• RhinoCAM MILL Professional: Ideal for complex 3D machining. Includes the Standard and Expert configuration plus advanced 3 Axis machining strategies, 5 Axis indexed machining, machine tool simulation, graphical toolpath editing and a host of other features.
• RhinoCAM MILL Premium: Tailored for complex 3D machining with both 3 Axis and full 5 Axis methods. Includes the Standard, Expert and Professional configurations plus 5 Axis simultaneous machining strategies.

The Warren Group located in Santa Fe Springs CA, designs and manufacturers prototype and production packaging solutions for the industrial, automotive and consumer products industries. For the past seven years, The Warren Group has relied on VisualCAM for SOLIDWORKS to program the toolpaths they need to drive their two 5×10 Multicam CNC machining centers.

The Warren Group also designs and machines their own tooling used in the production of thermoformed packaging products. In the example shown here, VisualCAM for SOLIDWORKS is used to produce the toolpaths required to machine this mold block from RenShape® Tooling board on the company’s 3 Axis MultiCAM CNC machining center. The completed mold is used to manufacture the thermoformed 0.020” clear PVC packaging for this product.

Let’s have a closer look.

3 Axis Roughing

In the illustrations below we see the 3 Axis Horizontal Roughing toolpath that VisualCAM calculated was needed to rough out the 3” thick piece of RenShape® Tooling board using a ⅜” diameter end mill. The Cut Parameters include a Stock allowance of 0.025”, an Offset Cut Pattern, Mixed Cut Direction, and a 0.125” Stepover. Cut Level Parameters include a 0.375” Stepdown, Depth First cut level ordering and a Bottom Z limit of -2.375”. For Engage/Retract, a Path motion is used with a linear extension of 0.275”. Cut Arc Fitting is applied at each Z level. The estimated machining time is 38 mins.

Here we see VisualCAM performing the cut material simulation for the actual 3 Axis Horizontal Roughing toolpath used to produce this mold. In the initial toolpath display you will see the arc motions displayed in dark blue.

Here we see the Z Level Display dialog showing us that a total of 7 levels are used and that the 4th level (at -1.475) is displayed.

2½ Axis Finishing

To begin the finishing process a series of 2½ Axis toolpath strategies (Pocketing, Profiling & Engraving) are used to machine the top and bottom base flanges using a ¼” end mill. Pocketing is used to machine the flange surfaces to a finished Z depth. Profiling and Engraving are used to clean up the edges between the top and bottom flanges. The toolpaths for these operations are shown together below.

2½ Axis Finishing Toolpaths, Pocketing, Profiling & Engraving

3 Axis Finishing

For the final finishing four separate 3 Axis Parallel Finishing toolpath strategies are used. Each follows the part surfaces in the Z Axis. The first two cut along the X axis zero direction using part boundary offsets of 1/16” and 1/32” as containment. Cut Parameters include Tool: 0.0625” radius 2 degree carbide Taper Mill, Tolerance: 0.001”, Stock: zero, Cut Direction: Mixed, Angle of Cuts: 0 (zero), Stepover: 10% (of the tool diameter), Z Containment Limit: -2.375, Linear Entry/Exit and Straight Cut Connections. The estimated machining time for the first two operations is just under 15 mins. The second two are identical except that they follow the Y Axis 90 degree direction and are completed in 12 mins.

3 Axis Parallel Finishing at zero degrees using 1/16” Part Offset

Here we see VisualCAM performing the cut material simulation for the initial 3 Axis Parallel Finishing toolpath. A total of four finishing toolpaths are used, two running at zero degrees (X) and two at 90 degrees (Y).

Machining Operations Information

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A special thanks to The Warren Group for allowing us to share their VisualCAM success story!

More about The Warren Group

The Warren Group specializes in custom packaging, displays and signage for the industrial, automotive and consumer products industries from their 15,000 square foot facility in Santa Fe Springs CA. From concept & design to prototype & production The Warren Group uses only the best CAD/CAM tools and software on the market, including VisualCAM-MILL for SOLIDWORKS! For more information about The Warren Group we invite you to visit them online at www.studiotwg.com.

One of the The Warren Group’s Multicam CNC Machining Centers in action.

The Warren Group located in Santa Fe Springs, CA, designs and manufacturers prototype and production packaging solutions for the industrial, automotive and consumer products industries. For the past seven years, The Warren Group has relied on VisualCAM for SOLIDWORKS to program the toolpaths they need to drive their two 5×10 Multicam CNC machining centers.

For packaging design & drafting, The Warren Group uses Impact from Arden Software, a database driven packaging design application. Once the design is complete, 2D flat patterns are opened in VisualCAM for SOLIDWORKS, a fully integrated, Gold Certified SOLIDWORKS partner application. The Warren Group takes advantage of VisualCAM’s ability to create custom knowledge bases that capture the CNC knowledge specific to their manufacturing processes. A typical packaging design is shown below.

Impact from Arden Software is used to design corrugated packaging. Here we see the flat pattern of a corrugated display package.

VisualCAM for SOLIDWORKS is used to produce toolpaths automatically from the company’s CNC Knowledge Bases. The G-Code posted from VisualCAM drives both of the company’s Multicam CNC Routers. This lettering is cut from PVC sheet stock to be mounted on the front face of the corrugated packaging design shown in Impact above.

Here we see the a prototype of the corrugated packaging and lettering cut with VisualCAM toolpaths.

A special thanks to The Warren Group for allowing us to share their VisualCAM success story!

More about The Warren Group

The Warren Group specializes in custom packaging, displays and signage for the industrial, automotive and consumer products industries from their 15,000 square foot facility in Santa Fe Springs CA. From concept & design to prototype & production The Warren Group uses only the best CAD/CAM tools and software on the market, including VisualCAM-MILL for SOLIDWORKS! For more information about The Warren Group we invite you to visit them online at www.studiotwg.com.

One of the The Warren Group’s Multicam CNC Machining Centers in action.

Christopher Dungey of Grand Junction, CO has been hand crafting cellos since 1979. In 2015 Chris purchased a Laguna IQ HHC 3 Axis CNC machining center and RhinoCAM. Chris will readily admit that even with some automation, it still takes 400-600 hours of labor and love to craft a Christopher Dungey Cello with #116 being completed as we speak, within the span of his 40-year career. 

However, cello making is an arduous profession that wreaks havoc on the upper arms, wrists and joints forcing short careers on many of his colleagues. With the help of RhinoCAM, Chris is able to automate the task of bulk material removal that 200 years ago would have been performed by apprentices. Chris has agreed to share with us a few of the RhinoCAM techniques he uses in this process. 

Part & Setup

Chris has spent a considerable amount of time reviewing and tweaking his 3D CAD models until they represent the perfect form that make his cellos unique. In image (a) below on the left we see the top side of the cello as a Rhino 3D part model. Notice the curvature in the front elevation. On the right image (b) we see the stock model in RhinoCAM. The holes at the north and south ends are for alignment while those located east and west are for fastening the stock to the table of the CNC machine.

Please note that all dimensions mentioned below are in inches. 

(a) Cello Top & Front Elevation

(b) Stock (600 x 900 x 33.5), Alignment & Mounting

Roughing

It is important to note here that the CNC machine is ONLY used for the bulk removal of excess wood. The final finishing work is all done by Christopher Dungey’s own two hands (see Hand Finishing below). 

Now for the tech talk: In the first image (a) below we see a 2½ Axis Profile roughing operation using a 12.5 diameter Ball Mill with the XY Stock allowance set to 3.0 mm and Cut Direction set to Conventional (Up Cut). The Z depth of this profiling operation leaves a 7.0 mm thickness at the base of the stock and two rectangular bridges (20 long x 7 high) at the north and south locations. Refer to the Rough Finishing section below to see the Bridges & Tabs clearly. 

The next two operations shown in images (b) and (c) are an interesting use of 3 Axis Parallel Finishing, but used as roughing, again with a 12.5 diameter Ball Mill. In the first operation (b) Chris has a stock allowance of 2.0, a Mixed cut direction, a 46% Stepover and then sets the Lowest Z Containment to 23.0.

This is followed by the same operation (c) but with Stock at 1.5 and the Lowest Z set to 13.5. Both (b) and (c) have Engage and Retract motions set to Linear but with zero length and Approach and Departure motions set to 0.6. This allows the tool to start cutting while centered on the inner edge of the stock left from the previous Profiling operation.

(a) 2½ Axis Profile Roughing	(b) Parallel Roughing with Z Limit (Level 1)
(c) Parallel Roughing with Z Limit (Level 2)

Rough Finishing

In these next series of images we see the final 3 Axis Parallel Finishing operation and the final 2½ Axis Profiling operation. The Parallel Finishing (a) is identical to the two shown above but with Stock and Z Limit both set to 0.0 and Stepover reduced to 12%. In (b) the second Profiling operation is shown, this time with the XY Stock allowance set to zero and the rectangular bridges (north & south) set to 25 long by 6 high. The north end bridge is shown in image (c). Also notice the scalloping of stock material left on the part shown in image (d). This is by design. The final exterior cut is done completely by hand (see Hand Finishing below).

(a) Parallel Finishing	(b) 2½ Axis Profile Finishing
(c) 2½ Axis Profile Finishing w/Bridges & Tabs	(d) Scalloping of Stock is left for Hand Finishing

Hand Finishing

Regardless of the use of modern CNC machine tools for bulk material removal, a Christopher Dungey Cello is a finely crafted instrument. The images below show you all you need to know about the quality, skill and craftsmanship incorporated into each and every Christopher Dungey Cello.

A Christopher Dungey Cello

Here are images of a completed Christopher Dungey Cello.

More about Christopher Dungey Cello Maker

We want to thank Chris for allowing us to share his story of a modern day Cello Maker and RhinoCAM! To see the completed handcrafted cello shown above, you’re invited to read more about Chris and RhinoCAM here:

• Case Study: RhinoCAM & Chris Dungy Cello Makers Inc.

To learn more about Christopher Dungey and his passion and talent for cello making, we invite you to visit his website at www.dungeycello.com and on Facebook. We also invite you to hear a Christopher Dungey Cello at these video links:

• Lynn Harrell’s 100th Birthday Tribute to Orlando Cole
• Andante (A Short Film)

Christopher Dungey of Grand Junction CO has been handcrafting cellos for the past 40 years just like mater crafters have done for hundreds of years. However, Chris realized early on that if he wanted to stay in the business of cello making he was going to have to incorporate machinery into the art and craftsmanship. In the early days he added band saws, planers, drill presses and even a pantograph at one time.

Then in 2015 Chris purchased a Laguna IQ HHC 3 Axis CNC machining center. For CAD Chris chose Rhinoceros for its ability to model the organic shapes that his cellos needed. RhinoCAM was then the obvious choice for toolpath generation because of its seamless integration with Rhino. Here are some photos from Christopher Dungey Cello Maker Inc. Enjoy!

Here we see RhinoCAM 2018 and a Parallel Finishing operation used as a material-removal roughing toolpath. In this operation the Stock to leave is set to 1.5 and the Z Limit is set to 13.5. A 12.5 diameter Ball Mill is used with a Stepover of 46%.

RhinoCAM is only used for bulk material-removal on the top and bottom of the cello. The finishing is all done by Chris’s own two hands, using the same techniques master crafters have employed for hundreds of years of cello making!

More about Christopher Dungey Cello Maker

We want to thank Chris for allowing us to share his story of a modern day Cello Maker and RhinoCAM! To see the completed handcrafted cello shown above, your invited to read more about Chris and RhinoCAM here:

• Case Study: RhinoCAM & Chris Dungy Cello Makers Inc.
• Blog: RhinoCAM assists in Cello Making Craft 

To learn more about Christopher Dungey and his passion and talent for cello making, we invite you to visit his website at www.dungeycello.com and on Facebook. We also invite you to hear a Christopher Dungey Cello at these video links:

• Lynn Harrell’s 100th Birthday Tribute to Orlando Cole
• Andante (A Short Film)

Irvine, CA, April 9, 2018: MecSoft Corporation, the developer of industry leading CAM software solutions, has announced the availability of VisualCAM 2018 for SOLIDWORKS, the latest version of MecSoft’s fully integrated Gold Certified CAM solution for SOLIDWORKS.  

VisualCAM 2018 for SOLIDWORKS now includes the ability to run inside the Assembly document of SOLIDWORKS. A picture of this is included below:

Other release highlights include:

• 2 ½ Axis – Automatic Feature Detection & Automatic Feature Machining
• 3 Axis – Horizontal Finishing follow containment, performance & stability improvements
• 4 Axis – Create Round Stock method & Helical Milling
• 5 Axis – Use 5 Axis continuous programming methods for 4 axis machining
• Productivity and User Interface enhancements

“The newly released ability to perform CAM programming inside an Assembly document of SOLIDWORKS opens up significant productivity improvements for our users.  This in addition to the innovations such as Automatic Feature Detection (AFD) & Automatic Feature Machining (AFM) along with the addition of new toolpath methods and enhancements to existing methods have been introduced.  MecSoft continues to deliver functionality only found only in products costing thousands of dollars more”, stated Joe Anand, President and CEO of MecSoft Corporation.

Free demo software of VisualCAM 2018 for SOLIDWORKS can be downloaded here.

About MecSoft Corporation

Headquartered in Irvine, California, MecSoft Corporation is a worldwide leader in providing Computer Aided Manufacturing (CAM) software solutions for the small to mid-market segments. These solutions include products VisualCAD/CAM®, RhinoCAM, VisualCAM for SOLIDWORKS® and AlibreCAM®. These software products deliver powerful, easy-to-use and affordable solutions for users in the custom manufacturing, rapid prototyping, rapid tooling, mold making, aerospace, automotive, tool & die, woodworking, and education industries.

For the latest news and information, visit mecsoft.com or call (949) 654-8163.

If you’re new to VisualCAMc, MecSoft’s Full-Cloud based Production CAM solution for Onshape, then you may not fully understand yet how your VisualCAMc toolpaths are associatively linked to your Onshape part model. In this blog we will take you through the steps needed to update your toolpaths automatically after making sketch and feature edits to your Onshape part.

Here are the basic steps. In the example below, changes made in Onshape, are automatically propagated to the VisualCAMc toolpaths!

Basic Procedure

1. Load a Part from Onshape into VisualCAMc and create your toolpaths. The sample part below has three toolpaths created (2-1/2 Axis Facing, 2-1/2 Axis Profiling and Hole Drilling).

Original Onshape Part	VisualCAMc Part w/Facing Toolpath
VisualCAMc Part w/Profiling Toolpath	Hole Drilling

2. Select the Part Studio tab to display your Onshape part.

3. Right-click on an Onshape sketch and select Edit.

4. Now select Top from the Onshape View Cube to see the sketch more clearly.

The View Cube

5. Edit a few sketch dimensions and then pick the check-mark to accept the sketch. We edited the coordinate location of all of the holes as well as the outer perimeter dimensions.

Current Onshape Sketch	Modified Onshape Sketch
Select the checkmark icon in the sketch editor to accept and close the sketch.

6. The Part will rebuild. Now select the Isometric View icon from the Onshape View bar to display the Isometric view.

TOP VIEW

Change to Isometric View

Isometric View

7. Now select the VisualCAMc tab.

8. Select the Load a Part button and reload your part model.

9. First lets update our Part Bounds Stock. Double left-click on the Stock icon in the Machining Job tree to display the Part Bounds Stock dialog. From this dialog pick the Calculate Geometry button and then pick the Save button. The new stock size will display on the part.

Part Bounds Stock dialog

New Part Bounds Stock Displayed

10. Because our Stock dimensions are changed, you will notice that our Work Zero now defaults to the WCS origin of our Onshape Part. Let’s change it back to where we had it (See the image in step 1 above). Double-left-click on the Work Zero icon in the Machining Job to display the dialog.

11. From the Work Zero dialog, select Set to Stock Box, Highest Z and the South West and then pick Save. This place the Work Zero where we had it before.

Work Zero is Updated

12. You will notice all of our toolpath operations are flagged as dirty to remind us that they need to be regenerated.

13. Just right-click on the Machining Job and select Regenerate. All of our toolpaths are recalculated from the updated part.

14. Selecting each operation from the Machining Job tree will display the updated toolpath based on the dimensional changes we made to the Onshape Part model.

Revised Onshape Part	2-½ Axis Facing Updated
2-½ Axis Profiling Updated	Drilling Toolpath Updated

Try It Yourself

If you want to learn more about the VisualCAMc Full-Cloud based Milling plugin for Onshape, check out MecSoft’s Products Page, Tech Blog and YouTube Channel for what’s new, specifications, videos, tutorials and more. To join the free VisualCAMc Beta program, go to the Onshape App store and add VisualCAMc to your Onshape account. Enjoy!

Try VisualCAMc For Onshape

This powerful cloud-based CAM tool works directly inside your Onshape Documents.

A tool holder collision on a cutting CNC machine can be costly and dangerous! That’s why MecSoft’s CAM plugins provide Tool Holder Collision detection in the Standard (STD) and higher configurations. If you’re a MecSoft CAM user (of VisualCAD/CAM, RhinoCAM, VisualCAM for SOLIDWORKS or AlibreCAM) this blog post will show you how to detect, recognize and correct Tool Holder Collisions before they reach your CNC machine!

Watch the video version of this blog post here!

What is a Tool Holder Collision?

As the name suggests, the tool holder is the tool that holds your actual cutting tool (End Mill, Ball Mill, Face Mill, etc.) to the rotating spindle of your CNC machine. A Tool Holder Collision is when the spindle of your CNC machine attempts any motion that causes the tool holder to come in contact with your workpiece. As you might expect a tool holder collision can cause considerable damage to your CNC machine not to mention bodily harm to the CNC operator!

Visual Tool Holder Collision Detection During Cut Material Simulations

During a cut material simulation, if the tool holder makes ANY contact with the workpiece, the computed area of contact is displayed in red on the simulated stock. This is illustrated in the 2-½ Axis Pocketing toolpath shown in the illustrations below. This feature is part of the Visual Tool Holder Collision capability and is available in Standard (STD) and higher configurations of MecSoft’s PC-based CAM Milling plugins.

NOTE: To avoid Tool Holder Collisions, ALWAYS perform and review a Cut Material Simulations on ALL toolpaths you plan to post to your CNC machine!

A 2-½ Axis Pocketing toolpath with the tool and tool holder located at the start of the first cutting motion.

During a cut material simulation if the tool holder makes contact with the workpiece, the Visual Tool Holder Collision area is displayed in red.

To Display the Tool Holder

If you do not see the Tool Holder during cut material simulations, make sure that you have it displayed. Check the display toggle at the base of the Machining Browser when the Simulate tab is selected. Also on the CAM Preferences dialog, make sure the checkbox to Display Tool Holder During Simulation is checked. This icon and checkbox are shown below with the Simulate tab on the left and the CAM Preferences dialog on the right.

The Simulate tab provides access to the Holder Visibility icon and the Simulation Preferences dialog.

Select Simulation from the CAM Preferences dialog to enable the Tool Holder Display checkbox.

Visual Tool Holder Collision Detection in the Machining Job Tree

If a Tool Holder Collision occurs, the operation in the Machining Job tree is flagged. If you expand the operation folder you will see that the Toolpath icon is also flagged. An example of these flags are shown below. This feature is part of the Visual Tool Holder Collision capability and is available in Standard (STD) and higher configurations of the product. 

If you see ANY of these flags in your Machining Job after a Cut Material Simulation, and are running the Professional (PRO) or Premium (PRE) configuration, go to the section below called How to Compute & Correct Tool Holder Collisions and follow the steps to take corrective action. If you are running the Standard (STD) or Expert (EXP) configuration, edit the Tool Length of the flagged operation and rerun the simulation.

Toolpath operations that contain Tool Holder Collisions are flagged in the Machining Job tree.

Visual Tool Holder Collision Detection in the Toolpath Viewer/Editor

You can gather additional information about a Tool Holder Collision. Just double-left-click on the Toolpath icon in the Machining Job tree. This will display the Toolpath Viewer/Editor. Each motion that has caused a Tool Holder Collision will be flagged. If you left-click on a flagged toolpath motion, the tool will display graphically on the screen at that collision point. Again, this feature is part of the Visual Tool Holder Collision capability and is available in Standard (STD) and higher configurations of the product.

Double-left-click on the Toolpath icon to display the Toolpath Viewer/Editor.

Any simulated tool motion that causes a Tool Holder Collision is flagged in the Toolpath Viewer/Editor.

How to perform Analytical Tool Holder Collision Detection and take Corrective Action if Needed

If you see Tool Holder Collisions in your Cut Material Simulations and the operation is flagged in the Machining Job tree, you can follow these steps to take corrective action. This is referred to as Analytical Tool Holder Collision Detection and is available in the Professional (PRO) and Premium (PRE) configurations of the product.

1. Go to the Tools tab on the Machining Objects Browser and select the Computer Tool Holder Collisions icon. It is the last icon on the right, on the Tools tab menu.

Locating the Compute Tool Holder Collisions icon from the Tools tab.

2. From the Detect Tool Holder Collision Areas dialog select the Compute button.

The Detect Tool Holder Collision Areas dialog is displayed Select the Compute button.

3. The toolpath and workpiece are analyzed for tool holder collisions. The results are displayed on the part in a color band of collision areas by depth. If a collision is detected a message displays telling you the Tool Length required to avoid the collision.

The Tool Holder Collisions are computed and displayed. A message tells you the Tool Length required to avoid the collision.

4. In this example, we see that the system has detected a Tool Holder Collision and is telling us that we should set the Active Tool Length to a minimum of 1.51250.

5. Pick OK to close the message dialog.

6. Now pick the Edit Tool button from the Detect Tool Holder Collision Areas dialog.

The Detect Tool Holder Collision Areas dialog with the Edit Tool button indicated.

7. This will display the Create/Edit Tool dialog with the Tool used in the flagged operation loaded for editing.

The Create/Edit Tool dialog is automatically displayed with the active tool where we can editing the Tool Length to avoid a Tool Holder Collision.

8. We set the Tool Length to 1.52, select the Save Edits to Tool button and then pick OK to close the dialog.

9. Now we go back to the Tools tab on the Machining Objects Browser and select the Computer Tool Holder Collisions icon again. From the dialog we select the Compute button again.

A recheck using the Detect Tool Holder Collision Areas dialog tells that No Holder Collisions were detected.

10. We see now that the message dialog says No Holder Collisions Detected. A quick check and we also see that the flags on the operation in the Machining Job tree and the Toolpath Viewer/Editor are gone.

Watch the video version of this blog post HERE!
It is demonstrated using VisualCAM for SOLIDWORKS.

Simulation Features by Configuration

The table below lists some of the more advanced simulation features available in MecSoft’s CAM Module plugins and in which configuration they are supported:

SIMULATION FEATURES	Configuration
	XPR	STD	EXP	PRO	PRE
Toolpath Animation
Cut Material Simulation
Advanced Cut Material Simulation
Visual Tool Holder Collision Detection
Analytical Tool Holder Collision Detection
Machine Tool Simulation

Let’s Review

Let’s to recap of what we’ve learned:

1. A Tool Holder Collision can occur during any toolpath where the total Z depth of the cut motion is greater than the active Tool Length!
2. ALWAYS perform a complete cut material simulation on all operations before posting G-Code to your CNC machine!
3. In Visual Tool Holder Collision Detection, available in Standard (STD) and higher configurations, collisions are displayed graphically during simulation and are also flagged in your Machining Job and in the Toolpath Viewer/Editor.
4. If you have the Professional (PRO) or Premium (PRE) configuration, use the Compute Tool Holder Collision Areas dialog to check for collisions and don’t forget to edit the active tool and then check for collisions again until the system tells you that no collisions are detected!
5. Always keep your CNC machine tool and it’s operator safe from Tool Holder Collisions!

Try a MecSoft pc-based CAM plugin today and see how Tool Holder Collisions are easily detected & corrected!

Irvine, CA, May 7, 2018: MecSoft Corporation, the developer of industry leading CAM software solutions, has announced the availability of AlibreCAM 2018, the latest version of MecSoft’s fully integrated CAM solution for Alibre Design 2018.

AlibreCAM 2018 now includes the ability to perform continuous 5 axis machining operations on Alibre Design models. A picture of a turbine blade being machined using a Swarf machining method is shown below:

Release highlights include:

• 2 ½ Axis – Fillet and Chamfer machining methods have been introduced
• 3 Axis – Horizontal Finishing follow containment, performance & stability improvements
• 4 Axis – Drive Surface machining
• 5 Axis – Continuous 5 axis machining methods such as Surface Normal, Curve Projection and Swarf Machining have been newly introduced
• Other Productivity and User Interface enhancements

“The newly released ability to perform 5 Axis continuous machining inside AlibreCAM along with the other numerous enhancements and additions opens up significant productivity improvements for our users. The powerful combination of Alibre Design and AlibreCAM, delivers functionality found only in products costing thousands of dollars more”, stated Joe Anand, President and CEO of MecSoft Corporation.

Free demo software of AlibreCAM 2018 can be downloaded here.

About MecSoft Corporation

Headquartered in Irvine, California, MecSoft Corporation is a worldwide leader in providing Computer Aided Manufacturing (CAM) software solutions for the small to mid-market segments. These solutions include products VisualCAD/CAM®, RhinoCAM, VisualCAM for SOLIDWORKS® and AlibreCAM®. These software products deliver powerful, easy-to-use and affordable solutions for users in the custom manufacturing, rapid prototyping, rapid tooling, mold making, aerospace, automotive, tool & die, woodworking, and education industries.

For the latest news and information, visit mecsoft.com or call (949) 654-8163.

Six years ago Erik Granberg of Granberg International began implementing CNC technology into their manufacturing process and currently has seven (7) Haas CNC machining centers running production full time. Erik has also implemented the Jergan Quick Exchange Die system on each of his Haas machines. This system allows his team to rapidly change setups, minimizing change-over time while increasing production volume and accuracy. Erik designs the many fixture plate configurations in-house using Alibre Design and uses the AlibreCAM plugin to generate the toolpaths and g-code programs needed to manufacture them. 

One of Erik’s custom designed fixture plates for their Quick Exchange Die system is shown with toolpaths displayed for the four ball lock guide pin & bushing hole locations.

The Ball Lock Guide Pin Hole Operation Set

One of the interesting things from a machining perspective are the four outer hole set locations (shown in blue/green) for the fixture plate ball lock guide pins and bushings. In AlibreCAM, only one hole set needs to be programmed. The g-code for the other three can be generated automatically using an XY Instance operation. The Machining Job is shown here.

The critical dimension is the center thru hole diameter of 1.3765” for the press-fit bushing. The g-code for this hole is posted to 6 decimal places of accuracy using a Hole Profiling finishing operation. See Adjusting Toolpath Accuracy below for more information. 

Each hole set consists of two Drill operations, two helical Hole Pocketing roughing operations and a final helical Hole Profiling finishing operation. The first smaller Drill operation provides centering stability for the second larger Drill, which in turn provides the access needed for the two helical Hole Pocketing roughing operations. The second Hole Pocketing roughing operation provides the needed access for the entry and exit of the final Hole Profiling finishing operation which cuts the final hole to the finished diameter. More details for each operation in this set are provided below.

Center Drill ¼” Drill, 0.25” deep, 0.05 peck increment.

Pilot Drill ⅝” Drill, 1.35” deep (thru), 0.25” step increment.

2½ Axis Hole Pocketing ⅜” End Mill, 2.5” dia., 0.26” deep, 40% stepover climb cut, 0.1” stepdown with cleanup pass at each cut level (dark blue). The helical entry is 0.25” dia. x 0.25” deep.

2½ Axis Hole Pocketing (Rough) ⅜” End Mill, 1.300” dia., 0.74” deep, 40% stepover climb cut, 0.15” stepdown with clean up pass at each cut level (dark blue). The helical entry is 0.125” dia x 0.25” deep.

2½ Axis Hole Profiling (Finish) ⅜” End Mill, 1.3765” dia., 0.74” deep x 0.1” helical pitch, climb cut. The linear entry is 0.25” with a 0.25” radius tangent engagement. The retract is also radial at 0.25”with a tangent linear departure of 0.25”

Publishing note: This animated GIF is for web display only. The actual resolution and quality of the cut material simulation that you experience with AlibreCAM is much greater.

Adjusting Toolpath Accuracy

Internally, AlibreCAM tool motions are calculated at double -precision accuracy up to 14 decimal places. The GOTO motion values displayed in the AlibreCAM Toolpath Viewer are shown at 6 decimal places. Here are the adjustments made in Alibre Design and AlibreCAM to tighten the accuracy required for the final finishing Hole Pocketing operation. It should be noted here that accuracy is relative. As you increase accuracy you also increase processing and machining time.

1. Adjust the accuracy settings of the Alibre Design File Properties dialog. For example, set Length Precision and Angle Precision to 6 (Decimal Places).

2. In the AlibreCAM toolpath operation that requires a high degree of accuracy, set the operation Global Tolerance to between 4 and 6 decimal places. The Cut Parameters tab of the Hole Profiling operation dialog is shown below.

3. Before posting your g-code edit your selected post using the built-in AlibreCAM Post Processor Generator. From your Set Post Processor Options dialog select your post from the Current Post Processor list (we selected haas) and then select the Edit… button. This will display the Post Processor Generator for that post.

4. Select the Motion section on the left.

5. For # of Decimal Places, set this to 6.

6. Then also check the box to Show trailing zeros. These selections are shown below.

7. Now, go to the CAM Preferences dialog and from the Machining section, uncheck each of the Arc Output options shown below:

8. Now from the machining Job tree in AlibreCAM, right-click on the operation requiring a high degree of accuracy, and select Post.

9. Here is the sample Haas g-code output for this toolpath in 6 decimal places of accuracy.

More about Granberg International

A special thanks to Erik Granberg and Granberg International for allowing us to share their AlibreCAM success story! For more information about Granberg International and their available product line we invite you to visit them on the web at https://granberg.com/, on Facebook, Twitter, YouTube and Instagram.

Granberg International, located in Pittsburg, CA is a second generation, family owned company and a world leader in the design and manufacture of chainsaw accessories. They say that “Necessity is the mother of all invention.” Well Erik Granberg, President and CEO tells the story of how his father started the company in the 1950s after experiencing the difficulty of clearing timber on a ranch the family had just purchased in British Columbia. 

That necessity led to the invention of the first portable chainsaw blade sharpener that is sold today worldwide! Hear Erik tell the story here! We recently sat down with Erik Granberg to learn more about the company and its use of AlibreCAM software from MecSoft Corporation.

The Alaskan® Sawmill

Following his early successes, Erik’s father then purchased the patent rights of what is known today as the Alaskan® Sawmill, a lightweight and innovative attachment that allows one person to perform accurate millwork onsite with only a chainsaw! Erik is continuing the Granberg family tradition of craftsmanship and innovation from their 12,000 sq/ft facility.

The Granberg Alaskan® Sawmill is a one person sawmill that allows you to mill rough cut lumber to exact widths from end to end using a chainsaw attachment.

Alaskan® Sawmill Video / More Videos

The AlibreCAM Difference!

Six years ago Erik began implementing CNC technology into their manufacturing process and currently has seven (7) Haas CNC machining centers running production full time. Erik has also implemented the Jergan Quick Exchange Die system on each of his Haas machines. This system allows his team to rapidly change setups, minimizing change-over time while increasing production volume and accuracy. Erik designs the many fixture plate configurations in-house using Alibre Design and uses the AlibreCAM plugin to generate the toolpaths and g-code programs needed to manufacture them. Let’s have a look.

Here we see Alibre Design with the AlibreCAM plugin loaded. The AlibreCAM Machining Browser is displayed on the left with the current Machining Job tree above and the current cutting tools listed below. One of Erik’s custom designed fixture plates for their Quick Exchange Die system is shown with toolpaths displayed for the four ball lock guide pin & bushing hole locations. (Top Right) The AlibreCAM toolpath simulation of the Hole Profiling finishing operation on the bushing hole diameter. (Bottom Right) The actual fixture plate mounted on the Quick Exchange Die in the Haas CNC machining center.

“Since implementing AlibreCAM and CNC six years ago we have increase our production volume here at Granberg International by 300%! AlibreCAM’s ability to quickly generate CNC programs from multiple Alibre Design configurations and iterations is one of the key factors of our recent success.” Erik Granberg, President/CEO, Granberg International

Here we see the fixture plate being setup on the Quick Exchange Die in the Haas CNC machining center.

More about Granberg International

A special thanks to Erik Granberg and Granberg International for allowing us to share their AlibreCAM success story! You can read the complete case study here. For more information about Granberg International and their available product line we invite you to visit them on the web at https://granberg.com/, on Facebook, Twitter, YouTube and Instagram.

In the Professional configuration of AlibreCAM you can take advantage of the XY Instance operation. This allows you to create linear or circular XY arrays of one or more toolpath operations. Here’s how its done using a part example submitted by Erik Granberg of Granberg International, located in Pittsburg, CA.

The fixture plate shown in this example is part of the Jergan Quick Exchange Die system Erik has implemented on each of his seven Haas machining centers. The instance is for the four ball lock guide pin and bushing locations. Here are steps for setting up the XY Instance operation in AlibreCAM.

1. Create the toolpath operations for the initial (master) toolpaths.

2. Create the XY Instance. From the Program tab, select Create Misc Operations and then XY Instance.

3. From the XY Instance dialog select the type of instance and specify the spacing parameters and then pick OK. In our example, we are creating a Linear Instance with an X Spacing of 16” and a Y Spacing of -12”. The +/- values are relative to the original toolpath location.

4. An XY Instance folder will be added to your Machining Job Tree.

5. Drag & drop each of the toolpath operations into the XY Instance folder in the order you want them to be posted.

6. Selecting the XY Instance folder will display all instances in Alibre Design graphics window.

7. Now right-click on the XY Instance folder and select Post to display the posted g-code. You will notice that each toolpath instance is posted.

More about Granberg International

A special thanks to Erik Granberg and Granberg International for allowing us to share their AlibreCAM success story! For more information about Granberg International and their available product line we invite you to visit them on the web at https://granberg.com/, on Facebook, Twitter, YouTube and Instagram.

Irvine, CA, May 30, 2018: MecSoft Corporation announces today the release of CAMJam 2018, the Video Training Companion for their popular VisualCAD/CAM®, RhinoCAM®, VisualCAM® for SOLIDWORKS and AlibreCAM® Milling modules. CAMJam 2018 is a video archive of training sessions conducted by the support staff at MecSoft Corporation. It includes all of the CAMJam 2017 version videos as well as updates for the new 2018 products.

“We’re very excited about our new CAMJam 2018 video archive. It builds upon previous versions and now includes videos on all of our CAM modules including MILL, TURN, NEST and ART. It also includes 5 axis milling, multi-axis robot machining, additional bonus videos and links to our popular Learn CAD/CAM blog series and case studies, all organized, indexed and searchable, so you know exactly which video to watch to get questions answered.” said Don LaCourse, Senior Application Engineer at MecSoft Corporation and one of the principals involved in the creation of this product.

CAMJam 2018 includes:

1. Over 60 new instructional videos covering the complete suite of the MecSoft CAM module functionality including MILL, TURN, NEST, ART and MESH!
2. CAMJam 2018 PDF document for the organization and easy retrieval from the video library.
3. All of the source part files referenced by the CAMJam video archive!

Sample of topics covered:

1. The NEW Automatic Feature Machining tools in the 2018 release!
2. A complete “What’s New” video and discussion on all of the new features in the 2018 release.
3. New bonus videos: Best Practices in 2½ Axis and 3 Axis Machining!
4. Machine Setup, Stock and Geometry considerations for 2½ Axis, 3, 4 and Indexed 5 Axis setups.
5. 2 through 5 Axis machining strategies.
6. Creating User Defined Form Tools for custom 2½ Axis Profiling operations.
7. The Post Processor Generator and Setup for 2½ Axis, 3, 4 and 5 Axis milling.
8. Implementing custom Tool Libraries and Rules-Based Machining Knowledge Bases.
9. Implementing User-specific defaults databases.
10. Using 2½, 3 Axis Machining Regions and Control Geometry effectively.
11. Viewing, Simulating and Editing your toolpaths operations.

About MecSoft Corporation

Headquartered in Irvine, California, MecSoft Corporation is a worldwide leader in providing Computer Aided Manufacturing (CAM) software solutions for the small to mid-market segments. These solutions include products VisualCAD/CAM®, RhinoCAM, VisualCAM for SOLIDWORKS® and AlibreCAM®. These software products deliver powerful, easy-to-use and affordable solutions for users in the custom manufacturing, rapid prototyping, rapid tooling, mold making, aerospace, automotive, tool & die, woodworking, and education industries.

For the latest news and information, visit mecsoft.com or call (949) 654-8163.

Conley Manufacturing located in Shelby Township just north of Sterling Heights, MI manufactures machined tool & die components for the automotive and aerospace production markets. Companies like Boeing, Cessna, Honda Jet, Ford, GM and Chrysler turn to Conley Manufacturing for specialized jigs, SPC (Statistical Process Control) checking fixtures and CMM (Coordinate Measuring Machine) holding fixtures. The company also machines inserts for plastic injection mold tooling.

Al Grifka, CNC Manager for Conley Manufacturing has been machining tool & die components using RhinoCAM for the past 5 years. Al comes from a family of engineering expertise. His father is an engineer with Chrysler Corporation and three of his cousins are all tool & die machinists with the top three automakers. We recently sat down with Al to discuss his use of RhinoCAM CNC software from MecSoft Corporation.

The RhinoCAM Difference

Al started his career operating 3 Axis CNC mills for a local machine shop. Demonstrating his skills in numerical control, Al was quickly promoted to a CNC programmer. Using RhinoCAM, Al demonstrated his skill set where it counts – cutting quality metal components alongside older and more experienced machinists, many of whom who were using Mastercam.

“When I helped opened this shop we knew that we were going to use Rhino and RhinoCAM! This combination together allows us to do both design and CNC programming. One of the many things I like about RhinoCAM is the High Speed Cut patterns. I can set our Haas VF2 to rough and remove a lot of material very quickly using RhinoCAM!” Al Grifka, CNC Manager, Conley Manufacturing, Shelby Township, MI

Quality & Craftsmanship

When you consistently provide accuracy and quality while producing SPC and DMM tooling for the automotive and aerospace industries, you know and your customers know how good you really are! That’s why we at MecSoft Corporation are proud that Al Grifka and Conley Manufacturing rely on our RhinoCAM CNC software!

Machining Core & Cavity Inserts

Conley Manufacturing also machines core & cavity inserts for plastic injection mold tooling. While Al is restricted from showing us his production automotive and aerospace tooling, he has agreed to collaborate with us on another one of his projects for the purposes of this case study. The convex cavity side insert for the injection mold to produce these glass frames is an excellent opportunity to discuss some of the techniques you can use in Rhino and RhinoCAM to ensure machining accuracy and quality especially relating to parting lines. 

The Convex Cavity Insert	The Concave Cavity Insert

The Convex Mold Cavity insert is open in Rhino. The RhinoCAM plug-in is loaded, the toolpath strategies are listed in the Machining Browser on the left with the Rhino Layer Manager shown on the right.

“For our CNC programming, RhinoCAM was the better choice than Mastercam. RhinoCAM is both cost-effective and easy to use. Coming from a tool & die family, I have a cousin who has been in this business for many years and has used many different CAM programs. The fact he recommended RhinoCAM over Mastercam was refreshing and helped to reinforced my decision to go with RhinoCAM!” Al Grifka, CNC Manager, Conley Manufacturing, Shelby Township, MI

Parting surface machining a mold cavity insert at Conley Manufacturing.

Parting line machining a mold cavity insert at Conley Manufacturing. (Inset Bottom Right) The Cavity surfaces are grey. Guide surfaces (in brown) are used to keep the cutting tool from riding on or along the parting line.

Watch the Cut Material Simulation

A Closer Look

Here are some close-up images of the finishing toolpaths at the cavity parting lines. The guide surfaces are not displayed.

(A)	(B)
(C)	(D)

Electrode Machining

Here is an electrode design for the convex cavity illustrated above. In electrical discharge machining (EDM) the desired cavity is burned away from the insert blank by a series of rapidly recurring current discharges between two electrodes that are separated by a dielectric liquid. One of the electrodes is called the tool-electrode, or simply the “electrode,” while the other is called the workpiece-electrode, or “work piece.” In this approach, the workpiece (shown on top in the image on the right below) is machined without the cavity while the electrode (shown on the bottom) is machined separately. EDM is used in areas that are difficult or impossible to machine directly.

(A)

(B)

More about Conley Manufacturing

Al Grifka is CNC Manager at Conley Manufacturing located in Shelby Township just north of Sterling Heights MI. Al performs precision tool & die machining and manufacturing for the automotive, aerospace and consumer products markets using RhinoCAM CNC software on the companies Haas VF2-3 Axis Machining Centers. We encourage you to visit them online at conleymanufacturing.com.

Here are some sample aluminum mold components from Conley Manufacturing:

See Also:

• Mold & Die at Conley Manufacturing (Case Study)
• Machining a Mold’s Parting Lines (Blog)

The #1 priority when machining mold cavity inserts is protecting the parting line! You should never allow the tool tip or tool radius to ride a parting line. This is illustrated in the images below. If this occurs you will see a degradation of the parting line that can cause mismatch and flash in the injection molded parts.

To maintain parting line accuracy and integrity in 3 Axis machining, techniques should be employed that prevent the cutting tool from riding on or along ANY parting line edge. With the use of guide surfaces, the side of the tool always cuts along the parting line in the Z Axis while the tip of the tool aways cuts past the parting line in the X and Y Axis. You can see the difference in quality in the RhinoCAM cut material simulations below!

What are Guide Surfaces?

Guide Surfaces are extra surface geometry that you add to your model that help guide the toolpath around parting line areas. Because they are visible at the time the toolpath is generated, the CAM system takes then into account and treats them like a part surface. In image (B) below we see that a guide surface was added that begins at the parting line and extends vertically tangent to the cavity wall. The height needs only be ½-1 times the diameter of the tool you plan to use to cut the cavity. We extended it higher in our illustrations to help clarify the technique. 

We have chosen the 3 Axis Advanced toolpath strategy called 3 Axis 3D Offset Pocketing to cut the cavity. When the tool reaches the top perimeter edge of the parting line, it encounters the guide surface and will continue to cut vertically until it reaches the top of the guide surface. This ensures that the parting line is cut with the side of the tool as it passes it vertically. The guide surface prevents the tool from riding on the parting line.

NOT RECOMMENDED!	RECOMMENDED!
(A) The tool tip is riding the parting line	(B) Only the side of the tool cuts the parting line
(C) Simulation results when tooltip rides the parting line	(D) Results when the side of tool cuts the parting line

The two cut material simulations shown above illustrates how the parting line degrades when it is ridden on by the tool, shown in image (C). On the right side image (D) you see the clean and accurate parting line edge created when the tool is guided by the guide surface. Note that the designated guide surfaces must be visible when the toolpath operation that cuts the cavity is executed. In image (B) above, the mold cavity is displayed as grey, the guides surfaces are brown and in image (D) the cut material simulation of the cavity is shown as magenta.

Using Guide Surfaces in XY Tool Motions

Here are some close-up images of the finishing toolpaths at the cavity parting lines. 

Once the cutting tool cuts past the parting surface boundary, the display of the guide surface prevents it from rolling over the parting line.

More Parting Line Comparisons

The following images below further illustrate how the use of guide surfaces can dramatically affect the quality of a 3 Axis mold cavity parting line. The two images are simulations from the same 3 Axis 3D Offset Pocketing Toolpath (not shown). When the toolpath on the left was generated no guide surfaces were displayed. The tool was allowed to ride on and roll over the parting line. When the toolpath on the right was generated, guide surfaces were displayed. The quality and sharpness of the parting line is clearly visible in the simulation.

(A) No guide surfaces are used. You see cut traces that the tool left behind when it rolled up along and on the parting line.	(B) Guide surfaces are used. You see a clean vertical cut resulting in zero mismatch and zero flash encountered on parts coming off this mold in production.

In the image (C) below we see the XY passes of the tool extend past the parting surface boundary to obtain a clean edge along the top of the parting line. Guide surfaces used for this image are displayed in image (D).

(C) The finishing toolpaths extend past the parting lines in X and Y with the use of Guide Surfaces.

(D) The guide surfaces are displayed.

In images (E) and (F) below we see that the tool path extends past the edge of the parting line surface upward to the top of the guide surface. The side of the tool always cuts cleanly across the parting line.

(E) The finishing toolpaths extend vertically past the parting lines in Z with the use of Guide Surfaces.

(F) The guide surfaces are displayed.

The completed cut material simulation for the mold cavity insert.

Watch the Cut Material Simulation

More about this Part

This mold cavity insert was submitted to us by Al Grifka, CNC Manager at Conley Manufacturing located in Shelby Township just north of Sterling Heights, MI. Al manufactures machined tool & die components for the automotive and aerospace production markets. In addition to mold inserts, companies like Boeing, Cessna, Honda Jet, Ford, GM and Chrysler turn to Conley Manufacturing for specialized jigs, SPC (Statistical Process Control) checking fixtures and CMM (Coordinate Measuring Machine) holding fixtures.

Read more about Conley Manufacturing

Al Grifka is CNC Manager at Conley Manufacturing located in Shelby Township just north of Sterling Heights, MI. Al performs precision tool & die machining and manufacturing for the automotive, aerospace and consumer products markets using RhinoCAM CNC software on the company’s two Haas VF2 Machining Centers. See also: Mold & Die at Conley Manufacturing (Case Study) Mold Machining at Conley Manufacturing (Blog)

MecSoft Corporation is excited to announce the release of The 2018 Cutting Tools Workbook, a FREE 100-page guide to working with cutting tools in its 2018 line-up of Milling Module CAM plugins including VisualCAD/CAM, RhinoCAM, VisualCAM for SOLIDWORKS and AlibreCAM.

Many of you have asked for more comprehensive information on working with Cutting Tools in our CAM module plugins. This updated workbook delivers with the following in-depth information.
 

Creating Tools

This updated workbook walks you through the process of creating tools and using the predefined tool libraries installed with the software as well as creating your own custom tool libraries. Also included is in-depth information on the Tools tab and the Create/Select Tools dialog including the Feeds & Speeds Calculator.

The Create/Select Tools Dialog

Tool Related Answers

This updated workbook also includes answers to many of the questions that users ask most, including how to define a custom tool, print your tool list, define tool related preferences and tool related optimization such as machining time estimates and more.
 

Advanced Topics

This updated workbook also answers more advanced questions such as how to include tool comments, define a tool change point and enable cutter compensation in your posted g-code. How to customize the Feeds & Speeds Calculator with your own custom materials is also explained.
 

Worksheets

You may be asking yourself why is this guide called a workbook? That’s because it includes worksheets on every tool type supported by the MILL module. You can print these worksheets and use them to help document your existing and new tool inventory for creating tools and setting up your tool library in the MecSoft CAM MILL module of your choice! A sample worksheet is shown below.

Sample worksheet from The Cutting Tools Workbook

Data Sheets

In addition to the worksheets mentioned above, the Reference section also includes the parameter values of every INCH and METRIC tool that comes installed in the predefined tool libraries so that you know exactly which parameter to adjust to make them YOUR custom tool library!

What’s Inside

The 2018 Cutting Tools Workbook is packed full of information that will help you become more proficient with your MecSoft CAM software. Here is the complete list of topics included in this must-have companion guide.

How to Download this Guide

The 2018 Cutting Tools Workbook is available as a FREE download to ALL MecSoft users! To download this 100 page guide, just select one of the links below:

• The VisualMILL 2018 Cutting Tools Workbook
• The RhinoCAM-MILL 2018 2018 Cutting Tools Workbook
• The VisualCAM for SOLIDWORKS-MILL 2018 Cutting Tools Workbook
• The AlibreCAM-MILL 2018 Cutting Tools Workbook

More Information

For more information about each of these Mill Module products, including data sheets, videos and other resources we invite you to visit the following product pages:

• VisualCAD/CAM-MILL (VisualMILL)
• RhinoCAM-MILL
• VisualCAM for SOLIDWORKS-MILL
• AlibreCAM-MILL

Dr. Casey Kerrigan is a Harvard Medical School graduate with a masters degree in Kinesiology (the study of body movement). Dr. Kerrigan is known internationally for her peer-reviewed published research on gait (the study of walking & running) and the effects of footwear on the joints in the body. She published her first research paper in 1998 demonstrating a link between high heels and knee arthritis. She subsequently discovered that even a small heel elevation as well as a lot of other features in traditional shoes, similarly increase impact on the joints.

Casey’s research, along with her years of clinical experience treating the wide variety of problems linked to poor footwear, led her to develop and launch OESH Shoes in Charlottesville VA where she and her team designs and manufactures her footwear with the help of VisualMILL from MecSoft Corporation. We recently sat down with Dr. Kerrigan to discuss her remarkable contributions to the footwear industry and her use of our VisualMILL software.

OESH & VisualMILL

In 2009 Casey was the first woman tenured professor and chair of the department of physical medicine and rehabilitation (PM&R) at the University of Virginia (UVA). Casey was also professor of mechanical and aerospace engineering when she left UVA to concentrate full time on footwear development. When it came time to prototype her footwear sole designs, Casey taught herself CAD/CAM, purchased a Supra 3 Axis vertical mill from CNC Masters who highly recommended that she take a look at VisualMILL from MecSoft Corporation to generate the 3 Axis CAM toolpaths she would need to machine the sole design molds her footwear required!

“VisualMILL is easy to learn and easy to use! I self-taught myself how to use the program from the MecSoft training videos. I’ve also trained two apprentices to use the software and neither one of them has had any trouble learning it.” Dr. Casey Kerrigan, Founder & President OESH Shoes, Charlottesville, Virginia

OESH Shoes developed their footwear prototype molds using VisualMILL CNC Software from MecSoft Corporation. Here we see the OESH La Vida shoe design and mold plate.

VisualMILL helps OESH design their 3D Printers!

Dr. Kerrigan has also developed her own production 3D printers that OESH uses to produce the soles for their line of 3D printed sandals. With a grant from the National Science Foundation Casey was able to refine the development of the thermoplastic extruder that her 3D printers required. 

Casey also taught her apprentice Maggie Rogers how to use VisualMILL! Maggie is a recent UVA graduate, designer and fabrication specialist with OESH. Maggie assists in the development of the company’s 3D printer extruder designs using Fusion 360. All of the g-code required to machine the design components were generated in VisualMILL using 2, 3 and 4 Axis toolpath strategies.

(Left) Dr. Casey Kerrigan inspects the bulk thermoplastic pellets used by the OESH 3D printers also shown. (Right) The OESH Athena 3D printed sandal in Poppy White.

Here is what Maggie Rogers had to say about VisualMILL:

“With the VisualMill program and our CNC milling machine I can quickly and easily machine new components for our 3D printers. We machine almost all the parts of our 3D printers right here in our Charlottesville factory, so development can go very fast and we can be constantly improving our shoe printing processes.” Maggie Rogers, Design & Fabrication OESH Shoes, Charlottesville, Virginia

Here we see VisualCAD/CAM with the VisualMILL plugin loaded. (Center) The Thermoplastic Heater Block 3D model is loaded and one of the 2½ Axis Profiling toolpaths is shown with the cutting tool displayed. (Left) Here we see the VisualMILL Machining Browser showing the Machining Job and the Toolpath Editor to the right. (Right) In the bottom right we see the cut material simulation for the 2½ Axis Chamfering operation. In the top right we see the actual component machined from 6061 aluminum.

More about OESH Shoes

We want to thank Dr. Casey Kerrigan and Maggie Rogers for their time and contributions to this article. For more information about Dr. Casey Kerrigan’s research and OESH Shoes we invite you to check out the following web links:

• The Dream Flat by OESH
• OESH Shoes online, Facebook and Twitter.
• Dr. Casey Kerrigan appears in the ABC 20/20 television program.
• More about Dr. Casey Kerrigan.

More about CNC Masters

To learn more about the great team at CNC Masters and the Supra 3 Axis vertical mill we invite you to visit them online at their website, Facebook and Twitter.