Advanced CS

GibbsCAM 2007
Gibbs and Associates
323 Science Drive
Moorpark, CA 93021
March 2007

Proprietary Notice
This document contains propriety information of Gibbs and Associates and is to be used
only pursuant to and in conjunction with the license granted to the licensee with
respect to the accompanying Gibbs and Associates licensed software. Except as expressly
permitted in the license, no part of this document may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language or computer
language, in any form or by any means, electronic, magnetic, optical, chemical, manual
or otherwise, without the prior expressed written permission from Gibbs and Associates
or a duly authorized representative thereof.
It is strongly advised that users carefully review the license in order to understand the
rights and obligations related to this licensed software and the accompanying documentation.
Use of the computer software and the user documentation has been provided pursuant
to a Gibbs and Associates licensing agreement.
1996-2007 All rights reserved. The Gibbs logo, GibbsCAM, GibbsCAM logo,
Virtual Gibbs, Gibbs SFP, MTM, SolidSurfacer, and Powerfully Simple. Simply
Powerful. are either trademark(s) or registered trademark(s) of Gibbs and
Associates in the United States and/or other countries. Windows Vista and the
Windows logo are trademarks or registered trademarks of Microsoft
Corporation in the United States and/or other countries. All other brand or
product names are trademarks or registered trademarks of their respective
owners. Contains Autodesk RealDWG by Autodesk, Inc., Copyright 1998-2006
Autodesk, Inc. All rights reserved.
Acknowledgements:
Written by Will. Gaffga
Thanks to Bill Gibbs, Bob Dunne, Jeff Meyers, Gary Esser and Israel Klain for their input
and assistance.

Printed in the United States of America

Modified: May 19, 2008 7:04 pm

Table of Contents

Ta ble of Co ntents
INTRODUCTION

Overview of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Rotary Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Machining with Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

COORDINATE SYSTEMS

What is a Coordinate System? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

CS1: The XY Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Multiple Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
HVD vs. XYZ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Creating Coordinate Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Steps For Creating and Modifying Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Minimum Plane Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Quick Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

PART SET-UP

13

Document Control Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Rotary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Four Axis Setup Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Five Axis Setup Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Clearance Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Master Clearance Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

INTERFACE

19

The Workspace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

View Control Palette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
CS Grid and Axis Markers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Graphics Preference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
CS Frame Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Modify Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Main Palette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Coordinate System List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Coordinate System List Context Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Coordinate System Palette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
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Change CS Origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Align Horizontal (H) Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Align Vertical (V) Axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Align CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Standard Plane Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

MACHINING

37

Advanced CS and Making Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Rotate Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Toolpath & Rendering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

ROTARY TABLES

41

How To Set Up Advanced CS for Rotary Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Rotary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Work Fixture Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3 Axis Posting of Advanced CS Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Axial Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Rotary Tables vs. Rotary Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
General Rotary Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

POST PROCESSING

49

Post Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

B-Style (Full WFO) Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
C-Style (Partial WFO) Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
D-Style (No WFO) Posts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Using 3 Axis Milling Posts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Advanced CS Post Processor Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Label Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Code Issues: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Post Output Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
B & C Style Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
D Style Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Output Comparison Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

USING COORDINATE SYSTEMS

59

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
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Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Coordinate System Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Creating the Primary Planes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
The XY Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Creating the XZ & YZ Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Modifying the Properties of Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Naming Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Displaying & Hiding Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Switching Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Deleting Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Changing the Origin of a Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
The XY Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Using XYZ and HVD Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Using Existing Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Toggling the Depth Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Aligning Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Single Axis Alignment by Manual Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Single Axis Alignment Using Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
CS Alignment by Rotation Using Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
CS Alignment by Rotation Using Specific Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
CS Alignment Using Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
CS Alignment Using 3D Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
3 Axis Part: Angled Webs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Creating the Angled Webs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
About the Part File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Creating the XZ Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Creating the YZ Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Creating the Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Aligning Geometry to the YZ Plane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
4 Axis Part: Slot Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Creating the Slot block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Part Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Back Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Front Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Right Side Angled Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Left Side Angled Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
5 Axis Part: Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Hinge Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Part Dimensions & Machine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Creating the Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Top & Bottom Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Back Side CS Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Assigning the Back Side Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
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Center Wall Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Pocket Geometry CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Pocket Geometry Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Angled Hole CS Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

MACHINING CSS

97

3 Axis Part: Angled Webs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

About the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Machining the Angled Webs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
The First Contour Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
4-Axis Part: Slot Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Defining the Slot Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Setting Up the Slot Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Machining The Slot Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Tool Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Center Pocket Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Operation 1, Pocketing the Middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Operations 2 & 3, 32 Right Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Operations 5 & 6, 32 Left Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
5-Axis Part: Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
About the Hinge Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Setting up the Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Rotary Set-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Tool Creation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Machining The Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Operation 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Operation 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Operation 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Operation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Operation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Operation 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

WORK FIXTURE OFFSETS

119

Family of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

Making the Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Part Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Tool Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Geometry Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
G55 Coordinate System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Machining the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Face Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
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Deep Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Deep Pockets - G55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Contour G55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Shallow Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Top & Bottom Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Making the Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Part Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
CS Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Geometry Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Machining the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Tool Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Top Side Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Top Side Holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Inserting A Program Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Back Side Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Back Side Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

TOMBSTONE MACHINING

139

Tombstone Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Method 1: per the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Part & CS Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Part & CS Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Unfolding a Part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Method 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Post Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

CREATION & MACHINING CONCEPTS

149

Multiple Part Origins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Using Multiple CSs for Geometry Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Part Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Second CS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Completing the Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Bottle Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
About Bottle Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Creating the Bottle Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Creating the Base Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Driving the Tool In Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
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About the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158

Setting Up the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Modifying the Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Profile Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Making the Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Machining the Grooves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Contour Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Rotary Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
The Rotary Part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
About the File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Making the Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
CS & Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Machining the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Contour Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162

PART PRINTS

163

GLOSSARY

175

INDEX

179

vi

INTRODUCTION

Introduction

CHAPTER 1 : Introduction
The Advanced CS option provides additional functionality for the Mill Module. The Advanced CS
option allows users to work with multiple coordinate systems in order to create and machine
geometry in more advanced ways than the Mill or Rotary Mill package provide. A Coordinate
System is a plane in space with an origin and three axes. What a coordinate system is and how it is
defined is thoroughly covered in the Coordinate Systems chapter starting on page 5

The terms coordinate system, plane and CS are

used interchangeably throughout the manual.

This manual includes various exercises that provide step-by-step tutorial instruction on how Advanced
CS incorporates multiple coordinate systems into the Production Mill Module. The Production Mill
Module contains 2 and 2 1/2 axis capabilities, but does not include support for Advanced CS or
SolidSurfacer. Strategies and suggestions for creating part geometry in 3D space using multiple
coordinate systems are also provided.

OVERVIEW OF FEATURES
What does Advanced CS offer compared to the Mill or Rotary Mill modules? The Mill module features
4th axis positioning around 0 (A or B axis rotations). The Rotary Mill module allows 4th axis rotary
machining, machine while rotating a rotary axis. Advanced CS offers the ability to work with 3D CAD
workplanes (coordinate systems), machine multi-sided parts with rotary axes, and do 4th and/or 5th
axis positioning.
The Advanced CS options additional functionality can be used in several different ways to maximize
the programming capabilities of the system, including:

Multiple coordinate systems for 3D geometry creation

4th and 5th axis rotary positioning
Tombstone machining
Use of work fixture offsets to machine multiple parts and/or multiple sides in a single program
Bottle Molds
Mill/Turn and MTM to include C, Y and B axis positioning
Z plane machining, G18, G19

These functions provide many additional capabilities to the system including acting as the foundation
for using the solid modeling and full 3-axis surfacing. It is essential that the user understands the
concepts presented in this manual before proceeding to other manuals including the SolidSurfacer
manual, which outlines solid modeling and full 3-axis machining.

 Introduction

HOW TO USE THIS MANUAL

Before using the Advanced CS module you should be familiar with the basic GibbsCAM Mill module.
If you have not read at least the Geometry Creation and Mill manuals, please do so before continuing
with this product. This manual will only briefly refer to items that are detailed in other manuals, it
assumes proficiency with the basic geometry creation and machining techniques of the system.

ROTARY POSITIONING
Customers who will be using the Advanced CS option to produce fourth and fifth axis positioning
moves on their rotary machines will need to use an Advanced CS Post Processor to generate the
necessary A and B moves. These users are encouraged to review the entire manual.

MACHINING WITH COORDINATE SYSTEMS

The Advanced CS option can be a very powerful addition to the Milling module for uses on a 3-axis
machine. The ability to create and work with multiple coordinate systems allows users to define part
geometry in non-XY planes and provide for accurate posted output. Some examples that are provided
are for bottle molds and Z plane machining. Multiple coordinate systems can also be used to utilize
work fixture offsets to machine multiple parts and/or multiple sides of parts in a single program. An
Advanced CS Post Processor is required to produce posted output that utilizes work fixture offset
(WFO). Users who wish to use the Advanced CS option for use with a 3-axis machine need to review
only the first three chapters of this manual.

SOLIDS
The Advanced CS option is a necessary component for the full 3D capabilities available with the
SolidSurfacer option, including solid modeling and full 3-axis machining of solids and complex
surfaces. Users who have purchased the Advanced CS option as a part of the 3D Milling package and
do not intend to use it for the rotary positioning, only need to review the first two chapters of this
manual, primarily the Multiple Coordinate Systems Chapter. This chapter outlines how the system
handles the creation, modification and utilization of multiple coordinate systems, which is essential to
creating complex solid and surface model parts.

COORDINATE
SYSTEMS

Coordinate Systems

CHAPTER 2 : Coordinate Systems

The Advanced CS option adds the ability to create and work with multiple planes or coordinate
systems. This chapter provides an introduction to working in 3D space, including creating and
modifying different coordinate systems and creating geometry based on these different coordinate
systems. Geometry can be created in any primary plane (XY, XZ and YZ) as well as any other planar
orientation. The foundation for using the solid modeling, full 3-axis surfacing and the rotary
positioning capabilities of the system is contained in this chapter. It is essential that the user
understands these concepts before proceeding to the subsequent chapters of this manual or the
SolidSurfacer manual, which outlines solid modeling and full 3-axis machining.

The terms coordinate system, plane and CS are

used interchangeably.

WHAT IS A COORDINATE SYSTEM?

A Coordinate System is a plane in space with an origin and three axes.

The origin is the point at which the axes intersect and serves as a zero reference point. The three
axes are the horizontal, vertical and depth axes. In the standard XY Plane, the X axis is the
horizontal axis, the Y axis is the vertical axis and the Z axis is the depth axis.

A Coordinate System is NOT a Workgroup.

Coordinate systems are completely independent of workgroups. Multiple coordinate systems can
be used in one workgroup and the same coordinate system can be used in multiple workgroups.
Often times it is helpful to have one coordinate system per workgroup, however that is only a
convenience, not a rule.

A coordinate system is an attribute of geometry elements (points, lines, circles, etc.).

Geometry is not contained in a coordinate system the way it is contained in a workgroup. When
geometry is created, dimensional information must be entered to indicate where the geometry
should be located. There must be a referencing system that makes the dimensional data
meaningful. This is the role of a coordinate system in the creation of geometry.

When using the Production Mill module, all geometry is created based on
the coordinate system defined as the XY Plane, which is CS1.

CS1: THE XY PLANE

The XY plane is the standard default plane. It is always CS1 and cannot be modified. The XY plane has
X as the horizontal axis, Y as the vertical axis and Z as the depth axis. The origin for this plane is
located at X0, Y0, Z0 which is based on the values entered for the stock size in the Document Control
dialog. While working in CS1, the buttons in the CS palette, which allow the user to modify
7

 Coordinate Systems

coordinate systems, are grayed out because CS1 cannot be modified. In order for the buttons in the CS
palette to become active, a new coordinate system must be created.

Figure 1: The CS palette is inactive (grayed-out) when the XY plane is

the current CS.

MULTIPLE COORDINATE SYSTEMS

Typically, a user will need more than one coordinate system. Multiple coordinate systems are used for:

3D geometry creation
Rotary part orientation for machining
Multiple work fixture offsets
Slicing planes
Body and sheet creation with solid and surface modeling tools
View saving

HVD VS. XYZ

These letters are reference labels for the axes of a coordinate system. Every coordinate system must
have a horizontal, vertical and depth axis, which is what H, V, and D stand for respectively. X, Y and Z
are the labels used for the horizontal, vertical and depth axes of the standard XY plane. The labels X, Y
and Z will be used as the axis labels if any or all of the axes align with the standard XY plane. The labels
used in the dialog may vary when the current coordinate system aligns with one of the primary planes.
The labels X, Y and Z will be used instead of H, V and D. These text boxes may be labeled X, Y or Z if
the current coordinate system aligns with one of the primary planes. Dialog boxes use the appropriate
letters. Regardless, the values always appear in the same order in the dialog boxes, horizontal, vertical
and then depth.

Coordinate Systems

CREATING COORDINATE SYSTEMS

New coordinate systems are created in one of three basic
ways by using the CS list dialog, from the CS pop-up menu
or the CS list context menu.
The CS list is accessed from the Coordinate Systems button in
the Main (top level) palette. Holding the mouse down on the
button will open the CS pop-up menu. The CS list dialog
(discussed in detail on page 25) allows users to create and
delete coordinate systems. New coordinate systems are
created by choosing New Coordinate System. The CS list also
indicates the current coordinate system by highlighting it in
the CS list.

CS Pop-Up Menu

CS List

When a new coordinate system is created, it will be a

duplicate of the current coordinate system. For example, if
CS1 (which is the XY plane) is the current coordinate system
when the New Coordinate System item is clicked, the system
will create another CS which is an exact duplicate of the XY
plane. The new CS will have the same origin, orientation, etc.
Once a new coordinate system is created, the buttons in the
CS palette become active so the new coordinate system can
be modified.

STEPS FOR CREATING AND MODIFYING COORDINATE SYSTEMS

1- Create a new coordinate system by clicking on the New Coordinate System item in the CS list (page 25). Label the CS with an identifying
name. (page 25)

 Coordinate Systems

2-

Modify the new CS to the proper planar orientation. (page 33)

Coordinate systems can be oriented by selecting defining planar geometry or by using the Align CS
dialog. The Align CS dialog allows the user to rotate a CS around any axis by a specified angle or
enter the coordinates for three points to define the plane.
Coordinate systems can also be defined from several combinations of geometry including 3
points, 2 lines, a line and a point, an arc or a planar curve. A normal vector (perpendicular) can
also be used to define the orientation of a CS. Normal defining geometry includes: 1 line, 2 points,
and a point and an arc (or spline).
3-

Check the depth axis polarity. (page 36)

The depth axis of a coordinate system is indicated by the positive or

negative sign on the axis markers. If there is a positive sign, the positive
direction of the depth axis is projecting out from the screen in the
current view. If a negative sign, the negative direction of the depth axis
is projecting out from the screen in the current view. The Toggle Depth
button in the CS palette is used to invert the polarity (positive/negative)
of the depth axis. The Home view always displays the part from a view
normal (perpendicular) to the current coordinate system where the
positive depth axis is projecting straight out from the screen.

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It is important to correctly orient the depth axis of coordinate systems. The tool always
approaches the part along the positive depth axis of the machining coordinate system. Also,
when using the solid and surface modeling tools, several functions are performed along the
depth axis.
Align the horizontal and vertical axes. (page 29 & page 31)

There are a few different ways to do this. The Align CS Plane button will rotate the horizontal and
vertical axes in 90 increments while the plane geometry is selected on the screen. Another
method is to use the Align Vertical Axis or Align Horizontal Axis buttons. These buttons align
either the horizontal or vertical axes with a selected line. Normally, the selected line is projected to
the current CS and the axis is aligned with the projected line. This will not change the actual
orientation of the plane. It only affects the axial alignment. The selected line will become the
horizontal or vertical axis of the plane.

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Holding down the Ctrl or Alt key while using the Align Horizontal Axis or Align Vertical Axis
buttons will adjust the axial alignment and adjust the depth orientation of the plane.

Coordinate Systems

5-

Change the origin for the new plane. (page 28)

The origin can be changed by entering the coordinates for the new origin in the Change CS Origin
dialog or by selecting the point to be the new origin and clicking on the Change CS Origin button
in the CS palette. Changing the origin for a plane does not affect the overall part origin which is
set in the Document Control dialog.

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When creating a new plane, its origin should be the point from which
the most dimensions are referenced.

MINIMUM PLANE ROTATION

When modifying coordinate systems, the system will rotate the current coordinate system the
minimum amount required according to the Right Hand Rule to set the correct orientation for the
new coordinate system. It is important to understand how the system establishes new coordinate
systems from the information provided by the user.
The system uses the Right Hand Rule to define the coordinate systems. To
make your hand appear like the picture to the right, open a part drawn in the
XY plane and place your right hand near the monitor with the front of your
hand facing you. Extend your thumb in the direction of the positive X axis and
point your index finger towards the positive direction of the Y axis. Bend your
middle finger so the tip is pointing at you and fold the other fingers down so
they are flat against your palm. Your middle finger represents the positive
direction of the Z axis.

When working in coordinate systems other than the standard XY plane, the
thumb represents the horizontal axis, the index finger represents the vertical axis and the middle finger
represents the depth axis. No matter how you rotate your hand around in 3D space, the positive
directions of each of the axes are still in the same relative orientation to each other. The positive
direction of the depth axis cannot be inverted without breaking your finger or inverting one of the
other axes.
The Right Hand Rule is also used to determine the direction of rotation around
an axis. Extend your thumb so it represents the positive direction of an axis. The
motion caused by closing the rest of your fingers around this axis represents the
counter-clockwise rotation direction for that axis. This can be helpful when
working with the Rotary Setup options in the Document Control dialog.

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 Coordinate Systems

QUICK OVERVIEW
A quick version of the process for creating and modifying coordinate systems is detailed below. The
order of operations is not required. After a new CS is made, the steps detailed below may be
followed in any order or skipped if not needed. This is simply a recommended process.
1. Create a new coordinate system by selecting the New CS command in the CS list or the CS list
pop-up menu in the Main palette. See CS List Pop-Up Menu on page 24 and Coordinate
System List on page 25.
2. Label the new CS with an identifying name. See Coordinate System List on page 25.
3. Modify the new CS to the proper planar orientation using the Align CS dialog or by selecting
the necessary geometry. See Align CS on page 33.
4. Check the depth axis polarity. Reverse the positive or negative direction of the depth axis as
necessary by clicking on the Toggle Depth button. See Toggle Depth on page 36.
5. Align the horizontal and vertical axes by selecting geometry or by using the Align H Axis or
Align V Axis dialogs. See Align Horizontal (H) Axis on page 29 and Align Vertical (V) Axis
on page 31.
6. Change the origin for the new CS by selecting a point or using the Change CS Origin dialog. See
Change CS Origin on page 28.
Use the Home view and the trackball part model (box with a T) for visualization of how the
current CS is oriented in reference to the overall part. See Menu Items on page 24.
The CS Grid and Axis Markers should always be displayed on the screen. The CS Grid is turned on
by depressing the Show CS button in the taskbar located below the menu bar along the top of the
screen. See View Control Palette on page 21.
Keep the CS list and the WG list open on the screen during part creation. See Coordinate System
List on page 25.
Carefully label all coordinate systems and workgroups with identifying names. See Coordinate
System List on page 25.
Create geometry at D=0 in planes and use the Modify > Force Depth or Translate, to place geometry
at the correct depth location in the coordinate system. See the Common Reference manual for
detailed information on these and all items accessed from the menu bar.

12

PART SET-UP

Part Set-Up

CHAPTER 3 : Part Set-Up

Advanced CS parts can be 3, 4 or 5 axis parts on a horizontal or vertical milling machine. As with all
GibbsCAM options, the Document Control dialog is used to set-up a part.

DOCUMENT CONTROL DIALOG

You should already be familiar with the Document
Control dialog and setting part units, material type and
stock size. You may also be familiar with selecting the
type of machine to use (lathes, 3 or 4 Axis mills, etc.)
from the Machine pull-down menu. Instead of selecting a
3 axis mill MDD (or a 4 axis mill MDD for simple
positioning & rotary milling), you will likely select a 4- or
5 axis mill MDD.
When a 4 or 5 Axis MDD is selected there is an
additional button in the Document Control dialog. The
Rotary Setup button allows you to specify the machines
points of rotation. The Rotary Setup information is very
important in order to generate the correct code to cut
the part. However, the Rotary Setup information does
not affect the actual programming of the part.
Among the 5 axis milling MDDs there are two MDDs
that output reversed rotary limits. One is horizontal, and
one is vertical. Some users may receive a warning about
machine limits when posting a 5 axis mill part. If you
experience this warning you may use one of the reversed
MDDs which will reverse the limits. Alternatively, you
may contact your Reseller or Gibbs and Associates Post
Department to request a custom MDD with rotary axis
limits that match your machine configuration precisely.

ROTARY SETUP
When a 4 axis or 5 axis machine is selected, the Rotary Setup button appears in the bottom portion of
the Document Control dialog. Information about the setup of the rotary axes is entered by clicking on
the Rotary Setup button. The information in the Rotary Setup dialog is used to calculate rotations and
the new origins that result from those rotations.

15

 Part Set-Up

Rotary Setup: Clicking on this button brings up either the 4 Axis Setup dialog or the 5 Axis Setup

dialog, depending on what selection has been made for the machine type. The values in
these dialogs will not affect the way the part is programmed or rendered in the system.
However, the values are very important because they affect the posted output. The
information contained in this dialog is intended to describe the physical orientation of the
setup of the machine the axes of rotation in relation to the mounted part stock.

Four Axis Setup Dialog

In the 4 Axis Setup dialog there are four options that indicate how the fourth axis will rotate in
reference to where the part is mounted. The + and sign indicates the polarity of the axis and is
used to determine whether a positioning move will be in a clockwise or counter-clockwise direction.
In the table diagram, the blue cube represents the stock, the short gray cylinder represents the 4th axis,
and the gray cube represents the table on which the 4th axis is mounted. The origin markers show the
positive direction of each axis. The clockwise direction for the 4th axis is shown in the picture relative
to the part. The values entered in the Y and Z or X and Z text boxes specify the distance from the
origin of CS1 to the centerline of the indexer..

1 - Table Diagram

2 - Axis of Rotation

3 - Axis of Rotation Position

Figure 2: 4 Axis Vertical Mill MDD Rotary Setup dialog.

Table Diagram: In the table diagram, the cube represents the stock. The origin marker shows the positive

direction of each axis. The arrows show the clockwise direction of each axis. The short gray cylinder
represents the 4th axis, and the gray cube represents the table on which the 4th axis is mounted. The
direction arrow in the center of the cylinder shows the positive direction of the axis of revolution.
Axis of Rotation: These selections are radio buttons; when one is selected the others are not. They
determine the orientation of the axes of rotation and should describe the physical orientation of the
machine. In most cases, the fourth axis on a horizontal machine is the Y+ axis. On a vertical machine,
the fourth axis is the X axis.
Axis of Rotation Position: The values specify the distance from the origin of CS1 to the centerline of the

indexer. These values will be used to correctly rotate the part into position and to correctly calculate
Z axis distances which relate mostly to tool length offsets.
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Part Set-Up

Five Axis Setup Dialog

In the 5 Axis Setup dialog, there are eight options which indicate how the fourth and fifth axes will
rotate in reference to where the part is mounted. The X and Y radio buttons tell the software the
polarity of the X and Y axes in relation to how the part is mounted on the table. This will be used to
determine whether a positioning move is clockwise or counter-clockwise. The clockwise direction for
both rotary axes is shown in the table diagram relative to the part. In this example shown below, the
part is mounted to the positive side of both the fourth (X) and fifth (Y) axis. The clockwise direction for
both rotary axes is shown in the picture relative to the part.

1 - Table Diagram
2 - Axes of Rotation

3 - 4th Axis of Rotation Position

4 - 5th Axis of Rotation Position

Figure 3: 5 Axis Vertical Mill MDD Rotary Setup dialog.

Table Diagram: In the table diagram, the cube represents the stock. The origin marker shows the positive

direction of each axis. The arrows show the clockwise direction of each axis. The intersecting cylinders
represent the fourth and fifth axis. The short cylinder is always the fourth axis and the long cylinder is
always the fifth axis. The direction arrows in the center of the cylinders indicate the positive direction
of the axis of revolution.
Axis of Rotation: These selections are radio buttons; when one is selected the others are not. They
determine the orientation of the axes of rotation and should describe the physical orientation of the

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 Part Set-Up

machine. In selecting the appropriate setting for your machine the first determination needs to be
which axis is the fourth axis (X, Y or Z). Once that is known, the number of options is reduced and you
will not be able to set the 5th axis to the same as the 4th. Next, determine whether the part will be
mounted on the positive or negative side of the 4th and 5th axis. It may be helpful to look at the 4 Axis
Rotary Setup dialog in order to better visualize which is the correct choice. Lastly, if an axis has a limited
rotary range, enter the angular values.
Position of Axis of Rotation: The values entered in the Y, Z and X, Z text boxes specify the distance from the

origin of CS1 to the centerline of each indexing axis. These values will be used to correctly rotate the
part into position and are dependent on the rotation of the fifth axis.

CLEARANCE PLANES
There are two types of clearance planes used by the system the operation clearance planes and the
master part clearance plane. The operation clearance planes are entered in the process dialog and are
the entry and exit clearance planes for the current operation. The master clearance plane, defined in
the Document Control dialog, is used when the tool is coming back from a tool change and during
part rotations. The operation clearance planes are relative to the machining coordinate system, but the
master clearance plane is not.

Master Clearance Plane

Operation Clearance Planes

Figure 4: Clearance Plane Settings

Master Clearance Plane

The Master Z Part Clearance Plane is a fixed Z height specified in CS1 coordinates. It is not relative to
the machining coordinate system being used by the current operation. Because of this, the Z value for
the master clearance plane output in the posted code will change from one machining coordinate
system to another. If this value is not entered correctly, it is very possible that the system will produce
unexpected negative Z rapid moves. Therefore, it is very important that the master clearance plane is
high enough to clear all possible rotations.

The system does not render moves to and from the tool change position. It is not always
obvious that there is potential interference when the tool retracts to the change position until
the posted code is generated. The actual Z values that are output are heavily dependent on the
values entered in the rotary setup and are not always obvious when programming the part
with the system. To avoid accidents, be sure to review all G-code for potential interference
before cutting any material.

For a specific example on part clearance planes, refer to the fifth axis rotary setup tutorial.
18

INTERFACE

Interface

CHAPTER 4 : Interface
This chapter describes interface items that are specific to the system when the Advanced CS option is
installed. As you should know, the system interface has three different levels of functionality. Each level
makes slight changes to the interface. In order to use the Advanced CS capabilities, the Level 2
interface must be selected. The interface level is specified in the File > Preferences > Interface Prefs
dialog. The Level 2 interface has a 16 button Main (top level) palette, a taskbar and other slight
interface differences. Some items in the Level 2 interface will be unavailable if the SolidSurfacer or
Multi-task Machining options are not installed.

THE WORKSPACE
VIEW CONTROL PALETTE
The View Control palette is not unique to the Advanced CS option, however, it
can be used to provide enhanced part visualization. The Home view is an
additional part view that is added with the Advanced CS option. The Home
view displays the part at a view normal to the current coordinate system. This
allows the user to view the part from the orientation that the tool will be
approaching and machining the part. Switching to the Home view displays the
part with the depth axis coming directly out of the screen, with the + at the
center of the axis markers.

Home view

CS GRID AND AXIS MARKERS

The coordinate system (CS) grid and axis markers are very important tools when working with
multiple coordinate systems. The CS grid graphically displays the planar orientation of the current
coordinate system. The CS grid and axis markers will be drawn on the screen when the Show CS
button in the taskbar is turned on (button depressed). When creating multiple coordinate systems, the
CS grid should be displayed on the screen at all times.
Show CS: The Show CS button
is located in the taskbar which is found at the top of the drawing
window, directly below the menu bar. When it is turned on, the CS grid and axis markers for the
current CS will be drawn on the screen.

The CS axis markers will be placed at the origin of the current coordinate system. The axis marker
arrows show the positive direction of the horizontal (H) and vertical (V) axes. At the intersection of the
axis marker arrows, there is either a plus + or minus sign. This indicates the polarity (positive/
negative direction) of the depth (D) axis with respect to the current view.
These arrows are labeled with an H and a V indicating the horizontal and vertical axes. If the H or V
axis aligns with one of the primary axes (X,Y or Z) the primary axis label will be used instead of an H
21

 Interface

or V. For example, when working in the XZ plane, the horizontal axis marker will be labeled with an X
(rather than H) and the vertical axis marker will be labeled with a Z (rather than V).
The grid is drawn in dark gray and shows the plane of the current coordinate system. Additional light
gray lines will be drawn showing where the coordinate system intersects with the stock size,

XY Plane CS

XZ Plane CS

YZ Plane CS

Figure 5: Axis markers for the three standard planes (XY, XZ & YZ).

Graphics Preference
The Graphics Preference which is accessed from the Preferences submenu under
the File menu contains an item called Grid Brightness. This affects the contrast
and brightness of the CS grid drawn on the screen. The brightness can be
adjusted by moving the slider. Clicking on the Apply button in the Graphics
Preference dialog will apply the changes.

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Interface

CS FRAME INDICATOR
The system can also display a CS frame
indicator that shows the origin of other
coordinate
systems.
CS
frame
indicators are composed of three lines
that indicate the orientation of the axes.
The CS frame indicator is not labeled; it
is simply three intersecting lines that
are displayed in red on the screen. The
current CS will still be designated with
labeled axis markers and the CS grid.
The CS frame indicator is displayed by
opening the eyeball icon in the CS list
(detailed on page 25). Double-clicking
on a CS eyeball icon in the CS list will
bring up the CS frame indicator for that
coordinate system. Multiple eyeballs
can be opened at one time by doubleclicking on more than one eyeball icon
so that the CS Frame Indicator will be
displayed for several coordinate
systems.

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CS Frame Indicator

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Hidden Indicator
Indicator for CS2
Indicator for CS3
Indicator for CS4

The CS Frame Indicators can be used to change coordinate systems. The

current CS can be changed by clicking on a CS Frame Indicator. The
coordinate system represented by the CS frame indicator selected will become
the current CS and the CS grid and axis markers will reflect this change.

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 Interface

MENU ITEMS
MODIFY MENU
The Change CS (XYZ) and Change CS (HVD) items are only available if
geometry is selected. Either item will reassign geometry to the current
CS. These items are also described int he common Reference manual but
as they are so essential to the topics in this manual they are included here
as well.
Change CS (XYZ): When Change CS (XYZ) is used, all selected geometry will be
assigned to the current coordinate system. The geometry will stay in its
same location in 3D space. It will change color to reflect the fact that it is
now in the current coordinate system. All selected arcs will be segmented
(changed into line segments), if the coordinate system they are being changed into uses a different
plane than their original coordinate system.
Change CS (HVD): When Change CS (HVD) is used, all selected geometry will be assigned to the current
coordinate system, and the HVD values of the geometry will be preserved. This means that the
geometry will be modified to be planar to the new CS location preserving the relative position.

MAIN PALETTE
The Main (top level) palette contains two buttons that are used specifically for
working with multiple coordinate systems. Depressing the CS list button
CS list
accesses theCS list which displays a list of all coordinate systems contained in a
file. This dialog is also used to create new coordinate systems. The CS list button
can also be held down (as opposed to a single click) to bring up a pop-up list of all CS palette
the coordinate systems. This pop-up list can be used to change the current
coordinate system. The CS palette button accesses the CS palette which is used
to modify coordinate systems.

CS List Pop-Up Menu: Holding down the CS list button will bring up a pop-up

menu showing all of the coordinate systems. The user can change the
current coordinate system by selecting one from the list and letting go of
the mouse button. After a coordinate system has been selected, the list
will disappear. The CS list pop-up menu contains the New Coordinate
System item which can be selected to create a new coordinate system.

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Interface

COORDINATE SYSTEM LIST

Clicking on the Coordinate Systems button will open the CS list.
This dialog displays a list of all existing coordinate systems,
highlighting the current coordinate system. Similar to the
Workgroup list, the CS list is used to create, show and hide
coordinate systems. The CS list also has additional commands
available through a context menu. It is strongly recommended that
the CS list remain open at all times when working with multiple
coordinate systems.
Number: All coordinate systems have a number for ease of reference. The number is not successive,

meaning that if you have coordinate systems numbered 1 through 4, and CS2 is deleted, the next CS
you create will be labeled as #2. In the tutorials section of this manual a CS will often be referred to by
number rather than by name. For example, rather than the XY plane the tutorial will use CS1.
Eyeball Icon: The CS list contains eyeball icons next to each of the coordinate systems. Double-clicking a
closed eyeball opens it and vice-versa. When open, the CS frame indicator for that coordinate system
will be displayed on the screen. This actions does not affect the current CS, which will remain
highlighted in the CS list. The CS grid and axis markers will be based on the current CS.

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Multiple frame indicators may be shown or hidden at the same time. Holding down the Shift
key when selecting eyeball icons will allow you to select a range of coordinate systems.
Clicking on an eyeball icon with the Ctrl key held down will allow you to select & deselect
individual planes. Once you have the planes selected that you wish to show or hide, double
clicking will show or hide all selected planes at the same time.

Comment: Coordinate systems may be named. The Comment item is

the name of a CS. Clicking on the name of a selected coordinate

system in the CS list will allow you to edit the CS name. The name
of the CS will also appear as the title for the CS palette. Because the
system names all new coordinate systems, User CS, it is an excellent
idea to enter a comment in order to differentiate one CS from
another. NOTE: The comment is only a reference name and does
not affect posted G-code executable command values.
WFO: This item is the Work Fixture Offset number of the CS. By
default the entry is blank and WFOs are not used. Clicking in the
WFO area of a CS allows you to assign a WFO number to the CS.
The number may be any positive integer (1, 2, 15, etc.). This
number is a Gibbs WFO number and correlates to machine
WFOs. The Post Processor handles the conversion of Gibbs WFO
#s to Machine WFO #s (i.e. G54 -G59 (& G54.1-G54.999) on
Fanucs and E1-999 on Fadals). The numbers may be in any order.

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 Interface

If a CS does not have a WFO number and it is not used in any machining operations then it is ignored.
If a CS without a WFO number is used, then the system will automatically assign a WFO number
based on CSs position in the CS list. In the above image CS2: YZ plane does not have a WFO number.
If the CS is used for machining, the operations associated with the CS will be assigned to WFO2. Note
that CS4 is designated as WFO2 this is perfectly fine. Multiple CSs may be assigned to the same
WFO, allowing multiple set-ups.
New CS: Click New CS to create a new coordinate system which will be a duplicate of the current
coordinate system. The new coordinate system will be labeled User CS in the CS list.

Coordinate System List Context Menu

The CS list has a context menu which is accessed by a right-clicking
the title bar of the CS list. The items contained in the context menu
relate to the creation and modification of coordinate systems.
New CS: Selecting the New CS item will create a new coordinate

system.
New CS from View: Selecting this item will create a new coordinate

system from the current view. This is an excellent way to save nonstandard part views.
Delete: Selecting this item will delete the current coordinate system, which is highlighted in the CS list.
This is also accomplished by pressing the Delete key.
Change CS (XYZ): This item is also found in the Modify menu and its functionality is the same (page 24).
When this item is selected, all selected geometry will be assigned to the current coordinate system,
and will stay in the same location in 3D space.
Change CS (HVD): This item is also found in the Modify menu with its functionality remaining the same

(page 24). When this item is selected, all selected geometry will be assigned to the current coordinate
system, and the HVD values of the geometry will be preserved. This means that the geometry will
move in 3D space to reflect the change to a different coordinate system.
Preferences: When this item is selected, the CS Preferences dialog

comes up on the screen. The CS Preferences dialog allows

users to set the guidelines for the automatic creation of new
coordinate systems. It is recommended that beginning users
check all of the items in the New CS section. This will result in
more coordinate systems being created but geometry will
not be modified.
These preferences affect the associativity between coordinate
systems, geometry and toolpaths. When these items are all
unchecked, geometry and toolpaths may change their position to reflect modifications made to the
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Interface

coordinate system on which they are based. In some cases, this may not be a desired effect, so these
preferences have been included to give the user control over CS associativity.
Self Definition: This item has an effect when modifying a CS and geometry is selected.

When this item is checked the system will automatically create a new coordinate system rather
than updating the current CS. This will only occur if geometry was selected to modify the CS and
it is assigned to the CS being modified. The result is that the geometry selected for the
modification will not change its location. The geometry will still be based on the coordinate
system in which it was created rather than having its location in 3D space moved to reflect the new
CS modification.
If this item is unchecked, any modifications to a CS will result in geometry in the CS moving
with the CS.
Geometry References: This item has an effect when modifying a CS that contains geometry.

When this item is checked, if a modification is made to a CS that was used for existing geometry,
the system will create a new coordinate system rather than modify the current CS, which would
result in moving the geometry.
If this item is unchecked, any modifications to a CS will result in geometry in the CS moving
with the CS.
Toolpath References: This item has an effect when modifying a CS that was used for machining.

When this item is checked, if a modification is made to a CS that was used as the Machining CS for
an operation, the system will create a new coordinate system rather than adjust the current
coordinate system. This prevents the changing of the position of toolpath.
If this item is unchecked, any modifications to a CS that was used for existing toolpath will result
in modified toolpath.
Out of Plane Rotation: This item has an effect when modifying a CS that was used for machining.

When this item is checked, the system will automatically create a new coordinate system
anytime geometry is rotated out of the plane in which it was based. Rotating out of plane would
be rotating geometry along its horizontal or vertical axis, as opposed to about its depth axis.
If this item is unchecked geometry may be rotated and the CS will not be modified.
Set New CS Visible: When this item is checked, the CS Frame Indicator will be displayed on the screen

for any CS that is automatically created by the system based on these preferences.

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 Interface

COORDINATE SYSTEM PALETTE

The CS palette tools allow you to modify the attributes of any CS, except CS1 which is not modifiable.
The name in the title bar of the palette is the name of the current coordinate system. The buttons in
the palette will be grayed out if the current coordinate system is CS1, because that coordinate system
cannot be modified. The CS palette is accessed by clicking on the CS palette button in the Main (top
level) palette. A CS has an origin (H0, V0, D0), axis alignment plane (H and V) and a planar alignment.

1 - Change CS Origin
4 - Align CS Plane
2 - Align Horizontal Axis 5 - XY Plane
3 - Align Vertical Axis
6 - XZ Plane

7 - YZ Plane
8 - Toggle Depth
Direction

Figure 6: The Coordinate System Palette

Change CS Origin
This button is used to modify the current coordinate system by designating a new origin. This
action will only affect the current coordinate system. The origin for the part will not be
changed. The part origin, which is in CS1, is set by the information entered in the Document
Control dialog.

If a point is selected when this button is clicked, the current CS origin will be moved to the
location of the selected point.

If no point is selected when the Change CS Origin

button is depressed, the Change CS Origin dialog will
appear on the screen. This dialog allows the user to
enter coordinates for the new origin. The
coordinates can be entered as XYZ coordinates or
HVD coordinates, depending on the radio button
depressed. The XYZ coordinates specify an
absolute position based on CS1, the standard XY
plane. The HVD coordinates specify an
incremental translation from the existing origin of the current CS.
Duplicate: The Duplicate item can be checked to create additional coordinate systems based on the

coordinates entered in this dialog. The Duplicate function is only useful when the HVD selection
is made for the origin coordinates. This is because if XYZ coordinates are being used the duplicate
coordinate systems would all be identical. With the Duplicate item checked, the system will not
modify the current CS, but will create duplicate coordinate systems based on the number entered
in the Times field. The origin for each new CS will be offset by the amount entered in the H, V and
D fields.
28

Interface

Align Horizontal (H) Axis

This button is used to change the alignment of the horizontal axis of the current coordinate
system. It can be used with a line selected or no geometry selected at all.
Geometry Selected: Clicking on this button with a line selected will project the selected line to the current

CS and align the horizontal axis with the projected line. This action will not change the origin of the
plane. It will only affect the axial alignment in plane.

Holding down the Alt key while clicking on this button will change the origin of the plane, as
well as the axial alignment, so that the selected line becomes the horizontal axis at V0. A second
click will reverse the polarity of the H axis (flip axis).

Holding down the Ctrl key while clicking on this button will create a new coordinate system
which will have the H axis aligned with the selected line.

Holding down the Alt + Ctrl keys simultaneously will create a new coordinate system, align the
H axis and change the origin of the plane so that the selected line is the horizontal axis.
Align H Axis Context Menu: The Align H Axis function has a
context menu associated with it which is accessed by
right-clicking the button. All of the functions contained
in the context menu can be performed in the ways
described above or by selecting the item from the
context menu.
Align H Axis: With geometry selected, this item will perform the standard align function where

the H axis will align with a projection of the selected line.

Align H Axis & Move: With geometry selected, this item will adjust the axial alignment as well as the

depth orientation of the plane to the line selected for the horizontal axis. The selected line will
become the actual horizontal axis of the plane. This may also be accomplished by holding the
Alt key down and selecting this item.
Create CS & Align H Axis: With geometry selected, this item will create a new coordinate system
which will have the H axis aligned with the selected line. The current coordinate system will
not be modified; the system will create a new CS and modify that CS. This may also be
accomplished by holding the Ctrl key down and selecting this item.
Flip Axis: Selecting this item will reverse the direction of the H axis, rotating it 180.

29

 Interface

No Geometry Selected: If no geometry is selected when the Align

Horizontal Axis button is clicked, the Align H Axis dialog will

appear on the screen. This dialog allows the user to enter
either two coordinates or an angle value to designate the line
that will be used to align the H axis. The H axis for the
current coordinate system will be aligned along the specified
line.
HV Point: The H and V coordinates entered are measured

from the origin of the current coordinate system. If the

item is checked, the H axis will be aligned with the
specified line and the origin will be changed so that it lies
on the selected line. The new origin will be a projection
of the old origin onto the line.

Move

HV Angle: The HV Angle entered specifies an incremental

rotation in a counter-clockwise direction in the CS Plane.
If the Duplicate item is checked, the system will create
duplicate coordinate systems based on the number
entered in the Times field. Each of the new coordinate
systems will have the H axis rotated by the specified
angle. For example, a value of 15 is entered for the
angle, the Duplicate item is checked and 3 is entered in
the times text box. The current CS would not be
modified. Three additional coordinate systems would be
created. The first CS would align the H axis with a line at a 15 angle from the original H axis, the
second at 30 and the third at 45.

30

Interface

Align Vertical (V) Axis

This button is used to change the alignment of the vertical axis of the current coordinate
system. It can be used with a line selected or no geometry selected at all.
Geometry Selected: Clicking on this button with a line selected will project the selected line to the current

CS and align the vertical axis with the projected line. This action will not change the origin of the
plane. It will only affect the axial alignment in plane.

Holding down the Alt key while clicking on this button will change the origin of the plane, as
well as the axial alignment, so that the selected line becomes the vertical axis at H0. A second click
will reverse the polarity of the V axis.

Holding down the Ctrl key while clicking on this button will create a new coordinate system
which will have the V axis aligned with the selected line.

Holding down the Alt + Ctrl keys simultaneously will create a new coordinate system, align the
V axis and change the origin of the plane so that the selected line becomes the vertical axis.
Align V Axis Context Menu: The Align V Axis function has a
context menu associated with it which is accessed by
right-clicking the button. All of the functions contained
in the context menu can be performed in the ways
described below or by using the context menu.
Align V Axis: With geometry selected, this will perform

the standard align function where the V axis will align with a projection of the selected line.
Align V Axis & Move: With geometry selected, this item will adjust the axial alignment as well as the

depth orientation of the plane to the line selected for the vertical axis. The selected line will
become the actual vertical axis of the plane. This may also be accomplished by holding the
Alt key down and selecting this item.
Create CS & Align V Axis: With geometry selected, this item will create a new coordinate system
which will have the V axis aligned with the selected line. The current coordinate system will
not be modified; the system will create a new CS and modify that CS. This may also be
accomplished by holding the Ctrl key down and selecting this item.

31

 Interface

Flip Axis: Selecting this item will reverse the direction of the V axis, rotating it 180.
No Geometry Selected: If there is no geometry selected when the

button is clicked, the Align V Axis dialog will appear on the

screen. This dialog allows the user to either enter two
coordinates or an angle value to designate the line that will be
used to align the V axis. The V axis for the current coordinate
system will be aligned with the specified line.
HV Point: The H and V coordinates entered are measured
from the origin of the current coordinate system. If the
Move item is checked, the V axis will be aligned with the
specified line and the origin will be changed so that it lies
on the selected line. The new origin will be a projection
of the old origin onto the line.

HV Angle: The HV Angle entered specifies an incremental

rotation in a counter-clockwise direction in the CS plane.
If the Duplicate item is checked, the system will create
duplicate coordinate systems based on the number
entered in the Times field. Each of the new coordinate
systems will have the V axis rotated by the specified HV
angle. For example, a value of 15 is entered for the angle,
the Duplicate item is checked and 3 is entered in the times
text box. The current CS would not be modified. Three
additional coordinate systems would be created. The first CS would align the V axis with a line at
a 15 angle from the original V axis, the second at 30 and the third at 45.

32

Interface

Align CS
This button is used to change the planar orientation of the current coordinate system. It can be
used with geometry selected or no geometry selected.
Geometry Selected: The Align CS button will produce different results depending on what geometry is

selected. Some groups of geometry will be used to define a plane, others will be used to define a
normal vector for a plane. Defining a normal vector is equivalent to defining the depth axis. The
groups of geometry necessary to define planes and normal vectors are listed below.
Plane Through Geometry Groups

Plane Normal Geometry Groups

Three Points

Two Points

Two Intersecting or Parallel Lines

One Line

One Point (not on the line) and One Line

Line and Point

One Arc

Spline and Point (normal to tangent vector of

spline at the point)

Planar Spline

Circle and Point (normal to tangent vector of

circle at the point)

Planar Edge (Solids)

Edge and Point

Planar Face (Solids)

Face (planar or non-planar) and Point

Figure 7: Geometry Groups for Aligning Planes

The plane can either be oriented so that it aligns through the selected geometry or normal to the
selected geometry. When using the Align CS button, the system will first attempt to align the CS
through the selected geometry, which means that the plane will be constructed so that all selected
geometry lies in it and the CS will be rotated parallel. If the geometry selection does not adequately
define a plane, the system will attempt to align the plane normal to the selected geometry. If the
geometry selected fails to adequately define a normal vector, the Align CS dialog will come up. The
Align CS dialog is described in the following section.

By itself, this button will not affect the origin of the coordinate system. Holding down the Alt
button when this button is clicked, the origin of the plane will also be moved to the depth of the
selected geometry.

Holding down the Ctrl key while clicking on the Align CS button will create a new coordinate
system and orient it according to the geometry selected or the information entered in the Align
CS dialog. The current coordinate system will not be modified; the system will create a new CS
and modify that CS.

33

 Interface

Holding down the Alt + Ctrl keys simultaneously will create a new coordinate system, align the
plane through the selected planar group geometry and modify the origin so that the selected
geometry actually lies in the modified plane.

Additional clicks on the Align CS button with geometry selected, will rotate the horizontal and
vertical axes around the depth axis in 90 increments.
Align CS Context Menu: The Align CS button has a

context menu associated with it which is accessed

by right-clicking the button.
Align Plane Thru: When this item is selected, the
system attempts to match the selected
geometry with one of the Plane Through
Geometry Groups. If the necessary
geometry is selected, the system will align
the plane through the selected geometry. The
origin will not be adjusted. If the geometry selection fails to define a CS, the Align CS dialog
will come up.
Align Plane Normal: When this item is selected, the system attempts to match the selected

geometry with one of the Plane Normal Geometry Groups. If the necessary geometry is
selected, the system will align the plane normal to the selected geometry. The origin will not
be adjusted. If the geometry selection fails at defining a normal vector, the Align CS dialog
will come up.

T
I
P

Several Align Normal capabilities cannot be accomplished using the Align CS button and must
be done using this menu item. In the cases where the Plane Normal Geometry Group contains
a selected point (spline and point, circle and point, line and point, edge and point, planar face
and point), the system will align the plane normal to the selected feature and through the
selected point, providing the point does not lie on the feature. If these selections were made
and the Align CS button was clicked, the system would align the plane through the selected
geometry rather than normal.
Align Plane Thru & Move: Selecting this item will align the plane through the selected planar group

geometry. The origin will be modified so that the selected geometry actually lies in the
modified plane. The function moves the origin by projecting it onto the new plane. This may
also be accomplished by holding the Alt key down and clicking the button.
Align Plane Normal & Move: Selecting this item will align the plane normal to the selected normal

vector geometry. The origin will be modified to a point on the selected normal vector. The
Align Plane Normal item also allows the user to select a point in addition to the normal vector
geometry and the system will align the plane normal to the selected geometry and through
the selected point.
34

Interface

Create CS & Align Plane Thru: Selecting this item will create a new CS, rather than modify the current

CS, and align it through the selected plane geometry. The origin will not be modified so the
selected geometry will not necessarily lie in the new CS. This may also be accomplished by
holding the Ctrl key down and clicking the button or clicking Do It.
Create CS & Align Plane Normal: Selecting this item will create a new CS, rather than modify the

current CS, and align the plane so that it is normal (perpendicular) to the selected normal
vector geometry. The origin will not be modified.
90 Rotate Axis: Selecting this item will rotate the horizontal and vertical axes in 90 increments

about the depth axis.

No Geometry Selected: If there is no geometry selected or if the selected geometry is inadequate to define a
plane, the CS Align dialog will come up on the screen. This dialog allows the user to change the
orientation of the plane without creating CS construction geometry. There are two ways to define the
plane using this dialog.
3D Points: This method requires
coordinates for three points
that will be used to define the
plane. The coordinates can be
entered as XYZ coordinates or
HVD coordinates depending
on which radio button is
depressed.
The
XYZ
coordinates
specify
an
absolute position based on
CS1, the standard XY plane.
The HVD coordinates specify
an incremental translation
from the existing origin of the current CS. It should be noted that these points are not actually
created as geometry, but are only used to align the CS.
Rotate: This method defines the

orientation of the CS by
rotating it about an axis. The
axis of rotation is determined
by the radio buttons in the
Axis section of the dialog. The
standard X, Y and Z axes can
be selected for the axis of
rotation. There are also H, V
and D selections which
designate that the axis of
35

 Interface

rotation be based on the current coordinate system. The two text boxes in the Axis section of the
dialog are used to designate the position of the axis of rotation. The Angle value entered
determines the number of degrees the CS will be rotated about the selected axis of rotation. The
CW and CCW radio buttons determine whether the CS will be rotated in a clockwise or counterclockwise direction. The CW and CCW directions are referenced by looking down the axis of
rotation in the negative direction. If the Duplicate item is checked, the system will create duplicate
coordinate systems based on the number entered in the Times field. Each of the new coordinate
systems will be incrementally rotated by the angle value.

Standard Plane Orientation

The following buttons on the Coordinate System palette all have three levels of use.
First click: The first click will align the current CS to the orientation of the plane specified using the

same origin.
Additional click: Once the plane is aligned click to rotate the plane about the depth axis in 90

increments.
Ctrl-click: The Ctrl key indicates that the a results should be a new CS based on the same origin

of the current CS.

Right-click: The context menu is a simplified method of producing the same results. For the
Create CS option the Ctrl key doesnt need to be pressed.

XY Plane: Align to the standard XY orientation. The

plane will rotate about the Z axis 90.
XZ Plane: Align to the standard XZ orientation. The
The plane will rotate about the Y axis 90.
YZ Plane: Align to the standard YZ plane or rotate
about the X axis 90.
Toggle Depth: Rotate 180 about the V axis to invert the

positive direction of the H and D axis. The right

hand rule of 3 axis space applies.

36

MACHINING

Machining

CHAPTER 5 : Machining
ADVANCED CS AND MAKING OPERATIONS
TOOLS
Tool set up and creation for Advanced CS is identical to the standard Mill package. Please see the Mill
Module manual for tool definition and use.

PROCESSES
Rotate Tab
The Rotate tab is available when a 4- or 5 axis MDD is selected. The information found in this section
is used to set the Machining Coordinate System.

Machining Coordinate System: Coordinate systems are not just for creating geometry, they are used for setting

the part orientation. The Machining CS (Machining Coordinate System) pull-down list contains all of
the coordinate systems in the current part. The part will be rotated so that the tool will approach the
part from the positive depth axis of this coordinate system. The geometry to be machined does not
have to lie in this plane. An example of this is geometry created in the XZ or YZ plane that is machined
from the XY plane, (see the 3 Axis Part: Angled Webs tutorial or Driving the Tool in Z.) Because of
this, be sure to review the toolpath to ensure you got the results you were expecting.
Position: Rotary Milling: This set of radio buttons allows you to set whether the operation is a standard

positioning operation (possibly including duplicating the toolpath at an angle) or a rotary toolpath
operation. This item is fully detailed in the Mill Module manual.

39

 Machining

OPERATIONS
Advanced CS operations are basically the same as standard 2D Mill toolpath (2D toolpath with a partcentric view where the tool moves around the part) except that the toolpath can be in a plane the Mill
Module would never be able to reach.

TOOLPATH & RENDERING

The Advanced CS module displays all toolpath that is around the part, including retracts to clearances
for positioning and rotations. This includes cut part rendering. As with all GibbsCAM products, the
rendering is part centric meaning the part is stationary and the tool moves about the part. While this
is not realistic, it provides greater rendering accuracy over what is being done to the part. Advanced CS
parts, however, do not show tools retracting to the tool change position. You should carefully check
the posted output to ensure there is no interference when the tool retracts.

40

ROTARY TABLES

Rotary Tables

CHAPTER 6 : Rotar y Tables

HOW TO SET UP ADVANCED CS FOR ROTARY TABLES
This chapter contains information for using the Advanced CS option to produce fourth and fifth axis
positioning moves for rotary tables. The system allows the user to designate a Machining CS for
operations. The Machining CS is set in the Rotate tab of the process dialog when defining the
operation parameters. Only one Machining CS can be used per process group. If the Machining CS is
changed in one process in a specific process group, all of the other processes in that group will use the
new Machining CS.

43

 Rotary Tables

ROTARY SETUP
The Rotary Setup information detailed in Rotary Setup on page 15 is very important in order to
generate the correct code to cut the part. However, the Rotary Setup information does not affect the
actual programming of the part with the system.

WORK FIXTURE OFFSETS

Work fixture offsets are defined by coordinate systems. The CS list
has an entry for designating a coordinate system as having a WFO
setting. By default WFOs are not specified. In order to activate
their use, a coordinate system is given a WFO number. Clicking in
the WFO column of a coordinate system in the CS list allows you
to assign a WFO number to the CS.
The WFO number is not the machine-specific G-code number
(G54, G54.1, E1, etc.) but a Gibbs WFO number. The Gibbs WFO
number is the 1st or 2nd or 3rd or 50th work fixture offset. The number may be any positive integer (1,
2, 50, etc.). When post processing the part the system will convert the Gibbs WFO number to the
machine-specific WFO numbers (i.e. G54 -G59 (& G54.1-G54.999) on Fanucs and E1-999 on Fadals).
The Gibbs WFO numbers in the CS list do not have to be in any order. If a WFO number is not
specified, the system will use the CS number as the Gibbs WFO number.
In the dialog above, CS1 does not have a WFO number so it will be automatically assigned to WFO1.
CS4 also does not have a WFO number so it will be assigned to WFO4. CS2 and CS3 have been given

44

Rotary Tables

specific WFO numbers. CS5 has been assigned to WFO1. That means that any operations performed
in this plane will be done from WFO1. Results of the output once posted would be as shown below.
Gibbs WFO

Fanuc

Fanuc

Fadal

Haas

G54

G54.1

E1

G54

G55

G54.2

E2

G55

G56

G54.3

E3

G56

G57

G54.4

E4

G57

...999

...G59

...G54.999

...E999

...G59, G110-G199

3 Axis Posting of Advanced CS Parts

The system has the capability to make local CS output from Advanced CS parts using 3 axis MDDs.
This functionality uses the Work Fixture Offset capability of your control. This capability allows axial
alignment in 3 axis MDDs. To accomplish this an Advanced CS B- or C-Style post should be used. The
numbers generated in the output are exactly as they are programmed in GibbsCAM. This is axial
alignment. Any moves to the Master Clearance Plane are output with the value entered for the part.
This function is useful to those who do not have rotary tables and those who use multiple set-ps for
different sides of a part, or manually flip parts.

45

 Rotary Tables

LIMITATIONS
Axial Alignment
The system uses the plane of a CS to determine the rotations needed to machine geometry that lies in
that plane. When this is done, the system calculates a rotation to create a plane parallel to the
machining coordinate system through the origin of the coordinate system. It does not line up the H
and V axis to match the coordinate system. This means that after several rotations the part may end up
being rotated so all of the X and Y values are switched and one of them is negated. This can be
especially confusing when the same coordinate system is re-used after doing machining in other
coordinate systems. The first rotations will often match the axis defined in the coordinate system, but
its possible that upon returning to the coordinate system the axes will appear rotated 90 or 180.

Rotary Tables vs. Rotary Heads

GibbsCAM supports rotary head positioning and 4th axis rotary milling, on any machine/control with
a Work Plane capability (toolpath output as 2D toolpath, with HV in the rotated plane). GibbsCAM
does not generally support rotary heads for positioning or simultaneous machining on machines that
require primary XYZ orientation of output toolpath.

GENERAL ROTARY SETUP EXAMPLE

In this example the machine type selected is a 4 Axis Horizontal Mill. In the 4 Axis Setup dialog,
choose fourth Y+ for the axis of rotation. For the position of the axis of rotation, enter 150 in the X text
box and -300 in the Z text box.

In our example, the part will be rotated to machine on the left side. This will cause the part to be
rotated 90 in the counter-clockwise direction. The rotated part origin will be at X450, Y0, Z-150. The
value for the Clearance plane output in the posted code will be Z250.

46

Rotary Tables

The following diagram illustrates how the rotated part origin is calculated based on the information
that has been given in the Rotary Setup dialog. The diagram shows the table and part being viewed
from the top as if you were looking straight down along the axis of rotation.
150 mm

300 mm

150 mm
251 mm
449 mm

101 mm

1 - Axis of Rotation (CW)

2 - Master Part Origin

3 - Master Part Clearance Plane

4 - Rotated Part Origin

5 - Part in Initial Position

6 - Part After Being Rotated

Figure 8: Part Rotation Calculations

Below, are sample G-code formats from each of the three styles of GibbsCAMs Advanced CS Post
Processors.The values in parentheses are output as comments in the posted code.
B-Style Post Processor

C-Style Post Processor

D-Style Post Processor

Master Part Origin:

Master Part Origin:

All origins are:

G54 (X0 Y0 Z0 B0)

G54 (X0 Y0 Z0)

G54 (X0, Y0, Z0).

Rotated Part Origin:

Rotated Part Origin:

G55 (X450 Y0 Z150 B90) G55 (X450 Y0 Z150)

Operations that use the rotated

origin would have X450 and Z150
added to each move.

Master Clearance Plane:

Master Clearance Plane:

Master Clearance Plane:

Output as Z250

Output as Z250

Output as Z100

Rotation is part of WFO.

Rotation is called in the code Rotation is called in the code

before positioning the tool above before positioning the tool above
the start point of the operation.
the start point of the operation.

47

 Rotary Tables

48

POST PROCESSING

Post Processing

CHAPTER 7 : Post Processing

POST PROCESSORS
There are three types of post processors available for the Advanced CS option. The differences in how
the three post processors output code are based on how work fixture offsets are handled. Machine
limitations and customer preference are the primary factors that affect which type of Advanced CS
post processor should be selected.
Advanced CS post processors are labeled with the prefixes B, C, and D which correspond to the way
each processor handles work fixture offsets (WFO). The B-style is designated as Full WFO; the C-style
is Partial WFO; and the D-style is No WFO.
If it is not specified in the WFO column of the CS list, the work fixtures that the Advanced CS
processor will use is determined by the machining coordinate systems (CS). The number of the WFO
is directly related to the number of the machining coordinate system. For example, CS1=G54 and
CS5=G58 on Fanuc controls. The first coordinate system will always be in the XY plane which is G54.
If no cuts are made in the XY plane or in any other CS that is designated as using the first WFO, the
posted output will not use G54.

B-STYLE (FULL WFO) POSTS

All Advanced CS post processors assume the starting rotary position of the machine is A0B0. With a BStyle (Full WFO) processor, the posted output contains a comment for each WFO which lists the
X,Y,Z,A and B settings that the work fixture must be set to. B-Style posts use a Work Fixture Offset
(WFO) to handle both the CS origin offset and any A or B axis rotations, if necessary. Only the WFO
will be called in the code, e.g. G55, G56. The B-style post will always output an A0 and B0 move for
every CS shift. Each of the WFO settings must be input at the control by the operator. This type of
processor is useful because changes can be made to the WFO at the machine without having to
change the part program itself. In order to use a Full WFO processor, the CNC machine must support
A and B WFO settings and have multiple WFO capability.
The Master Clearance Plane, entered in the Document Control dialog, is calculated in the code based
on the rotations being made and the information entered in the Axis Setup dialog. It should be noted
that the Master Clearance Plane calculated in the code changes depending on the Machining CS. The
Entry Clearance Plane is relative to the machining CS so the Entry Clearance Plane will stay the same
value that was entered in the process dialog. This treatment of the Clearance Planes is true for B-style
and C-style post processors.
The Full WFO post processors verify that the CNC machine can handle the number of WFOs being
used. If the number of programmed WFOs exceeds the number that the machine can handle, the
processor adjusts and functions like a No WFO processor, as described below.

51

 Post Processing

C-STYLE (PARTIAL WFO) POSTS

All Advanced CS post processors assume the starting rotary position of the machine is A0B0. The
Partial WFO processor requires that X, Y and Z values be entered at the control by the operator for
each WFO but output the A and B rotation moves in the posted code. The WFO will be called in the
code, e.g. G55, G56 and the A and B rotation moves will also be called in the code. These values are
output on a comment line exactly like the Full WFO processor. All Advanced CS post processors
assume the starting rotary position of the machine is A0B0. The A & B positioning moves will be
output in the program each time a rotation occurs. If changes need to be made to the angular rotation
they can be manually edited in the program or the GibbsCAM file (a .vnc file) can be modified and the
program reprocessed.
The Partial WFO post processors verify that the CNC machine can handle the number of WFOs being
used. If the number of programmed WFOs exceeds the number that the machine can handle, the
processor adjusts and functions like a No WFO processor, as described below.

D-STYLE (NO WFO) POSTS

These posts are used on machines that do not have any WFO. With the No WFO processor, the
system outputs all X,Y, Z and A & B values integrated into the output. It should be noted that all
machining is done in G54. D-style posts will calculate machining coordinate values from CS1
coordinates into coordinates for the operations machining CS. No WFO settings are input at the
control, so any edits needed must be done by hand or changed using the systems file and then
reprocessed. This option is necessary for machines that do not have the ability or have limited ability
when dealing with WFOs.
The Master Clearance Plane, entered in the Document Control dialog, is relative to the machining CS
so it will stay the same value that was entered in the Document Control dialog. The Entry Clearance
Plane will be calculated in the code based on the rotations being made. Notice that it changes
depending on the machining CS.

In order to use multiple parts on different sides of a tombstone with an Advanced

Mill post processor, the control must support A and/or B values in work fixtures.
The index from one part to another must be placed in each work fixture.

USING 3 AXIS MILLING POSTS

The system has the ability to get local CS output from Advanced CS parts for 3 axis posts. This
functionality uses the Work Fixture Offset capability of your controller. This allows axial alignment in
3 xis MDDs or allows a post to specify 3 axis output from a custom 4 or 5 axis post. Basically this
means that you can use a 3 axis post with Advanced CS parts when doing Work Fixture Offsets. The
system will automatically unfold the part (as detailed in the Unfolding a Part tutorial) and set the
WFOs.

52

Post Processing

ADVANCED CS POST PROCESSOR DEFINITIONS

An Advanced CS post is needed when coordinate systems are defined in any part. An Advanced CS
post has the same capability as a 3 axis post. A 3 axis post is no longer needed if an Advanced CS post is
available.

LABEL DEFINITIONS
There are three different letter designations for Advanced CS Posts. Most customers use either a B or
C style post. Both the B and C style posts fall back to D style output if they exceed the
maximum number of work fixture offsets available for a particular CNC machine.
B

This post style is useful for multiple setups of the same part, tombstone work and machines
without automatic rotation capability.

The B style post uses a Work Fixture Offset for any machining coordinate system. All of the X, Y, Z,
A and B axis offsets must be stored in the control's Work Fixture Offsets. The output of the rotary axes
will always be zero (A0 and/or B0). The X, Y, Z, A and B axis offsets are output in the operation
comments.
Example:
C

Fanuc 6M [FW] B001.16.pst

This post style is useful if you have a 4th and/or 5th axis rotary table.

The C style post also uses Work Fixture Offsets for any machining coordinate system. Only the X, Y
and Z axis offsets must be stored in the control's Work Fixture Offsets. The A and B axis rotations are
output in the G-code. The X, Y and Z axis offsets are output in the operation comments.
Example:

Fanuc 6M [PW] C001.16.pst

D This post style is useful for 4th and/or 5th axis parts and you do not want to use Work Fixture
Offsets. It is also useful if you do not like having to input data into the control's Work Fixture Offsets.

The D Style post uses one Work Fixture Offset for the entire part. This means that the X, Y and Z
axis values in the G-code are offset based on the machining coordinate system. The A and B axis
rotations are output in the G-code.
Example:
N

Fanuc 6M [NW] D001.16.pst

Any Advanced CS post can be modified into a Long Hand post.

Examples: Fanuc 6M [FW] NB299.16.pst
Fanuc 6M [PW] NC299.16.pst
Fanuc 6M [NW] ND299.16.pst

53

 Post Processing

CODE ISSUES:

Advanced CS vs. Simple Positioning and/or Rotary Mill

1. An Advanced CS post is incompatible with a Simple Positioning and/or Rotary Mill post. If
you use coordinate systems to specify rotations, you need to use an Advanced CS post.

Master Clearance Plane

1. The value entered into the Z clearance plane in the Document Control dialog is a fixed point
in space. This position or location is not relative to the current coordinate system. In other
words, this value is always local to the home coordinate system.
2. This value is output at the beginning of each new tool operation and at the beginning of a
same tool operation if there is a new coordinate system specified.
3. If this value is not entered correctly, it is very possible that the system will produce unexpected
negative Z rapid moves. Therefore, It is essential to make sure this value is clear of all
machining coordinate system rotations.

Rotate to Shortest Distance

1. The system calculates the shortest distance to rotate from one coordinate system to another.
For example, the system will output a positive move in the clockwise direction to get from
270 to 0 degrees. The system will output a negative move in the counterclockwise direction
to get from 90 to 0. The system will output either a clockwise or a counterclockwise move
to get from 180 to 0.

POST OUTPUT SAMPLES

This section shows the G-code output of the part shown to the right. The
code is output without comments and is aligned in a table so that you
can compare the output. The part is a simple 5 axis part with three
coordinate systems. The pockets (circles with a 30mm diameter) are cut
with a 20mm endmill to a depth of 20mm. You may note that the CS list
entries are assigned WFO numbers. While this feature is very useful, it is

54

Post Processing

not always needed as the system automatically uses CS1 as WFO1, CS2 as WFO2, etc. In this case we
simply wanted to reinforce the use of the WFO numbers.

B & C STYLE OUTPUT

The Master Clearance Plane, 75mm in this example, is calculated in the code based on the rotations
being made and the information entered in the Axis Setup dialog. This changes depending on the
machining CS. The Entry Clearance Plane is relative to the machining CS so it will stay the same value
that was entered in the process dialog. (The processes were set up using a clearance plane of 5.0mm.)
This treatment of the Clearance Planes is true for B style and C style post processors.

D STYLE OUTPUT
The Master Clearance Plane is relative to the Machining CS, so it will stay the same value that was
entered in the Document Control dialog. The Entry Clearance Plane will be calculated in the code
based on the rotations being made. This changes depending on the machining CS.

OUTPUT COMPARISON TABLES

The following two tables show the G-code generated by this part, in all three styles. The first table is
code only, to maximize ease of comparison. The second table, including comments, will show even
more differences between the formats.

55

 Post Processing

Table 1: Comparison of B, C and D Style Output

B Style Post

C Style Post

D Style Post

%
O1
N1G17G40G80
N2T1
N3M6
N4G54
N5S218M3
N6G90G0X0.Y5.A0.B0.
N7G43Z75.H1
N8M8
N9Z5.
N10G1Z-10.F22.
N11M98P2
N12G0Z5.
N13G1Z-20.F22.
N14M98P2
N15G91G28Z0.
N16G55
N17G90G0X0.Y5.A0.B0.
N18G43Z125.H1
N19Z5.
N20G1Z-10.F22.
N21M98P3
N22G0Z5.
N23G1Z-20.F22.
N24M98P3
N25G91G28Z0.
N26G56
N27G90G0X0.Y5.A0.B0.
N28G43Z50.H1
N29Z5.
N30G1Z-10.F22.
N31M98P4
N32G0Z5.
N33G1Z-20.F22.
N34M98P4
N35M9
N36G91G28Z0.
N37M5
N38M30
O2
N1G3J-5.
N2G0Z5.
N3M99
O3
N1G3J-5.
N2G0Z5.
N3M99
O4
N1G3J-5.
N2G0Z5.
N3M99
%

%
O1
N1G17G40G80
N2T1
N3M6
N4G54
N5S218M3
N6G90G0X0.Y5.A0.B0.
N7G43Z75.H1
N8M8
N9Z5.
N10G1Z-10.F22.
N11M98P2
N12G0Z5.
N13G1Z-20.F22.
N14M98P2
N15G91G28Z0.
N16G55
N17G90G0X0.Y5.A-90.B0.
N18G43Z125.H1
N19Z5.
N20G1Z-10.F22.
N21M98P3
N22G0Z5.
N23G1Z-20.F22.
N24M98P3
N25G91G28Z0.
N26G56
N27G90G0X0.Y5.A-90.B-90.
N28G43Z50.H1
N29Z5.
N30G1Z-10.F22.
N31M98P4
N32G0Z5.
N33G1Z-20.F22.
N34M98P4
N35M9
N36G91G28Z0.
N37M5
N38M30
O2
N1G3J-5.
N2G0Z5.
N3M99
O3
N1G3J-5.
N2G0Z5.
N3M99
O4
N1G3J-5.
N2G0Z5.
N3M99
%

%
O1
N1G17G40G80
N2T1
N3M6
N4G54
N5S218M3
N6G90G0X0.Y5.A0.B0.
N7G43Z75.H1
N8M8
N9Z5.
N10G1Z-10.F22.
N11M98P2
N12G0Z5.
N13G1Z-20.F22.
N14M98P2
N15G91G28Z0.

56

What it is

Operation #1, G54

Z Step 1

Z Step 2

Op #2, No WFO in D

N16G90G0X0.Y55.A-90.B0.
N17G43Z75.H1
N18Z-45.
N19G1Z-60.F22.
N20M98P3
N21G0Z-45.
N22G1Z-70.F22.
N23M98P3
N24G91G28Z0.

Rotations
Master Clearance Plane
Entry Clearance Plane
Z Step 1

N25G90G0X225.Y55.A-90.B-90.
N26G43Z75.H1
N27Z30.
N28G1Z15.F22.
N29M98P4
N30G0Z30.
N31G1Z5.F22.
N32M98P4
N33M9
N34G91G28Z0.
N35M5
N36M30
O2
N1G3J-5.
N2G0Z5.
N3M99
O3
N1G3J-5.
N2G0Z-45.
N3M99
O4
N1G3J-5.
N2G0Z30.
N3M99
%

Rotations
Master Clearance Plane
Entry Clearance Plane
Z Step 1

Z Step 2

Op #3, No WFO in D

Z Step 2

Sub-Routine

Sub-Routine

Sub-Routine
Exit Clearance Plane

Post Processing

Table 2: Post Output With Comments

B Style Post

C Style Post

D Style Post

%
O1( PROGRAM: POST SAMPLE B.NCF )
( FORMAT: FANUC 6M [FW]
B001.16M.PST )
( 6/26/03 AT 11:03 AM )
( OUTPUT IN ABSOLUTE MILLIMETERS
)
( PARTS PROGRAMMED: 1 )
( FIRST TOOL NOT IN SPINDLE )
N1G17G40G80
N2T1
N3M6
( OPERATION 1: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#1 - XY PLANE )
( G54 = X0. Y0. Z0. A0. B0. )
N4G54
N5S218M3
N6G90G0X0.Y5.A0.B0.
N7G43Z75.H1
N8M8
N9Z5.
N10G1Z-10.F22.
N11M98P2
N12G0Z5.
N13G1Z-20.F22.
N14M98P2
N15G91G28Z0.
( OPERATION 2: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#2 - XZ PLANE )
( G55 = X0. Y50. Z-50. A-90. B0. )
N16G55
N17G90G0X0.Y5.A0.B0.
N18G43Z125.H1
N19Z5.
N20G1Z-10.F22.
N21M98P3
N22G0Z5.
N23G1Z-20.F22.
N24M98P3
N25G91G28Z0.
( OPERATION 3: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#3 - -YZ PLANE )
( G56 = X225. Y50. Z25. A-90. B90. )
N26G56
N27G90G0X0.Y5.A0.B0.
N28G43Z50.H1
N29Z5.
N30G1Z-10.F22.

%
O1( PROGRAM: POST SAMPLE C.NCF )
( FORMAT: FANUC 6M [PW]
C001.16M.PST )
( 6/26/03 AT 11:03 AM )
( OUTPUT IN ABSOLUTE MILLIMETERS
)
( PARTS PROGRAMMED: 1 )
( FIRST TOOL NOT IN SPINDLE )
N1G17G40G80
N2T1
N3M6
( OPERATION 1: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#1 - XY PLANE )
( G54 = X0. Y0. Z0. )
N4G54
N5S218M3
N6G90G0X0.Y5.A0.B0.
N7G43Z75.H1
N8M8
N9Z5.
N10G1Z-10.F22.
N11M98P2
N12G0Z5.
N13G1Z-20.F22.
N14M98P2
N15G91G28Z0.
( OPERATION 2: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#2 - XZ PLANE )
( G55 = X0. Y50. Z-50. )
N16G55
N17G90G0X0.Y5.A-90.B0.
N18G43Z125.H1
N19Z5.
N20G1Z-10.F22.
N21M98P3
N22G0Z5.
N23G1Z-20.F22.
N24M98P3
N25G91G28Z0.
( OPERATION 3: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#3 - -YZ PLANE )
( G56 = X225. Y50. Z25. )

%
O1( PROGRAM: POST SAMPLE D.NCF )
( FORMAT: FANUC 6M [NW]
D001.16M.PST )
( 6/26/03 AT 11:02 AM )
( OUTPUT IN ABSOLUTE MILLIMETERS
)
( PARTS PROGRAMMED: 1 )
( FIRST TOOL NOT IN SPINDLE )
N1G17G40G80
N2T1
N3M6
( OPERATION 1: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#1 - XY PLANE )

N26G56
N27G90G0X0.Y5.A-90.B-90.
N28G43Z50.H1
N29Z5.
N30G1Z-10.F22.

N4G54
N5S218M3
N6G90G0X0.Y5.A0.B0.
N7G43Z75.H1
N8M8
N9Z5.
N10G1Z-10.F22.
N11M98P2
N12G0Z5.
N13G1Z-20.F22.
N14M98P2
N15G91G28Z0.
( OPERATION 2: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#2 - XZ PLANE )

N16G90G0X0.Y55.A-90.B0.
N17G43Z75.H1
N18Z-45.
N19G1Z-60.F22.
N20M98P3
N21G0Z-45.
N22G1Z-70.F22.
N23M98P3
N24G91G28Z0.
( OPERATION 3: CONTOUR )
( WORKGROUP001 )
( TOOL 1: 20. ROUGH ENDMILL )
( CS#3 - -YZ PLANE )

N25G90G0X225.Y55.A-90.B-90.
N26G43Z75.H1
N27Z30.
N28G1Z15.F22.

57

 Post Processing

Table 2: Post Output With Comments (Continued)

B Style Post

C Style Post

D Style Post

N31M98P4
N32G0Z5.
N33G1Z-20.F22.
N34M98P4
N35M9
N36G91G28Z0.
N37M5
N38M30
O2
( SUB NUMBER: 2 )
N1G3J-5.
N2G0Z5.
N3M99
O3
( SUB NUMBER: 3 )
N1G3J-5.
N2G0Z5.
N3M99
O4
( SUB NUMBER: 4 )
N1G3J-5.
N2G0Z5.
N3M99
%
( FILE LENGTH: 1183 CHARACTERS )
( FILE LENGTH: 10.14 FEET )
( FILE LENGTH: 3.16 METERS )

N31M98P4
N32G0Z5.
N33G1Z-20.F22.
N34M98P4
N35M9
N36G91G28Z0.
N37M5
N38M30
O2
( SUB NUMBER: 2 )
N1G3J-5.
N2G0Z5.
N3M99
O3
( SUB NUMBER: 3 )
N1G3J-5.
N2G0Z5.
N3M99
O4
( SUB NUMBER: 4 )
N1G3J-5.
N2G0Z5.
N3M99
%
( FILE LENGTH: 1159 CHARACTERS )
( FILE LENGTH: 9.94 FEET )
( FILE LENGTH: 3.10 METERS )

N29M98P4
N30G0Z30.
N31G1Z5.F22.
N32M98P4
N33M9
N34G91G28Z0.
N35M5
N36M30
O2
( SUB NUMBER: 2 )
N1G3J-5.
N2G0Z5.
N3M99
O3
( SUB NUMBER: 3 )
N1G3J-5.
N2G0Z-45.
N3M99
O4
( SUB NUMBER: 4 )
N1G3J-5.
N2G0Z30.
N3M99
%
( FILE LENGTH: 1076 CHARACTERS )
( FILE LENGTH: 9.25 FEET )
( FILE LENGTH: 2.89 METERS )

58

USING
COORDINATE
SYSTEMS

Tutorials On Using Coordinate Systems Introduction

CHAPTER 8 : Using Coordinate Systems

INTRODUCTION
The following tutorials will demonstrate how to work with coordinate systems or planes. There
are three primary coordinate systems you should become familiar with to define parts. The primary
planes are the XY, XZ and YZ coordinate systems. You should already be familiar with the XY plane.
The X axis is horizontal, the Y axis is vertical and the Z axis is the depth axis. The depth axis of a
plane is not visible but its orientation can be seen by a + or at the origin of the plane. The plus
or minus symbol represents whether we are looking at the positive or negative side of the depth
axis.
All standard milling parts are defined from the XY plane (which cannot be modified). The XZ and
YZ axes are defined by rotating 90 clockwise about the X or Y axis. From these coordinate systems
we can define other coordinate systems that are rotated, flipped or modified at an angle.
The first tutorial begins with a general overview of different concepts when working with
Coordinate systems. Then, we will explore adding geometry to the modified Coordinate Systems.

CS: The term CS means coordinate system and is used frequently.

CS1, CS2, etc.: CS followed by a number denotes a particular CS in the CS list. All coordinate systems
have a number and can be named.
mm: All parts in these tutorials are in metric values. A millimeter is about 1/25th of an inch. The part
files generally have fairly round numbers so the mental conversion to inch should be fairly easy, i.e.
100mm is about 4".

61

Tutorials

NOTES

 Tutorials On Using Coordinate Systems Coordinate System Basics

COORDINATE SYSTEM BASICS

Creating the Primary Planes The XY Plane

This exercise is designed to introduce you to creating coordinate systems

and to familiarize you with the interface items used. The exercise has two
parts. The first part is simply creating the standard coordinate systems (the
XY, XZ and YZ planes) at the origin of the part. In the second part of the
exercise we will learn another method for making coordinate systems as
well as get an introduction on modifying the planes.

CREATING THE PRIMARY PLANES

The XY Plane
We will start by creating a 100mm cube. You do not need to select a specific MDD as we will
not be creating any toolpath for this part but you should select a vertical mill MDD to ensure
your results look the same as those in the tutorial. We have selected a 5 Axis Vertical Mill MDD
for this example as that is what would be required to access all the coordinate systems.
Launch GibbsCAM if it is not running.
Ensure that the Show Stock & Origin
Show CS

and

items are active.

Create a new part named CS Basics with

dimensions as shown.

The system automatically creates the XY

plane when a new part is made. This
base coordinate system may not be
modified. The position of the XY plane
is defined by the origin of the part, as set
up in the Document Control dialog. We
placed the origin at the very center of
the 100mm cube.

Switch to the isometric view (Ctrl+I) and unzoom (Ctrl+U) the part.
62

Tutorials On Using Coordinate Systems Coordinate System Basics

You can now clearly see the origin and that the XY plane is at the center of the part. The + at
the center of the axes markers indicates that we are looking at the positive end of the depth axis.
A would indicate the negative view.

Open the CS list and Coordinate System palette by clicking on the Coordinate Systems
palette

Creating the Primary Planes Creating the XZ & YZ Planes

Creating the XZ & YZ Planes

and CS

buttons in the Main palette.

The CS list is used to create, show and switch between coordinate systems. The CS
palette is used to modify the current coordinate system. The name of the current
coordinate system is displayed in the CS palettes title bar.
When you open these items you will only see the XY plane in the CS list. All of the
buttons in the CS palette are disabled or grayed out. This is because the XY plane can
not be modified.

CS List

CS Palette

Right-click the CS list title bar and choose Preferences.

Ensure the following settings are selected.

Click New CS in the CS list to create a new coordinate system.

63

Creating the Primary Planes Creating the XZ & YZ Planes

Tutorials On Using Coordinate Systems Coordinate System Basics

The new coordinate system is called

User CS002. The new coordinate
system is in same place as the XY
plane. By default, newly created
coordinate systems are based on the
last active coordinate system.
Now that we have a coordinate
system that may be modified, the CS
palette is active and can be used to
modify the coordinate system.

1234-

Click the XZ button

Change CS Origin
Align Horizontal (H) Axis
Align Vertical (V) Axis
Align CS Plane

in the CS

palette.

The coordinate system has been repositioned. At the origin

of the CS you can see that the horizontal axis is marked as
X and the vertical axis is marked as Z. We will now
make the YZ plane.
Click New CS to make a second coordinate system.
The new coordinate system is called User CS003 and it is
based on the XZ plane. Each new CS will continue to
increment the name in the list.
There are three short red lines
at the center
of the part. These lines are a marker for the origin
of a visible coordinate system. A visible CS has an
open eye in the CS list. When a CS is visible and
not active the grid is not displayed.
We will now modify the current CS to be the YZ
plane.

64

5678-

Align to XY Plane
Align to XZ Plane
Align to YZ Plane
Toggle Depth Direction

 Click the YZ button

in the CS palette.

The coordinate system has been repositioned. At the origin

of the CS you can see that the horizontal axis is marked as
Y and the vertical axis is marked as Z. The sign
indicates that we are looking at the negative side of the
depth axis.
We have just created the three primary planes of a mill part.
The origin of each CS is at the center of the part. We will
now modify this part to make it a little more useful by
defining the coordinate systems at the edge of our stock
boundary. While doing this we will learn how to name
coordinate systems and get an introduction to moving them
around.

MODIFYING THE PROPERTIES OF COORDINATE SYSTEMS

Naming Coordinate Systems
It is highly recommended that you give coordinate systems a name or description. This is
especially true when working with parts that contain more than a few coordinate systems.
With CS3 highlighted click the comment.
The comment becomes a text entry field.
Rename CS3 YZ plane.
Rename CS2 XZ plane.
Select CS3 YZ plane.

Displaying & Hiding Coordinate Systems

There is an eye icon
next to each coordinate system in the CS list. The eye works just like
the workgroup list. When the eye is open you can see a CS, when closed the CS is hidden. The
CS list is different from the Workgroup list in that hiding a workgroup will hide the geometry
that is in the workgroup. Hiding a coordinate system does not hide any geometry associated
with the CS. Hiding a CS merely hides the red coordinate system marker
that designates
the origin of a CS.

65

Modifying the Properties of Coordinate Systems Displaying & Hiding Coordinate

Tutorials On Using Coordinate Systems Coordinate System Basics

Modifying the Properties of Coordinate Systems Deleting Coordinate Systems

Tutorials On Using Coordinate Systems Coordinate System Basics

Double-click the eye icon

next to CS2 (the XZ plane) to hide

the coordinate system.

Did you notice how the red coordinate system marker

disappeared?
Double-click the closed eye icon

next to CS2 to show

the CS.

The coordinate system marker is now back.

Switching Coordinate Systems

Switching between coordinate systems is very easy and there are multiple ways to change the
current CS. The most common method is to use the CS list. Simply click a CS comment or
number in the list and you will switch to it.
Click CS2 XZ plane.
Did you notice how the CS palette changed from the YZ plane to the XZ plane? We will now
use another method to switch between coordinate systems the Coordinate Systems button
in the Main palette.
Close the CS list by clicking the close button

or the CS list button.

When the CS list is not open the CS list button displays a triangle. The triangle signifies that this
button has a flyout menu similar to the standard menus such as Edit > Select. Hold the button
down to open flyout CS list. This is a quick list to all the coordinate systems defined in the part.
Click and hold the CS list button

until a menu apears and select

CS3, the YZ plane.

T
I
P

There is a third method for switching to a different

CS. Clicking on the coordinate system marker of a
visible CS will switch you to that CS. Since the origins
for the current coordinate systems are virtually
identical, it would be difficult to demonstrate this.
However, it is discussed on page 70.

Deleting Coordinate Systems

Deleting a coordinate system is as easy as making one. You simply select it and press the delete
key on your keyboard. Alternatively, you may click the trash icon at the bottom corner of the
workspace. If there is geometry assigned to the CS it may be deleted or changed to CS1.
66

Tutorials On Using Coordinate Systems Coordinate System Basics

Open the CS list.

Remove CS3 YZ plane, by pressing the Trash button.
Remove CS2 XZ plane, by pressing the Delete key.

CHANGING THE ORIGIN OF A PLANE

We will now redefine the stock boundaries so the parts primary
coordinate systems are on the edge of the stock. We will define the XY
part so that all geometry will be in the H+V+ quadrants. Therefore
we want the coordinate system origins on the bottom left corner of
the parts sides. This set up is useful for 5 axis machines that can access
these faces.
XZ

YZ

The XY Plane
Open the Document Control dialog

and set the dimensions to be

+X= 100, X= 0, +Y= 100, Y= 0, +Z= 100, Z= 0.

This placed the XY plane at the bottom of the cube, but we want it at
the top. Since CS1 cannot be modified, the only way to accomplish this
is to change the Document Control dialog settings.

67

Changing the Origin of a Plane The XY Plane

You should have only CS1 in the list. We are now ready to move on to learning how to modify
coordinate systems.

 Tutorials On Using Coordinate Systems Coordinate System Basics

Change the Document Control dialog

settings to

+X= 100, X= 0, +Y= 100, Y= 0, +Z= 0, Z= -100.

Changing the Origin of a Plane The XY Plane

As you can see, the XY plane is now at the top face of the
workspace stock with the origin at the bottom left corner of
the plane.

68

Tutorials On Using Coordinate Systems Coordinate System Basics

Using XYZ and HVD Values

We will first create and name the XZ and YZ planes. These planes will be identical to the XY
plane but we will move the coordinate systems into place.

T
I
P

Changing the Origin of a Plane Using XYZ and HVD Values

Click New CS in the CS list.

Alternatively, you may use the Coordinate Systems button flyout menu
as discussed previously on page 66 to create a new CS and switch
between different coordinate systems.

Rename the CS XZ plane.

Create another new coordinate system and name it YZ plane.

Select the XZ plane in the CS list and click the

XZ button.

Select the YZ plane in the CS list and click the

YZ button.

While these coordinate systems are fully

defined as the XZ and YZ planes, they
still need to be modified to be on the
lower left corner of the plane. The origin
of the XZ plane must be moved down to
the bottom left corner and the YZ plane
must be moved across the part and then
down.

XZ plane

YZ plane

Select the XZ plane CS.

Click the Change CS Origin button.
The Change CS Origin dialog allows you to move a coordinate systems origin in ether XYZ
(absolute from the XY plane) or HVD (relative) values. We need to move this plane by 100 in Z
to get it to the desired location.
69

 Tutorials On Using Coordinate Systems Coordinate System Basics

Select XYZ and enter the data

Changing the Origin of a Plane Using XYZ and HVD Values

shown and Do it.

The origin for CS2 is now at

the bottom left corner of the
stock. You can also clearly
see the coordinate system
marker for the YZ plane
situated at the top left corner
of the current CS. We will
now modify the YZ plane.
Select the YZ plane by
clicking the CS marker.

We need to move the plane across the part (100mm) and down (100mm). Since these values
are relative to the current origin, we will use the HVD option.
Select HVD and change the data
as shown and Do it.

We now have a part set up

that has the three primary
planes in the lower left
corner of the top, front and
side of the part. We will now
create another CS to
illustrate another important
function
for
creating
coordinate systems.

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Tutorials On Using Coordinate Systems Coordinate System Basics

Using Existing Geometry

We will now try another useful method for aligning a plane. Typically, a part has an existing
point or a known point that can be used as a reference for a planes origin.
In the YZ plane, create the point shown.

Changing the Origin of a Plane Toggling the Depth Axis

Create a new CS and name it YZ plane

reversed.

If there is an existing point to use for

an origin the point may be used to
automatically align the plane.
Select the point.
Click the Change CS Origin button.
Deselect the point.

Toggling the Depth Axis

You will notice that the axis markers for YZ plane reversed have a
sign at the intersection. We will use the Toggle Depth button to
change the polarity of the depth axis. The depth axis is always
indicated by a + or sign at the intersection of the two axes
markers. The + indicates that the positive direction of the depth
axis in the current view is pointing forward or coming towards you.
The indicates that the negative direction of the depth axis is
pointing torward you.
Click the Toggle Depth button.
When you toggle the depth, the system will rotate the
depth axis 180 around the vertical axis. This has the effect
of inverting or flipping the direction of the horizontal axis
as well as the depth axis. The vertical axis is not affected.
This only has an effect on the orientation of the coordinate
system not on the actual orientation of the part.

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 Tutorials On Using Coordinate Systems Coordinate System Basics

Aligning Coordinate Systems Single Axis Alignment by Manual Input

ALIGNING COORDINATE SYSTEMS

There are many ways to align a coordinate system. Coordinate Systems can be aligned by
designating where a horizontal or vertical axis lies; planes can be snapped to geometry; and
planes can be rotated. We will now cover four primary methods of aligning a CS. the first two
items will use the Align Horizontal Axis and Align Vertical Axis buttons. We will then use the
Align CS button for two other methods.

Single Axis Alignment by Manual Input

Create a new CS based on CS4 and name it Learning.
Ensure that all geometry is deselected and click the Align H Axis button.
The Align H Axis (or V Axis) dialog allows us to align the horizontal or vertical axis of the current
CS by using either user input points or to rotate the plane at a given angle. By default, actions
performed by this function will duplicate and modify the current plane instead of moving it.
Enter the values shown and Do It.
Two additional planes are created named Learning,
mod (1) and Learning, mod (2).

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Tutorials On Using Coordinate Systems Coordinate System Basics

Single Axis Alignment Using Geometry

Aligning Coordinate Systems Single Axis Alignment Using Geometry

We will now use geometry to align the vertical axis of a CS.

Switch to CS5: Learning and hide the markers for CS4, CS6 & CS7.
Create a 45 line through the point at the origin.
Select the line and click the Align V Axis button.

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If you are aligning a plane to connected

geometry, it is recommended that you select
only the line (or two points) you wish to align
the axis to. If you select multiple features (such
as double-clicking the geometry) the system will
align the plane to the lowest numbered line.

CS5 has been aligned to the 45 line. As a result, the line

has also been rotated. Geometry automatically moves with
modifications to a CS. Moving the geometry is the default
system behavior.

This default behavior can be avoided in several ways.

The first and most common is to use an alternative
aligning command by right-clicking on an Align
button. The default action performed when clicking
on an Align button is the first item, Align V Axis. These
items are discussed in detail on page 31.
Another option is to change the default behavior of
new coordinate systems. This is done through the CS
Preferences dialog which is found by right-clicking on
the CS list title bar. Detailed information on these
options can be found on page 26.

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Aligning Coordinate Systems CS Alignment by Rotation Using Specific Values

Tutorials On Using Coordinate Systems Coordinate System Basics

CS Alignment by Rotation Using Geometry

Rotating a coordinate system can be done by specifying a
rotation about a specific axis by a given amount or can be
done about geometry. We will start with geometry.
Select the line.
Click the Align CS Plane button.
Notice how the CS has flipped. A selected line is used to
designate the positive direction of the depth axis. Using the
Align CS Plane command with geometry will not move the
origin of the CS but will rotate the CS so its depth axis is
aligned to the original position of the line.

CS Alignment by Rotation Using Specific Values

Deselect the line.
Click the Align CS Plane button.
Enter the HVD values shown and Do It.
We have specified that the coordinate system is going to be rotated about X0Y0 by 45 degrees in
a clockwise direction using absolute (XYZ) values.

74

If we had specified the

rotation was to use relative
(HVD) values, the dialog
would have displayed H0 and
V0 and the results would
look like the image shown.

75

Aligning Coordinate Systems CS Alignment by Rotation Using Specific Values

Tutorials On Using Coordinate Systems Coordinate System Basics

 Tutorials On Using Coordinate Systems Coordinate System Basics

Aligning Coordinate Systems CS Alignment Using Geometry

CS Alignment Using Geometry

Geometry used to align a plane may be a set of points, a shape (open or closed), or a
combination of lines and points. Here we will first use a set of points to define the planes
alignment, then we will use a closed shape. Please note that if the transformations shown here
do not work then you may need to change your CS Preferences.
Switch to CS2: XZ plane
Create points at X100, Z0 and X100, Z100.
Select the two points as well as the point that lies in the YZ plane.
Switch to CS5: Learning and click the Align CS Plane button.

The CS remains essentially unchanged, it has only rotated

90. That is because the plane is already parallel to the
selected points. Any additional clicks on the Align CS Plane
button will continue to rotate the CS by 90 increments.
Undo (Ctrl+Z) the align and delete the two points we just
created.

In the YZ plane, create a 20mm square around Y50, Z50.

Switch to CS5: Learning, double-click the square and click
the Align CS Plane button.

The origin of the plane stays in the same position but the
plane swings around to be parallel to the geometry.

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76

To move the origin when aligning a CS, one of the

move options must be chosen from the Align CS
Plane context menu (right-click).

Tutorials On Using Coordinate Systems Coordinate System Basics

CS Alignment Using 3D Points

The last CS Alignment exercise will be user-defined 3D points.

Enter the values shown, making sure to use the XYZ values and the Move option before clicking on Do It.

The results are an angled plane. the plane aligns to the top-right corner of the XY plane
(X100,Y100,Z0), and the top-left and bottom-right corners (X0, Y100, Z100 & X100, Y0, Z100)
of the bottom of the part.

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Existing points can be interrogated (Alt+click & Shift+Alt+click) to fill in data but the
retrieved data is relative to the current coordinate system. If you want absolute data be sure
to switch to the XY plane, interrogate the points and then switch back to the coordinate
system you are going to modify.

77

Aligning Coordinate Systems CS Alignment Using 3D Points

Deselect all geometry and click the Align CS Plane button.

 Tutorials On Using Coordinate Systems Coordinate System Basics

Aligning Coordinate Systems CS Alignment Using 3D Points

Because we selected the Move option, the depth origin of

plane was moved to align with those points. If we had not
selected Move, the results of the CS alignment would look
like this image. The plane does align with the points, but the
origin remains where it was.
You may now save this part if you wish, but it will not be
used in any other tutorials.

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Tutorials On Using Coordinate Systems 3 Axis Part: Angled Webs

3 AXIS PART: ANGLED WEBS

CREATING THE ANGLED WEBS

About the Part File
There is a pre-existing part file for this
exercise. The file name is Angled webs.vnc
and it may be found in the install directory for
the part files or on your GibbsCAM
installation CD. If for some reason you do not
have the part you may re-create it using the
part print.
Open the file Angled Webs.vnc.
The part is 200x200x50mm set up on a 3 Axis
Vertical Mill MDD. It contains three tools a
45mm drill, a 13mm Rough endmill and a
45mm rough endmill. There is geometry
representing one set of the open pockets and
the thru-hole. There are also pre-generated
operations to clear out the hole and the open
pockets. As you can see, there is only one set
of geometry for the open pockets. The Transform Toolpath plug-in was used to duplicate and
rotate the toolpath.

Creating the XZ Plane

We need to create the contours that will generate the angled webs. In order to do this, we need
to make two additional coordinate systems, the XZ plane and the YZ plane. The web contours
will be drawn in these two planes.
Click New CS in the CS list.

79

Creating the Angled Webs Creating the XZ Plane

In this exercise, we will create a part that has angled webs that require following a 3D contour in
order to machine it properly. The Advanced CS option is necessary to generate this type of toolpath
because the contour that we will be machining lies in a plane other than the standard XY plane.
Creating the contour in another coordinate system allows the system to be able to correctly offset
the tool cutting in Z. We will machine the part from the XY plane. This type of operation can be
created on any contour that lies in a plane that has Z as an axis. Providing that Z is an axis in the
plane, the system can follow a 3D contour, correctly offsetting the tool. Refer to the part print
Angled Webs on page 165 for this exercise.

 Tutorials On Using Coordinate Systems 3 Axis Part: Angled Webs

Modify the CS to the XZ plane

and rename it XZ plane.

The polarity of the depth axis does not need to be adjusted

because we will be machining these shapes in the XY plane.

Creating the Angled Webs Creating the Geometry

Creating the YZ Plane

Two of the web contours need to be defined in the YZ plane to provide for proper machining.
Create a new CS by clicking New CS in the CS list.
Modify the CS to the YZ plane

and name it YZ plane.

Creating the Geometry

To create the part geometry we will create one profile of the
angled web. We will then Duplicate and 2D Rotate the geometry about the origin.
Switch to CS2 XZ plane. Create a new
workgroup and create the contour geometry.

From the home view (Ctrl+H) of the XZ

plane, your screen should look like the
following picture. The home view always
shows the part along the positive depth
axis of the current CS.
The web contour needs to be duplicated
in the four locations that need to be cut.
Switch to CS1 and double-click the web
contour geometry.

Select Modify > Duplicate And...

Dup And 2D Rotate the web as shown.

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Tutorials On Using Coordinate Systems 3 Axis Part: Angled Webs

We have duplicated and rotated the geometry

at a 90 angle, 3 times.

Switch to the YZ plane.

Select the two web contours shown.
Select Modify > Change CS (XYZ).

By using Change CS (XYZ), the shapes will stay in the same location but will now be drawn in
cyan, rather than magenta, to indicate that they are defined in the current CS.
The geometry and coordinate system creation is complete. We will create the machining
operations in the tutorial 3 Axis Part: Angled Webs on page 99.

81

Creating the Angled Webs Aligning Geometry to the YZ Plane

Aligning Geometry to the YZ Plane

 Tutorials On Using Coordinate Systems 4 Axis Part: Slot Block

4 AXIS PART: SLOT BLOCK

In this exercise we will create three new coordinate systems. The first CS will be one of the primary
planes, the YZ plane, and the others will be created by rotation using the Align CS dialog. Refer to
Slot Block on page 166 for this exercise.

CREATING THE SLOT BLOCK

Part Set-Up
Create a new part with the following stock dimensions:

Creating the Slot block Back Profile

+X = 125, X = 125, +Y = 250, Y = 250, +Z = 0, Z = 150.

This part will be machined later in the Machining tutorials. At this point in the tutorial it does
not matter if a specific MDD is used but for consistency, we shall choose one.
Select a 3 Axis Vertical Mill MDD.

Back Profile
Switch to the isometric view (Ctrl+I).
Create a New CS and name it YZ Plane.
Click the YZ button

in the CS palette.

Click the Change CS Origin button

the following information and Do it.

Switch to the home view (Ctrl+H).

82

and enter

Tutorials On Using Coordinate Systems 4 Axis Part: Slot Block

When working in the home view, you are viewing

the part from a position normal (perpendicular) to
the current coordinate system. Geometry creation
can proceed from this point as if you were working
in 2D. The only difference is the labels for the
horizontal, vertical and depth axes (coordinates). In
this case, the horizontal axis is labeled as the Y axis, the vertical axis as the Z axis, and the depth
axis as the D axis (not the Y axis because the depth axis polarity is reversed).
Not only is the orientation of the depth axis important for the machining of the part, but
also many of the solid modeling functions in the system are dependent on the depth axis,
such as extrusions and revolutions.

Creating the Slot block Front Profile

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Create the geometry for the YZ Plane.

Because we set the origin in the position
that we did, you should be able to use the
dimensions provided on the blueprint.
Remember the origin acts as a zero
reference mark for dimensioning. Make sure
that the D (depth) value in the geometry
dialogs is 0.
Switch to the isometric view (Ctrl+I).

Front Profile
Now, we will duplicate the shape along the
depth axis.
Select the entire closed shape created in the YZ Plane by doubleclicking on it.

Select Modify > Duplicate And...

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 Tutorials On Using Coordinate Systems 4 Axis Part: Slot Block

Select Force Depth and enter the values shown.

Creating the Slot block Right Side Angled Face

This will duplicate the selected geometry and move it the specified
amount along the depth axis. We could also have used the Translate
item in the Dup And dialog to accomplish the same thing.

Right Side Angled Face

Now, we will create the 32 plane that lies on the right side of the part. There are two primary
methods for changing the orientation of a CS to a non-standard plane. You can either select
plane group geometry, which is the minimum amount of geometry necessary to accurately
define a plane, or you can use the Align CS dialog, which allows you to enter specifications to
properly orient the plane. We will use the Align CS dialog to rotate the plane to the correct
orientation.
Switch to CS1.
We have switched to CS1 so that the new CS will be a duplicate of the XY plane rather than the
XZ plane.
Create a New CS and label it 32 Right.
Make sure all geometry is deselected before clicking on the Align
CS button.
Click the Align CS button

84

in the CS palette.

Tutorials On Using Coordinate Systems 4 Axis Part: Slot Block

The Align CS dialog will

appear on the screen. If it
does not, you have
geometry selected and the
system is attempting to
orient the plane according
to the selected geometry.

information as shown.

The system will modify the new coordinate system

by rotating it from its current orientation, which is
the standard XY plane. In this case, the CS will be
rotated 32 about the X axis in a counter-clockwise
direction. The location of the X axis which will be
rotated about is determined by the values entered
in the Y and Z text boxes.
The planar orientation of the coordinate system
will change, but the origin will not be affected. To
further modify the new CS to properly create the
slot geometry, we will need to change the origin.
We can change the origin of a CS by entering coordinates in the Change CS Origin dialog, which
is how we modified the last CS. Another method for changing the origin is to select an existing
point and click the Change CS Origin button. This action will cause the selected point to
become the new origin for the CS. In this case, we will select an existing point to change the
origin.

85

Creating the Slot block Right Side Angled Face

Select Rotate and enter the

 Tutorials On Using Coordinate Systems 4 Axis Part: Slot Block

Select the point shown and click the Change CS Origin

Creating the Slot block Right Side Angled Face

button.

Switch to the home view (Ctrl+H).

In order to get an idea of the orientation of the part, look at the
trackball in the center of the View Control palette.

This gives you an indication of the view at which you are looking at
the part and also the orientation the part will be in when it is
machined.
Create the slot geometry.
The labels in all of the geometry dialogs should read H for the Horizontal axis, V for the
Vertical axis and D for the Depth axis as the none of the axes in the current coordinate system
align with the primary X, Y and Z axes. Make sure the CS grid and axis markers are drawn on
the screen so you can keep in mind how the part dimensions should be entered.

86

Tutorials On Using Coordinate Systems 4 Axis Part: Slot Block

Switch to the isometric view (Ctrl+I).

Left Side Angled Face

Now, we will create the 32 plane on the left side
of the part.
Make sure that the current CS is the 32 Right plane
so that the new CS is a duplicate of that plane.

Creating the Slot block Left Side Angled Face

Create a new CS and name it 32 Left.

Open the Align CS

dialog
and enter the information.

We have rotated the current CS a total of 64. A 32

rotation would have oriented the plane so that it
were parallel to the XY plane. The additional 32
places it in the proper orientation for the right side
of the part.

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 Tutorials On Using Coordinate Systems 4 Axis Part: Slot Block

Select the point shown and change th CS origin.

It may be difficult to see the labels on the axis markers in the
current view and specifically to tell the polarity of the depth
axis (indicated by the + or sign on the axis markers).

Creating the Slot block Left Side Angled Face

Ensure that you are in CS4, the 32 Left plane.

Select the right hand slot geometry and duplicate it.
Select Modify > Change CS (HVD).
This moves the geometry around to the new CS and the arcs are
not converted to splines, which can happen when performing
certain modifications to geometry.
Mirror the slot geometry about V0.
The final part geometry should look like this.

88

Tutorials On Using Coordinate Systems 5 Axis Part: Hinge

5 AXIS PART: HINGE

In this exercise, we will create four coordinate systems, using a normal vector to define one of the
planes. Refer to the part print Hinge on page 167 for this exercise.

HINGE SET UP
Part Dimensions & Machine Type
Create a new part (Hinge.vnc) with the following stock dimensions:
+X = 150, X = 0, +Y = 75, Y = 0, +Z = 0, Z = 90.

We will not go into the rotary setup for the part in this section. That will be described in detail
in the Machining CSs section on page 108.

CREATING THE HINGE

Top & Bottom Geometry
The first thing we will create is the parts
top profile. We will then duplicate the
geometry and change its depth to create
the bottom profile.
Create the top view geometry in the XY plane.
The top view geometry we want to create
is the rounded contour.

89

Hinge Set Up Top & Bottom Geometry

Select a 5 Axis Horizontal Mill for the Machine.

 Tutorials On Using Coordinate Systems 5 Axis Part: Hinge

Now, we will duplicate this shape to

create the back side geometry for the
hinge.
Select the entire contour then Dup And

Creating the Hinge Assigning the Back Side Geometry

Translate the shape to a depth of Z90.

Switch to the isometric view (Ctrl+I).

Back Side CS Creation

We will now create a new CS in
preparation for the machining of this
part. When creating machining
operations, the tool approaches and
cuts the part along the positive depth
axis of the CS selected as the Machining
CS. The standard XY plane does not
have the depth axis in the correct
position to machine the back side of
the part.
Create a new CS and name it XY back side.
This will be an exact duplicate of the XY plane, which is the correct orientation. We simply need
to change the origin and toggle the depth axis.

Assigning the Back Side Geometry

Select the point shown and click the Change CS Origin button.

Click the Toggle Depth button.

Clicking the Toggle Depth button will flip the depth axis which also has the
effect of inverting the horizontal axis. Any rotations of the coordinate system
axes, follow the Right Hand Rule, see Right Hand Rule on page 177 for a definition.

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Tutorials On Using Coordinate Systems 5 Axis Part: Hinge

Notice that from this view, you see a

sign on the axis markers
indicating that you are viewing the
part along the negative direction of
the depth axis. Use the home view
and the trackball to get an idea of
the orientation of the CS and the
part.

Select the entire shape that was just moved

and select Modify > Change CS (XYZ).

This shape should now be drawn in

blue on the screen, indicating that it
was created based on the current coordinate system. The Change CS (XYZ) function assigns all
selected geometry to the current coordinate system. The geometry stays in the same location
in 3D space in which it was created.

Center Wall Creation

We will now create a new workgroup the geometry for the angled center wall. This geometry
will be created in the standard XY Plane, CS1.
Create a new workgroup and switch to the XY Plane.
Create the center wall geometry.
You do not need to worry about creating
the geometry at the appropriate depth
because we can use Modify > Force Depth
or Modify > Translate.
Note that it is not necessary to draw the
entire shape that is shown in order to
properly program this part. However, we
are drawing this for visualization
purposes.

91

Creating the Hinge Center Wall Creation

You will notice that both shapes are

magenta. This indicates that these
shapes were created in a different
coordinate system.

 Tutorials On Using Coordinate Systems 5 Axis Part: Hinge

Use Modify > Translate or Force Depth to

place this shape at a depth of Z: 38 and Z:
52mm.

Cut and paste this geometry into WG1.

Creating the Hinge Pocket Geometry CS

Pocket Geometry CS
We will now create geometry for a
pocket in the XZ plane. The pocket
will create the separation of the two
sides of the hinge. In order to make
the geometry we need a new
coordinate system.
Create a new CS named XZ top side.
Align the new CS to the XZ plane.
We will modify this new CS to be flush with the top of the part, with its
vertical axis aligned to the front profile geometry.
Switch to WG1 and align the CS origin

to the point shown.

Toggle Depth axis.

The CS should now be aligned to the Y+ side of the part. To correctly orient the axes of this
coordinate system, we will use the Align Vertical Axis button.

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Tutorials On Using Coordinate Systems 5 Axis Part: Hinge

Align Vertical Axis

to the line shown.

This will rotate the axis markers so

that the vertical axis aligns with the
selected line.
Make sure the line is still selected and click
the Align Vertical Axis button

again.

Creating the Hinge Pocket Geometry CS

Switch to the home view (Ctrl+H).

Our plane is now correctly oriented.

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Once an axis has been aligned, additional clicks

on the Align Axes buttons with geometry selected
will flip the alternate axis 180.

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 Tutorials On Using Coordinate Systems 5 Axis Part: Hinge

Pocket Geometry Creation

Create the pocket geometry as shown.

Creating the Hinge Angled Hole CS Creation

The pocket geometry should be flush with the end of the

part. The line that is on the edge of the part should be
designated as Air geometry so that when we machine the
geometry, the tool will overlap the geometry, creating an
open pocket.
At this point, you should have three coordinate systems and
two workgroups. Separating geometry into different
workgroups is not necessary however, it often simplifies
geometry creation.

Angled Hole CS Creation

To complete the part, we need to create one more CS for the
hole on the angled wall.
Create a new CS based on CS3 named Hole.
We will use a normal vector to correctly orient this plane.
Normal vectors are perpendicular to the plane.
Select the line shown which is the normal vector to the CS we wish to
create.

Click the Align CS button.

The Align CS button will attempt to align the plane through
the selected geometry. In the case where not enough
geometry is selected to accurately orient the plane, the
system will attempt to align the plane normal to the selected
geometry which is what we have done in this case. The
modified CS will be perpendicular to the line we selected.
Select the point shown.
The point is the vertex of the 90 angle on the center wall.

94

Air Geometry

Tutorials On Using Coordinate Systems 5 Axis Part: Hinge

Click the Change CS Origin button.

Creating the Hinge Angled Hole CS Creation

The picture shows the correct placement

and orientation of the plane in the top
view. The plane should be correctly
oriented with the positive depth axis
pointing out indicated by a + sign at the
center of the axis markers. If it is not,
toggle the depth.
Switch to the home view (Ctrl+H).
Create the circle for the drill hole.
The geometry for this part is now complete.
Save this file ( Hinge.vnc) as it will be machined in the Machining
section.

95

Creating the Hinge Angled Hole CS Creation

Tutorials On Using Coordinate Systems 5 Axis Part: Hinge

96

MACHINING CSS

Tutorials On Machining CSs 3 Axis Part: Angled Webs

CHAPTER 9 : Machining CSs

This chapter describes the uses of the Advanced CS option with a 3, 4 & 5 axis machine. The types
of parts described in this chapter require the creation of multiple coordinate systems to properly
define the part geometry and provide for accurate posted output. Multiple part programming and
tombstone programming will be covered in the following chapters.
This chapter is divided into two sections. Parts in both sections use multiple coordinate systems for
machining and do not involve rotary positioning.
In the first section, all of the parts are created using a 3 axis Machine Type and are posted with a
Standard Mill Post Processor. Coordinate systems are used to define part geometry in the
appropriate locations. Once that is done, the parts are programmed with the system as if they were
being done using the Production Mill Module.

3 AXIS PART: ANGLED WEBS

This exercise illustrates that contours that are defined in any Z plane (a plane where Z is an axis) can
be machined from the XY plane. This part will be machined with a 3 axis mill.

ABOUT THE PART

The geometry and coordinate system creation
was completed in the tutorial 3 Axis Part: Angled
Webs on page 79. This part is created using a 3
Axis Vertical Mill MDD. Some of the machining
operations for this part are pre-generated and all
of the required tools are already in the tool list.
This includes a 45mm Drill, a 13mm Rough
Endmill and a 45mm Rough Endmill.

99

Tutorials

The second section uses coordinate systems to utilize work fixture offsets for machining multiple
parts and/or multiple sides of parts in one program. These examples require an Advanced CS Post
Processor to produce the appropriate posted output which uses G55, G56, etc. for the work fixture
offsets. These exercises can be programmed to run on a 3 axis milling machine and use the standard
XY plane for all of the machining operations. However, an Advanced CS Post Processor is required
to use work fixture offsets.

 Tutorials On Machining CSs 3 Axis Part: Angled Webs

MACHINING THE ANGLED WEBS

The First Contour Process

Machining the Angled Webs The First Contour Process

The only thing that remains to be cut are the four webs to create the angled walls. Thus far all of the
machining operations could have been done with a standard mill. The operations we need to create
to cut the webs will follow the contours we created in the XZ and YZ planes.
Create this Contour process with tool #3.
Notice that the Floor Z value is 0.
This way the toolpath will follow the
contour and the depth of cut will be
determined by the selected contour.
The Floor Z value in the process
dialog controls the depth value in
reference to the geometrys
coordinate system. The value of 0 is
good to use if the geometry is at a
depth of 0 in the CS and the CS is in
the correct position. Also, the
Machining CS is the XY plane, not
the plane that the contour was
defined in. All of the web contours
will be machined from the XY plane.
Select the web contour from CS1 as shown.
The following picture is displayed from
the Front view. The current CS is the
XY plane.

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Tutorials On Machining CSs 3 Axis Part: Angled Webs

Click the Do It button.

Machining the Angled Webs The First Contour Process

Deselect the operation and repeat the

process for the other three webs as
shown.

The information in the

Contour process data remains
exactly the same. Simply select
the cut shapes and properly
position
the
machining
markers.

Render the contours.

This part is now complete.

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 Tutorials On Machining CSs 4-Axis Part: Slot Block

4-AXIS PART: SLOT BLOCK

Defining the Slot Block Setting Up the Slot Block

DEFINING THE SLOT BLOCK

The coordinate system construction and geometry
creation for this exercise were done in 4 Axis Part:
Slot Block on page 82. In this exercise we will
pocket the center of the part and we will face mill
and pocket both of the 32 coordinate systems.
Refer to the part print Slot Block on page 166 for
this exercise.
Open the Slot Block.vnc file.
In order to face mill and pocket the two 32
planes we need a machine with a rotary axis.
We will machine this part on a 4 Axis Vertical
Mill. While there are several ways this could be
set up, we will create the part as if it were
mounted to the machine on a fixture plate.
This is illustrated in the above image. The part is shown inside a transparent stock body which
is mounted to the fixture plate.

Setting Up the Slot Block

Open the Document Control dialog and select the 4 Axis Vertical Mill
MDD.

Adjust the stock values to X+100, 100, Y+250, 250,

Z+ 0, -125. Set the Clearance Plane to 25mm.

Click the Rotary Setup button

and enter

the information shown.

This specifies that the point of rotation is

the part origin. This would require that the
part be carefully positioned on the fixture
plate such that Z0 is actually at the center of
rotation.

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Tutorials On Machining CSs 4-Axis Part: Slot Block

MACHINING THE SLOT BLOCK

Tool Definition
We will use only two tools to machine this part, a Face Mill
and a Rough Endmill.
Create a Face mill with a 100mm diameter and a 75mm flute length.
Create a Rgh EM with a 25mm diameter. This is also a flat bottomed
tool.

Center Pocket Geometry

The first operation we will create will be a pocketing
operation to rough out the center portion of the block. In
order to do this we will need to create the pocket geometry.
Create 200x140mm rectangle at the origin in the XY plane. Define the left and right sides of the rectangle as Air
geometry so that we can easily machine this open pocket.

Notice the smaller sides of the rectangle are

designated as Air geometry so that the
pocketing routine will remove all of the necessary
material.

Air Geometry

103

Machining The Slot Block Center Pocket Geometry

This is a flat bottomed tool.

 Tutorials On Machining CSs 4-Axis Part: Slot Block

Operation 1, Pocketing the Middle

Create this Roughing process

Machining The Slot Block Operation 1, Pocketing the Middle

with the Rough Endmill.

In the Rotate tab ensure

that the Mach CS is set to
the XY plane. The Open
Sides data does not need
to be changed, the default
values are adequate.

Select the pocket geometry

and create the operation.

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Tutorials On Machining CSs 4-Axis Part: Slot Block

Operations 2 & 3, 32 Right Face

We will now create operations to face mill and pocket the 32 planes.
Create this Rouging process

Machining The Slot Block Operations 2 & 3, 32 Right Face

with the Face Mill.

We have designated a
material height of
65mm because the
stock material is well
above Z0. This will
ensure we do not
violate the part. The
actual stock extends to
a little more than
63mm above Z0.
Set the Mach CS option in
the Rotate tab to 32
Right.

Because
the
face
milling
roughing
option allows you to
face off the entire
stock, we can combine
the
pocketing
operation with the roughing operation in the same Process list.

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 Tutorials On Machining CSs 4-Axis Part: Slot Block

Create this Roughing process

Machining The Slot Block Operations 2 & 3, 32 Right Face

with the Rough Endmill.

The settings in the

Rotate tab do not need
to be checked. Simply
setting this option once
in a process will affect
all other processes in
the list.

Select the slot geometry and create the operation for the
slot.

Dont forget to deselect the previous operation

before creating this toolpath.
Render the part.

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Tutorials On Machining CSs 4-Axis Part: Slot Block

Operations 5 & 6, 32 Left Face

Now, we will machine the other 32 plane. We can use the same process group to machine the
other side.

Machining The Slot Block Operations 5 & 6, 32 Left Face

Deselecct the operation tiles.

Change the Mach CS in the Rotate tab to 32 Left.
All the other information in process dialogs should remain
the same. The other processes in the group will all change
their CSs as well.
Select the other slot geometry for the left side and create the
toolpath.

Render the part.

Note that you did not have to switch coordinate systems.
All of the operations to cut the part have been created.

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 Tutorials On Machining CSs 5-Axis Part: Hinge

5-AXIS PART: HINGE

ABOUT THE HINGE PART
The coordinate system construction and geometry creation for this exercise were done in the
exercise 5 Axis Part: Hinge in the previous chapter. Refer to the part print Hinge on page 167 for
this exercise.

SETTING UP THE HINGE

About the Hinge Part Rotary Set-Up

Open the Hinge.vnc part file.

You may recall that the part is 150x75x90mm (X+150 X-0, Y+75,
Y-0, Z+0 Z-90. This part will be programmed for a 5 Axis
Horizontal Mill. The part is gripped from the front (Y side). In
another situation we would probably leave more material on the
Y side of the part so that the part can be cut off, but for greater
visualization of the part we are not including the extra material
that would get cut off.

Rotary Set-Up
Open the Document Control dialog.

Click the Rotary Setup button

and enter the

information in the 5 Axis Setup dialog as shown.

The part is oriented so that the 4th axis is

centered in X and Z while the 5th axis is centered
in Z and 75mm below the bottom of part.
Set the parts Clearance Plane to 120mm.
It is a little more than 106mm from bottom-center of the part
(where the machine will rotate) to a top corner. 120mm will
give us adequate clearance when the part moves.

108

X
Y

Tutorials On Machining CSs 5-Axis Part: Hinge

Tool Creation
Create the following tool list:
#

Type

Total Length Diameter

Corner/Tip

# Flutes

Flute Length Material

1
2
3
4

Rgh EM
Rgh EM
Shell
Drill

75mm
100mm
75mm
75mm

13mm
0mm
0mm
118

2
2
4
2

50mm
80mm
50mm
N/A

75mm
26mm
50mm
8mm

HSS TiN Coated

HSS TiN Coated
HSS TiN Coated
HSS

MACHINING THE HINGE

Machining The Hinge Operation 1

Operation 1
The first operation will contour the
front side of the part. We will use the
rough endmill with the 13mm
bottom corner radius to create the
necessary fillet.
Create this Contour process with tool #1.
The cut depth of -38mm will cut to
the center wall of the part. With an
Entry Move & Exit Move of 38mm the
tool will plunge down, off of the part
by just more than its radius, then
feed into the part. We do not need to
enter any data in the Open Sides or
Rotate tabs.

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 Tutorials On Machining CSs 5-Axis Part: Hinge

Select the cut shape by positioning the

machining markers as shown.

The start and end point

markers are placed on the
connecting points at the edge of
the part.

Machining The Hinge Operation 2

Click the Do It button.

Operation 2
Next, we will contour the other
portion of the front side profile.
Create this Contour process with tool #2.
Note that we have a line and radius
value applied to the entry and exit
moves. Again, we do not need to set
anything in the Open Sides or Rotate
tabs.

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Tutorials On Machining CSs 5-Axis Part: Hinge

Select the cut shape by positioning the machining

markers as shown.

Click the Do It button.

Machining The Hinge Operation 3

Render the operations.

Now, we will contour the back side of the part. The
processes will be identical to the first two operations,
except for the machining CS and the selected cut shape.

Operation 3
Switch to the XY back side CS.
Change to the home view (Ctrl+H).
Double-click operation #1 to reload it.
Open the process dialog and change the Mach CS in the Rotate tab to XY
back side.

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 Tutorials On Machining CSs 5-Axis Part: Hinge

Select the cut shape by positioning the

machining markers as shown.

Machining The Hinge Operation 4

Click the Do It button.

Operation 4
As with Operation 3, the
information in the process
dialog for this operation is the
same as for operation #2,
except that the Machining CS
must be set to the XY back side
CS.
Double-click operation #2 to
reload it.

Open the process dialog and change the Mach CS in the Rotate tab to XY back side.
Select the cut shape by positioning the machining
markers as shown.

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Tutorials On Machining CSs 5-Axis Part: Hinge

Click the Do It button.

Machining The Hinge Operation 5

Render the part.

Operation 5
The next operation will pocket out
the top side of the part.
Switch to the CS, XZ top side.
Create this Roughing process with tool #2.
Set the Mach CS to XZ top side.

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 Tutorials On Machining CSs 5-Axis Part: Hinge

Select the pocket geometry

and click the Do It
button.

Machining The Hinge Operation 6

Render the operations.

Operation 6
In order to complete the part, we must generate operations
to create the angle on the center wall and drill the hole.
Switch to CS4: Hole and change to the home view (Ctrl+H).
First, we need to create a line in this CS so that we can create
a contouring operation which will create the angled wall.
Create a horizontal line at V=0.
The line should be terminated at each end so that we can
position the start and end point machining markers.

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Tutorials On Machining CSs 5-Axis Part: Hinge

Create this Contour process with tool #3.

Select Hole as the Mach CS.

Machining The Hinge Operation 6

The 25mm line gives us room for the tool to feed

onto and off of the part. The Surface Z value of
39.05102mm is acquired by interrogating any of
four points.

Select the new line and position the machining markers as shown.

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 Tutorials On Machining CSs 5-Axis Part: Hinge

Machining The Hinge Operation 7

Click the Do It button.

Render the operation.

Operation 7
The final operation drills the hole in the
angled wall.
Create this Holes process with tool #4.
Select Hole as the Mach CS as the machining CS.
A full diameter depth of -50mm will drive
the tool through the left side of the part.
Select the geometry for the hole and click the
Do It button.

All the operations to program the part

have now been completed.
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Tutorials On Machining CSs 5-Axis Part: Hinge

Render the operations.

Note that the hole goes through the left side of the part.
Normally, fourth and fifth axis rotary parts are processed
using a C-style post processor so that the rotations are
output in the code, rather than as a WFO. An example of
the output is seen to the right.

Machining The Hinge Operation 7

WFO Change
Rotation

Save this part.

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Machining The Hinge Operation 7

Tutorials On Machining CSs 5-Axis Part: Hinge

118

WORK FIXTURE
OFFSETS

Tutorials On Work Fixture Offsets

CHAPTER 10 : Work F ixture Offsets

We have seen how multiple coordinate systems allow us to manipulate the part and machine it.
Another use for multiple coordinate systems is to utilize work fixture offsets (WFO) to machine
multiple coordinate systems and/or multiple sides of parts in a single program. In order to use
work fixture offsets, parts must be post processed with an Advanced CS Post Processor, typically a
B-Style post.
This chapter contains two exercises which use WFOs. The first creates two parts, a left and right,
and machines them using WFOs. The second exercise machines the top and bottom sides of a part
in a single program.
When using work fixture offsets, the system matches each coordinate system with a WFO. This is
done in the order of the coordinate systems in the CS list dialog. CS1 is always WFO 1 (G54); CS2 is
always WFO 2 (G55); CS3 is WFO 3 (G56); etc. This can be over-ridden by specifying a WFO
number in the CS list, see WFO on page 25. By assigning a specific WFO number to a CS you can
more easily create and modify your part.

Tutorials
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 Tutorials On Work Fixture Offsets Family of Parts

FAMILY OF PARTS
In this exercise, we will create geometry for the left side of a part, mirror the geometry to create the
right side of the part, and then machine both parts in a single program using different machining
coordinate systems for work fixture offsets. The left side will be done in G54 and the right side in
G55. Refer to the part print Family of Parts on page 168 for this exercise.

MAKING THE MODEL

Part Set-Up
Making the Model Geometry Creation

Create a new metric part with a 3 Axis Vertical Mill MDD with the dimensions as
shown and a Clearance Plane value of 15mm.

Tool Definition
Create the following tool list:
#

Type

Total Length

Diameter

Corner/Tip

# Flutes Flute Length

Material

1
2
3
4
5

Face Mill
Fin EM
Rough EM
Drill
Fin EM

63mm
166mm
123mm
100mm
123mm

160mm
25mm
16mm
40mm
16mm

1mm
0mm
0mm
118
0mm

5
3
3
2
3

HSS TiN Coated

HSS TiN Coated
HSS TiN Coated
HSS TiN Coated
HSS TiN Coated

15.5mm
90mm
63mm
N/A
63mm

Geometry Creation
Create the part geometry with the center of the
D-hole at the origin.

You only need to create the outer profile

of the walls for the part, but you will also
need to create the inner profile of the
exterior wall for machining. The Plug-ins
> Create DHole will create the D-hole but
remember to add the radius to the flat
diameter (125) to get the proper flat
distance.
To create the geometry for the right side of the part, we will duplicate and mirror the left side
geometry.
Select all (Ctrl+A) of the geometry.

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Tutorials On Work Fixture Offsets Family of Parts

Choose Modify > Duplicate And... Mirror the

geometry about the X axis at 250mm.

G55 Coordinate System

Now, we will create a new coordinate
system for the right side of the part.

Making the Model G55 Coordinate System

Create a new CS and name it G55.

Select the point shown and click the Change CS Origin button.
Shift+drag to select the mirrored geometry and choose Modify > Change CS
(XYZ).

The geometry will remain in the same

location, however it is now defined in
CS2 and is drawn in blue and yellow
rather than magenta, indicating that it is
based on a different coordinate system.

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 Tutorials On Work Fixture Offsets Family of Parts

MACHINING THE PART

The geometry and coordinate
system creation is complete. Now,
we will create machining operations
to cut both sides of the part.

Machining the Part Deep Pockets

Face Mill
First, we will create an operation to
face mill the top of the part. We will
face off the entire stock in one
operations which will encompass
both sides of the part.
Switch to CS1.
Create this Roughing process with tool #1.

Click the Do it button.

Deep Pockets
Next, we will create operations to
pocket out the D-hole and slot. We
will use separate process groups for
each side of the part. This allows us
to set a different machining CS (G55)
for the right side operations. In the
posted output, the left side operations will use G54 and the right side operations will use G55.
The work fixture offsets will contain the origin shifts for each coordinate system.

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Tutorials On Work Fixture Offsets Family of Parts

Create this Roughing process with tool #2.

Make sure that the Mach CS is set to
the XY plane.
Select the D-hole and slot geometry on the
left side part and click the Do it button.

Deep Pockets - G55

Machining the Part Deep Pockets - G55

The same process can be used for

the right side pockets.
Make sure the operation tiles are
deselected in the Operations list.
Change the Mach CS to G55.

Select the D-hole and slot geometry on the

right side part and click the Do it button.

125

 Tutorials On Work Fixture Offsets Family of Parts

Contour
Next, we will create operations to
contour the outside profile of each
part.

Machining the Part Contour G55

Create this Contour process with tool #2.

Positioning the machining markers as

shown.

Click the Do It button.

Contour G55
Use the same Contour process with G55
selected for the Mach CS. Select the outside
contour of the right side part for the cut
shape. Click the Do it button.

The cut part rendered image should

look like the image to the right.
Thus far we have created the
operations in the relative order that
we want them to be machined. We
have alternated between machining
the left side and right side, using G54 and G55, to minimize the tool changes. Another method
would be to create all the operations to machine the left side part and then create the
operations to machine the right side. Once all of the Operation tiles have been created in the
Operations list, they can easily be arranged into optimal order for the most efficient machining.
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Tutorials On Work Fixture Offsets Family of Parts

For the remainder of the exercise, instruction will only be given on creating the operations to
machine the left side of the part. When youve created the left side operations, use the same
process information to create the operations for the right side of the part. Just remember that
you need to change the Mach CS to the G55 coordinate system in the process dialog for the
right side operations. The next set of operations will drill and pocket the two holes.

Holes
Create this Holes process with tool #4.

Machining the Part Holes

Create this Roughing process with tool #3.

Select the two circles and click the Do it

button.

Create the drilling and pocketing operations

for the right side part. Make sure that you
change the Mach CS to G55.

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 Tutorials On Work Fixture Offsets Family of Parts

Machining the Part Shallow Pockets

Shallow Pockets

128

Tutorials On Work Fixture Offsets Family of Parts

The final set of operations will pocket out the inside of the part, creating the 0.1" wall around
each of our pockets.
Create this Rouging process with tool #3.
Create this Contour process with tool #5.
Select the outside contour of the part and each of the four pockets inside. Click the Do it button.
Create the set of operations for machining the right side part using the same parameters in the process dialogs
using the Mach CS: G55.

When using work fixture offsets to machine multiple parts, a B Style Advanced CS Processor
should be used so that the code calls G54 or G55 for the offset shifts rather than specifying them
in the code itself. This way, the proper origin shifts can be entered at the machine in the work
fixture offsets to reflect the actual locations of the parts on the machine.

129

Machining the Part Shallow Pockets

All of the operations to machine both the left and right side parts have been completed.

 Tutorials On Work Fixture Offsets Top & Bottom Machining

TOP & BOTTOM MACHINING

In this exercise, we will create a program that will machine the top and bottom of a single part. This
is often accomplished using pallets and flipping the pallet for the back side of the part; a manual
fourth axis rotation. Because of this, we will program this part for a 4-axis vertical machine, in order
to generate accurate code. However, this part is designed to be machined on a 3-axis machine with a
manual flip for the back side operations. We will insert a program stop to facilitate the flip. Refer to
the part print Top & Bottom on page 170 for this exercise.

MAKING THE MODEL

Part Set-Up
Making the Model CS Creation

Create a new metric part with a 4 Axis Vertical Mill MDD. The
part should have stock dimensions as shown with a Clearance
Plane value of 250mm. Select a die cast aluminum alloy for
the part material if you have the CutDATA material database.

Click the Rotary Setup button

and enter
information into the 4 Axis Setup dialog as shown.

A Master Clearance Plane value of 250mm will give us plenty of room to

rotate the part about the Y axis.

CS Creation
First, we will create a new coordinate system for the back side of the part.
This CS will be the XY plane with a different origin. The way we have set up
the part, we will be using the Y axis as the rotation axis around which the

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Tutorials On Work Fixture Offsets Top & Bottom Machining

part will be flipped. The following diagram is intended to illustrate how to visualize where the
origin should be for the back side coordinate system.

Y Axis
Origin 1
to
Bot
Origin 2

Top

Top

Origin 1
Origin 2

Origin 2

tom
B ot
Origin 2

Making the Model Geometry Creation

Origin 1

X Axis

Origin 1
4th Axis Y Flip

4th Axis X Flip

Create a new CS and label this CS Back Side.

Click the Change CS Origin button in the CS
palette and enter the information shown.

Toggle the depth

of the CS.

The parts coordinate systems are set.

We will now create the part geometry.

Geometry Creation
Switch to the Home view for CS2, Back Side.

You can use the part model on the track

ball to get an idea of the orientation of
this CS in relation to the top of the part
indicated by the T on the model.
Create the geometry for the back side of the part
which is drawn in view B-B on the part print.

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 Tutorials On Work Fixture Offsets Top & Bottom Machining

Switch to CS1: XY Plane. Create the top side

geometry shown in view A-A on the part print.

All of the geometry and coordinate

systems are now correctly defined. We
will now move on to setting up the
machining of this part.

MACHINING THE PART

Tool Definition
Machining the Part Tool Definition

Create the following tool list:

132

Type

Total Length

Diameter

Corner/Tip

# Flutes

Flute Length

Material

1
2
3
4

Rgh EM
Fin EM
Drill
Drill

110mm
110mm
82mm
120mm

12mm
12mm
6mm
12mm

0mm
0mm
118
118

3
3
2
2

53mm
53mm
N/A
N/A

HSS TiN Coated

HSS TiN Coated
HSS TiN Coated
HSS TiN Coated

Tutorials On Work Fixture Offsets Top & Bottom Machining

Top Side Pocket

First, we will create the operations
to machine the top side pocket.
Create this Roughing process with tool #1.
Be sure to select CS 1 as the Mach CS
in the Rotate tab.

Machining the Part Top Side Pocket

Create this Contour process with tool #2.

Select the pocket and island geometry and

click the Do It button.

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 Tutorials On Work Fixture Offsets Top & Bottom Machining

Top Side Holes

Create this Holes process with tool #3.
Select the points or circles for the top side drill
holes and click the Do it button.

Machining the Part Top Side Holes

Holes operations can be applied to either

points or circles.

Render the operations.

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Tutorials On Work Fixture Offsets Top & Bottom Machining

Inserting A Program Stop

The operations to machine the top side of the part are complete. Now, we
need to insert a program stop into the posted code before the back side
operations. The program stop will allow for the flipping of the part. A
program stop can be specified in the Operation Data dialog of any
operation.
Right-click the operation tile and select Operation Data.

Selecct the Program Stop option in the Operation

Data dialog.

This will create a program stop, usually

M0, in the posted code after operation #4 has been completed. Additionally, we inserted an
operation comment, Flip the part, that will show up in the posted output.

Back Side Pocket

Now, we need to program the
operations to cut the back side of
the part. We need to make sure the
Mach CS is set to the Back Side
coordinate system.
Create this Roughing process with tool #1.
Be sure to select CS 2 as the Mach CS
in the Rotate tab.

135

Machining the Part Back Side Pocket

Another way to access the Operation

Data dialog is by double-clicking on the
tab for the operation tile. The operation
tab is the item that has the number of the
operation on it.

 Tutorials On Work Fixture Offsets Top & Bottom Machining

Machining the Part Back Side Pocket

Create this Contour process with tool #2.

Select the slot on the bottom side of the part

and click the Do it button.

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Tutorials On Work Fixture Offsets Top & Bottom Machining

Back Side Holes

Create this Holes process with tool #4.
All of the operations to machine both
the top and bottom of the part have
been completed.

Machining the Part Back Side Holes

When using work fixture offsets to

machine different sides of a part, a B-Style
Advanced CS Processor should be used to post
the file. The operations that machine the top
side of the part will all be done in G54. Then
there will be a program stop in the program so
the operator can flip the part. The back side
operations will be done in G55 so the origin shift
for G55 must be entered for the work fixture
offset correctly at the machine. The highlighted
rows show the Program Stop and the rotation.
137

Machining the Part Back Side Holes

Tutorials On Work Fixture Offsets Top & Bottom Machining

138

TOMBSTONE
MACHINING

Tutorials On Tombstone Machining Tombstone Machining

CHAPTER 11 : Tombstone Machining

TOMBSTONE MACHINING
There are several ways to accomplish tombstone machining with the system. All of them require
the Advanced CS option and a CNC machine capable of handling B-axis numbers in the WFO. The
post processing is the same for all methods. The following three sections go over the different
methods. The pictures shown below show our perspective of the tombstone and parts. Refer to the
part print Tombstone Machining on page 169 for dimensional data.

Top view

Front view

Clamp

Clamp

Clamp

Clamp

Tombstone

Clamp

Clamp

Clamp

4 - Fourth part
5 - Front view of first part
6 - Left side of second part

Tutorials

1 - First part
2 - Second Part
3 - Third Part

7 - Right side of fourth part

8 - Origins

Figure 9: Top and Front views of a Tombstone Setup

METHOD 1: PER THE MACHINE

In this example we will create what will actually
be happening at the machine. The initial stock
size will encompass the tombstone, and the first,
second, and fourth part. For this example, we are
looking at the front view, as shown above. We
will create the geometry and operations
necessary to machine everything available from
the front view; the front side of the 1st part,
the right side of the 4th part and the left side of
the 2nd part. Then the post processor will be
used to duplicate this information for the other
three sides of the tombstone. This method has
the benefit of allowing us to see the tool move
from the side of one part to the face of another
so that we can check for tool interference. This
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 Tutorials On Tombstone Machining Tombstone Machining

example is created in the sample part Tombstone Method 1.vnc.

Part & CS Set-Up

Set-up a 4 axis horizontal part with the stock size large enough to encompass

Method 1: per the Machine Part & CS Set-Up

the first part, second part, fourth part, and the tombstone including the
clamps.

We will create three coordinate systems, one for each side of the
part. All of these coordinate systems will be set in the XY plane,
but will have different origins. The advantage to setting three
separate planes is that the information entered in the machining
process dialogs such as the clearance positions and cut depths are
relative to the origin and coordinate system in which you are
working. The images in this tutorial show a part with custom
stock that encompasses the tombstone and all four parts.
In the standard XY plane create origin points for each of the sides.
These origin points can lie anywhere in the plane. For
the part that we have included for the first example we
chose the bottom left hand corner of each side to act as
the origin.

Create a new CS. Change the origin to the origin point you
created for the 1st part. Label this CS Front view of 1st
part.

Create a new CS (CS3). Change the origin to the origin point

you created for the 4th part. Label this CS Right view of
4th part.

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Tutorials On Tombstone Machining Tombstone Machining

Create a new CS (CS4). Change the origin to the origin point

you created for the 2nd part. Label this CS Left view of
2nd part.

Machining
Switch to CS2. Create a new workgroup. Label this workgroup
Front of 1st part. In order to better visualize whats
going on, create an outline for the stock size of the front of the
part. Create the geometry and operations for the machining of this side.

Method 1: per the Machine Machining

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 Tutorials On Tombstone Machining Tombstone Machining

Switch to CS4. Create a new workgroup. Label this workgroup

Left side of 2nd part. Create the stock outline for
the left side. Create the geometry and operations for the
machining of the left side. In the sample file there are two holes
on the left side.

Switch to CS3. Create a new workgroup and label this workgroup

Method 1: per the Machine Machining

Right side of 4th part. Create the stock outline

for the right side. Create the geometry and operations for the
machining of the right side. In the sample file there is one
drilled hole on the right side.

The rendered image will not look correct unless extra

operations are created to clear off the extra stock
between the parts. This can be done by creating
contour operations with a large tool to wipe off the
excess on each side. These operations should be
thrown away before post processing. In our example
we have cleared off the excess stock. This is not
necessary, but does make the rendering process more
visually representative.

144

Tutorials On Tombstone Machining Tombstone Machining

METHOD 2
In this example we will create one complete part, as if we were simply machining a single unit.
This allows us to verify that the toolpaths will generate the correct part. It is especially useful
when checking to make sure cuts made in one side intersect cuts made on another where they
are supposed to.
When were finished, we can do one of two things. We can either post process the file as is and
strip out the extra B moves from a C or D style processor (there will be three of them,) or we
can create new coordinate systems like in example one and unfold the part so it looks like it
would on the tombstone. Unfolding the part is more work inside of the system, but it does help
us see the part as it would be machined.

Method 2 Part & CS Set-Up

Part & CS Set-Up

Set-up a 4 axis horizontal part. The stock dimensions should be that of a single part.
We will create three coordinate systems, one for each side of the part.
The first CS will be for the front side of the part and will lie in the XY
plane. The second CS will be for the right side of the part and will lie
in the -YZ plane. The third CS will be for the left side of the part and
will lie in the YZ plane.
Again, in the standard XY plane, create origin points for each of the sides.
These origin points can lie anywhere in the plane. For the part that
we have included as Example 2, we chose the bottom left hand
corner of each side to act as the origin.
Create a new coordinate system (CS2).
Change the origin to the origin point you
created for the front side of the part. Label
this CS Front side.

Create a new CS (CS3). Set the plane to the

YZ plane. Change the origin to the origin
point you created for the right side of the
part. Label this CS Right side.

Front Side

Right Side

Create a new CS (CS4) Toggle the depth.

Change the origin to the origin point you
created for the left side of the part. Set the
plane to the YZ plane. Label this CS Left
side.

Left Side

145

 Tutorials On Tombstone Machining Tombstone Machining

Machining
Switch to CS2. Create a new workgroup and
label the workgroup Front side. Create
the geometry and operations for the machining
of the front side. In the sample file named
Tombstone Method 2.vnc, there are 2
operations on the front side of the part.

Switch to CS3. Create a new workgroup. Label

Method 2 Unfolding a Part

this workgroup Right side. Create the

geometry and operations for the machining of
the right side. In the sample file there is one
drilled hole on the right side.

Switch to CS4. Create a new workgroup. Label

this workgroup Left side. Create the
geometry and operations for the machining of
the left side. In the sample file there are two
holes drilled on the left side.

If you render the part at this point you will be

able to see what one finished part will look
like.

If you are using a B or C style post

processor, you can post process the part
now. If you process at this point you will need to remove the B axis moves and change the
numbers at the control for the origins of the WFOs. If you are using a D style post processor,
you must unfold the part before post processing.

Unfolding a Part
When you unfold a single part, it will work
the same as method 1. To unfold a single
part, we need to change the three coordinate
systems so that they match the ones we
created in Example 1. The sides will
automatically unfold out and move into
position. We will also change the stock size to
encompass parts one, two, and four, as well as
the tombstone.
Switch to CS1, the XY plane. Create origin points for the
three side. These origin points will be in the same
locations as the origin points in Example 1, Front view.

146

Tutorials On Tombstone Machining Tombstone Machining

Switch to CS2, the Front side. Change the origin to the new origin point you created for the Front side. When you
switch the origin of the plane, the operations that you created in that coordinate system should shift accordingly
so you do not need to adjust or reprocess the operations.

Switch to CS3, the Right side. Change the origin to the new origin point you created for the Right side. Note that
the origin for the plane containing the right side is actually on the far left side when it is unfolded because in this
set up we are machining the right side of the fourth part which is attached to the tombstone on the left. (see front
view picture on the 1st page) Also, you need to set this CS to the XY plane.

Switch to CS4, the Left side. Change the origin to the new origin point you created for the Left side. Again, the
origin for the left side appears on the right side in this set up. Also, you need to set this CS to the XY plane.

METHOD 3

147

Method 3 Unfolding a Part

This example is designed to reduce the number of WFOs needed to machine the part. Instead
of creating different coordinate systems, we will simply use the standard XY plane. You only
need one WG and one CS. All geometry is created and machined in the standard XY plane.
Basically, this is how tombstone milling would be accomplished without using the Advanced CS
module. Using this method the depth values need to be calculated and entered in the process
dialogs. The rendered image will have the same problems as Example 1. To solve this you will
need to create temporary operations to remove the excess stock. This method is useful if your
machine can only handle a small number of WFOs.

 Tutorials On Tombstone Machining Post Processing

POST PROCESSING
Using any of the methods outlined above, once you have created the part, post process the file using
work fixture offsets and 4 parts. Advanced CS post processors come in three styles.
B Style: WFOs used for origins and indexing for single and multiple parts.
C Style: WFOs used for origins for single parts. WFOs used for origins and indexing between

parts for multiple parts.

D Style: WFOs only used for indexing between multiple parts.

Method 3 Unfolding a Part

If your CNC machine does not have the number of WFOs required to machine the part, B and C
style processors will revert to D style.
The indexing must be handled by the work fixtures. The first three work fixtures will be at B0, the
next three at B90, the next three at B180, etc. If there are partial rotations for the parts, they will be
handled by creating additional coordinate systems and will result in more than three coordinate
systems per side. The actual rotation to get to these other sides will show up as BXX commands in
the code for the C and D style processors. Since each side will have the correct rotation for the part
in the WFO, the partial rotations will work fine. The B style post will output a comment containing
the partial rotation amount. For the parts on the second, third, and fourth sides of the tombstone,
the 90 index increment will need to be added to the partial rotation amount.

148

CREATION &
MACHINING
CONCEPTS

Tutorials On Creation & Machining Concepts Multiple Part Origins

CHAPTER 12 : Creation

& Machining

This chapter contains short, how-to tutorials. Each tutorial is focused on a topic, such as making a
bottle mold, working with multiple part origins or driving a tool along the Z axis.

MULTIPLE PART ORIGINS

USING MULTIPLE CSS FOR GEOMETRY CREATION
In this exercise, we will use multiple part origins to simplify the creation of geometry. The different
part origins will not be used with work fixture offsets as they are in Family of Parts or Top &
Bottom Machining exercises found in the chapter, Work Fixture Offsets on page 119. Rather, it is
the way the part is dimensioned that makes using different part origins the best way to create the
part geometry. This exercise uses a standard Mill post processor and a 3-axis MDD. Refer to
Multiple Origins on page 171 for this exercise.

Part Creation
Create a new metric part using a 3 Axis Mill MDD with a stock size of
X=-5, 300; Y= -5, 225; Z= -25, 0.

Create the geometry for the outside contour

that is dimensioned from the 0, 0 origin on
the part print.

Second CS
The line that connects the angled lines
to complete the outside contour is
dimensioned from a different origin
on the print. While we could figure
out the dimensioning for this line, it
would take a bit of work. Instead, we
will create another coordinate system
with a new origin.

151

Tutorials

First, we will create the outside contour of the shape. All of the lines that compose the outside
contour, except for one, are easily created in CS1.

 Tutorials On Creation & Machining Concepts Multiple Part Origins

Using Multiple CSs for Geometry Creation Completing the Geometry

Create a new CS and select the point shown to

as the origin.

The new CS is an exact duplicate of the

standard XY plane; the only thing that
has changed is the origin. To further
modify the new CS, we will set the
horizontal axis to one of the angled
lines. This will not change the planar
location of the coordinate system, only
the CS grid orientation.
Align the horizontal axis to the line shown.
Now, the angled line that completes
the outside contour is very simple to
create. You can simply define the line
as a vertical line with an H value of
200mm.
Create the line to finish the outside contour
and the hexagon while working in CS2.

Completing the Geometry

Switch to CS1 and select the hexagon and line
we just created in CS2.

Choose Modify > Change CS (XYZ).

All of the part geometry should now
be either yellow or blue in CS1
indicating that it is based on the
current CS.
Connect the outside contour and create the bolt
hole pattern to complete the part geometry.

Your screen should look like the

picture to the right.

152

Tutorials On Creation & Machining Concepts Multiple Part Origins

Using Multiple CSs for Geometry Creation Completing the Geometry

The part can be machined just as it would be if

you were working with the Production Mill
Module. All operations should have the
Machining CS in the process dialogs set to
CS1: XY Plane.

153

 Tutorials On Creation & Machining Concepts Bottle Mold

BOTTLE MOLD
In this exercise we will make a bottle mold. This exercise uses a pre-existing part file that contains
the bottle profile and a tool.

About Bottle Molds Creating the Base Curve

ABOUT BOTTLE MOLDS

Bottle molds are created in the system using the 2 1/2 axis surfacing capabilities. More specifically,
bottle molds are created using the swept shape option for machining contours. Swept shapes are
created by designating a base curve, which is the cut shape, that will be machined based on a drive
curve. The drive curve designates the shape of the wall that will be swept around the base curve to
create the surface.
For bottle molds, the base curve is an arc and the drive curve is the contour that represents the
shape of the bottle. Normally, the base curve is defined in either the XZ or YZ planes and the drive
curve is defined in the standard XY plane. All machining will be done from CS1, which is the
standard XY plane.
The general rule when creating bottlemolds is that the depth axis of the base curve must align with
the vertical axis of the drive curve (the bottle profile). When the Machining CS and the drive curve
plane are perpendicular, the system will output G17, G18 and G19 codes to provide for the
machining of the arc rather than breaking it into line segments.

CREATING THE BOTTLE MOLD

For this part, we will create the base curve, which is a 13mm arc in the XZ plane. The drive
curve, which is the shape of the bottle in the XY plane, is already created to save time. We will
need to properly position the drive curve to complete the part. Refer to Family of Parts on
page 168 for this exercise if you need to recreate the profile shape.
Open the file Bottle Mold.vnc, which is located in the Part Files > Advanced CS folder.
This part is set up to use a 3 Axis Vertical Mill. The Clearance Plane value of 15mm is plenty of
clearance over our X:10/+193, Y: 10/+70, Z: 50/0mm part.

Creating the Base Curve

First, we will create the base curve geometry, which is a 13mm arc in the YZ plane.
Create a new CS.
Modify the CS to the YZ plane.

154

Tutorials On Creation & Machining Concepts Bottle Mold

Click the Toggle Depth button.

In this coordinate system we will create
the base curve geometry, which will be
an arc.
Create a 13mm circle in the YZ plane around

We need to create terminator points to create the semi-circle (arc)

that will act as our drive curve.
Now, we will create the drive curve geometry which is the contour
of the bottle. There must be terminators at both ends of the drive
curve.
Correctly positioning the drive curve is very important in order to generate the desired
toolpath. The general rule is that the vertical axis of the drive curve is going to align with the
depth axis of the base curve.
In this exercise, we will create the drive curve geometry in CS1, which is the standard XY plane.
Once the geometry is created, we will 2D Rotate the contour 90 so that the vertical axis of the
drive curve will correctly align with the base curve depth axis.

155

Creating the Bottle Mold Creating the Base Curve

the centerpoint H -31, Z0, D0.

 Tutorials On Creation & Machining Concepts Bottle Mold

Change to CS1 and create the drive curve geometry.

Refer to the part print for the dimensions.

Creating the Bottle Mold Creating the Base Curve

The drive curve geometry does not need to be

created in position because we will be rotating
it. However, it is drawn in the following picture
in position for visualization purposes.
Now, we need to rotate the drive curve 90 so
that it is oriented correctly.
Make sure that you are working in CS1. Select the drive
curve shape. Choose Modify > 2D Rotate and enter the
information shown.

The orientation of the drive curve is what is

important, not its' exact location in the coordinate
system. As long as the shape is rotated 90, the point
around which it is rotated is not important. The
location of the bottle mold toolpath will be
determined by the base curve, which is in position.
Next, we will create contouring processes which will
generate the bottle mold toolpath.
Create a 10mm Ball Endmill.

156

Tutorials On Creation & Machining Concepts Bottle Mold

Create this Contour process with the

ball endmill.

Creating the Bottle Mold Creating the Base Curve

Since our flute length is smller

than our final depth of cut we
will need to do this contour in
several Z passes. Z stock will
create the contour toolpath
and translate the cut in Z the
distance specified. We will take
two passes with Z stock
applied before taking the final
cut. The only information we
really need to be concerned
with is entered in the Wall
Choices dialog.
Click the Wall Control button and
enter the information shown.

Select the arc as the base curve. Set

the direction to contour into the arc.

The machining markers that

appear
for
contouring
operations will come up on the
screen. The D-marker, which
designates the drive curve for
swept surfaces, will also appear.
Click the Do it button.
Using the same process, create 2 more contour ops
with Z Stock at 7 and then 0.

157

 Tutorials On Creation & Machining Concepts Driving the Tool In Z

DRIVING THE TOOL IN Z

ABOUT THE PART
In this exercise we will start with a mostly completed
part. We will add the finishing touches be adding
grooves along the edges of the part.

Start

Finish

Open the part file Z Machining.vnc from the Part Files

> Advanced CS folder.

About the Part Profile Shape

If you would like, now is a good time to run cut

part rendering as it will help you familiarize
yourself with the part.

Setting Up the Part

From the XZ plane copy (Ctrl-C) the profile geometry (the magenta geometry).
Create a new WG called Grooves and a new CS called CW 22.5.
Paste the copied geometry into the Grooves WG.
You may note that the geometry is still magenta. That is because the geometry is still assigned
to the XZ plane. We will need to change that.
If you are not already it, switch to the CS CW 22.5.
Assign the geometry to the current CS using Change CS (XYZ).

MODIFYING THE GEOMETRY

Profile Shape
We used a 13mm BEm to cut the part, so we have a 6.5mm radius on the
bottom of the part. We will be driving the tool onto the part and up the
profile but the profile stops at the top of the fillet. Therefore, we need to
create the geometry to replicate the fillet. This way the tool can start off
the part and cut up the edge of the part.
Make a vertical line tangent to the right side of the profile.
Make a horizontal line 6.5mm below the profile.
Create a circle with a 6.5mm radius between the two lines. The circle will arc down and to the right from the
profile, as shown in the image.

158

Tutorials On Creation & Machining Concepts Driving the Tool In Z

Connect the new arc to the profile geometry and terminate the line at the stock boundary
(X=42.5mm).

You may delete the vertical line, but do not delete the horizontal line. In fact,
make sure the horizontal line is connected to the arc we will use it for
driving the tool onto the part. The line does not need to be terminated.

Modifying the Geometry Making the Grooves

Making the Grooves

To create the groove profiles we need to duplicate the
geometry, and then duplicate and rotate the
geometry and the CS into the proper positions.
Select the profile geometry. Duplicate and mirror the geometry
about the X axis.

Deselect the geometry.

You should now have identical geometry on both
sides of H0. We now need to rotate the CS &
geometry. Deselecting the geometry is important as
we are going to be modifying the CS origins.
Open the CS Align dialog and rotate the CS clockwise about
the Z axis by 22.5.

The geometry should move with the CS. If the

geometry does not move, Undo the rotation and
change the CS Preferences by right-clicking the CS
list title bar.
Rotate & Duplicate the CS 3 times by 45around Z.
2D Rotate & Duplicate the geometry 3 times by 45around X0Y0 (from the XY plane).
You should now have four pairs of profile geometry that align to four planes.
Assign each pair of geometry profiles to the planar CS.
It is important to get the geometry into the proper CS at the proper depth because the
machining depth is specified by the geometrys CS.

159

 Tutorials On Creation & Machining Concepts Driving the Tool In Z

MACHINING THE GROOVES

Contour Operations
To machine the part we will need to
select each profile shape and apply a
contour process to it.
If you are not already in it, switch to XY

Machining the Grooves Contour Operations

plane.

Select each profile shape geometry

individually and apply the machining
settings as shown to make an operation for
each shape. You will need to repeat this
seven times.

Be sure to deselect each operation

tile before selecting the next profile
geometry and making the next
operation.
Render the operations.

160

Tutorials On Creation & Machining Concepts Rotary Milling

ROTARY MILLING
Rotary milling can be done in any CS whose origin is at the part origin & whose axis of rotation
lies in the origins planes. The rotary machining motion is always about the axis with 360 of
rotation. Rotary milling may not be done around an axis perpendicular to the parts rotary axis,
which means you may not do B-axis rotations or rotations about the 5th axis.

THE ROTARY PART

About the File

Open the part file Rotary Text.vnc.
This part is partially complete with pre-existing ops including 3 drilling operations and a rotary
milling operation. This drilling operations require Advanced CS to make the YZ plane &
machine from it. The rotary operation does not need Advanced CS. That is done in a Rotary
Milling WG. One point is made, (in this case X4, A-90, R35) a second point is made at the end
of the spiral, including rotations (X46, A1350, R35) and a line is connected between the points.
The angle is determined by multiplying the # of rotations by 360 plus the starting points angle,
in this case (360x4)+(90).

161

The Rotary Part About the File

We will now do a quick exercise that goes over

some of the ways coordinate systems may be
used with rotary machining. We will start with
an existing part with a rotary operation. We will
make a new CS, define some text geometry and
engrave the text shapes.

 Tutorials On Creation & Machining Concepts Rotary Milling

MAKING THE TEXT

CS & Geometry
Make a new CS and set it to the XZ plane.
Move the CS origin as shown.
Rotate the CS about the depth axis by 45 clockwise as
shown to the right. Name the CS XZ mod.

Create text geometry as shown. Be sure that you are in

Making the Text Contour Process

WG1 as it is a rotary milling WG.

MACHINING THE PART

Contour Process
Using tool #5 (a 3.15mm center drill)
create a Contour process to engrave the
text using the parameters shown. Be sure
to set the rotate tab as shown.

When rendered the part should

look like the following image.

162

PART PRINTS

96 mm

8 mm

96 mm R 64 mm

R 56 mm

Part Print 1: Angled Webs

8 mm

R 6 mm

R 7 mm

R 25 mm
R 6 mm

R 7 mm

200 mm

38 mm

12 mm

25 mm
64 mm

165

166

120 mm

125 mm

25

mm

46
50

mm

140 mm
60 mm

500 mm

60 mm

148

125 mm

50 mm

R 25 mm

Part Print 2: Slot Block

50 mm

200 mm

24 mm

13 mm

14 mm

90 mm
R 13 mm
38 mm

Part Print 3: Hinge

15 mm

R 13 mm

75 mm
24 mm
90
130
62 mm

A-A
R 25 mm

R 37.5 mm

13 mm

100 mm
14 mm

r 4 mm
32.7677 mm

A-A
7 mm

167

35
115

210

R 25 x7
115

R 30

R 70

30

225

Part Print 4: Family of Parts

60
55

5 mm

X0, Y0
380

R 30
180

X0, Y-170

25

30

55

130

R 65
135
90

135

195

35
Z-55
Z-25 x2

Z-55 x4

Z-30 x4

168

125

Part Print 5: Tombstone Machining

100

10
X0, Y0
140

20

Z50

R 20

Z50

169

10

100 80

A'

12.5

37.5

62.5

100
200

R3

75

Z-25

Z-38

25

R6

Part Print 6: Top & Bottom

50

A
B'

170

50
A

171

125 95

15

19

15

80
125

16

143

R 4.5

75

125

Z-13

200

Part Print 7: Multiple Origins

62.5

125

172

13

20

R5

R 25

10

190

145

R 13
R 13

95

Part Print 8: Bottle Mold

58

173

16 mm

52.5 mm 18.75 mm

82 mm

65.6 mm

R 4.7 mm x8
13 mm

100 mm

R 19 mm

Part Print 9: Z Machining

6.5 mm
41 mm

73 mm

1.7 mm

28 mm

97

R 14 mm
10 mm

31 x2

R 7 mm

R 5 mm

9 mm
8 mm

174

GLOSSARY

Glossary

CHAPTER 14 : Glossar y
Axes

Fixed, intersecting, perpendicular lines that lie in the same plane. The three axes
are the horizontal (H), vertical (V) and depth (D) axes. In the standard XY Plane,
the X axis is the horizontal axis, the Y axis is the vertical axis and the Z axis is the
depth axis.

Axial

Term used to describe the state of being around, on or along an axis.

Axial Alignment

Axial Alignment refers to the alignment or position of an axis.

Cartesian Coordinates

A pair of numbers that locate a point in a plane by its distances from two or
more axes.

Coordinate System

A plane in space with an origin and three axes.

CS

Short for Coordinate System.

Normal

Geometry or planes are normal when they are perpendicular or at right angles.
Also the point of tangency between a line and a curve.

Origin

The origin is the point at which the axes of a coordinate system intersect and
serves as a zero reference point.

Parallel

Lines and planes are parallel when the lines or planes extend in the same
direction and are the same distance apart at every point.

Perpendicular

A line or plane is perpendicular when it is at right angles to a given plane or line.

Planar

A term used to describe two or more items when they lie in the same plane.

Plane

A flat, even surface that wholly contains every straight line joining any two
points lying in it.

Primary Plane

There are three primary planes for milling parts, the XY, XZ and YZ planes.

Right Hand Rule

The Right Hand Rule is used to help you visualize the Horizontal, Vertical and
Depth axes of a coordinate system. See page 11.

Tangent

Geometry or a plane is at a tangent (or tangential) when it is touching and not

intersecting a line, curve or curved surface at only one point.

WFO, Gibbs

Work Fixture Offset as seen by the GibbsCAM system.

WFO, Machine

Work Fixture Offset set on your control.

177

 Glossary

178

INDEX

Index

NUMERICS

4 Axis Setup: 16

Change CS (HVD): 24, 26

5 Axis Setup: 17

Change CS (XYZ): 24, 26

90 Rotate Axis: 35

Change CS Origin: 28
Change CS Origin dialog: 28
Clearance Planes: 18

Clearances, display of: 40

Coordinate System: 3
Definition: 7
Machining: 39

Advanced CS: 54
Align Axes: 10
Align CS: 33
3D Points: 35
No Geometry Selected: 35
Rotate: 35
With Geometry Selected: 33
Align CS Right Mouse Menu: 34
Align H Axis: 29

Coordinate Systems
Creating: 9
Creating & Modifying: 12
Creating & Modifying Options: 26
Show & Hide: 25
Create CS & Align H Axis: 29
Create CS & Align Plane Normal: 35
Create CS & Align Plane Thru: 35

Align H Axis & Move: 29

Create CS & Align V Axis: 31

Align Plane Normal: 34

Align Plane Normal & Move: 34
Align Plane Thru: 34

CS Frame Indicator: 23, 25

CS Grid: 12, 21

Axis of Rotation Position, 4-axis: 16

CS List
Eyeball Icon: 25
New CS: 26
Pop-Up Menu: 24
Right Mouse Menu: 26
WFO: 25, 44

Axis of Rotation, 4-axis: 16

CS list: 9, 25

Axis of Rotation, 5-axis: 17

CS List Number: 25

Align Plane Thru & Move: 34

Align V Axis: 31
Align V Axis & Move: 31
Axis Markers: 12, 21

CS Name: 25
CS Origin: 21

B
B-Style Post Processors: 51

CS Palette: 28
CS Preferences: 26
Geometry References: 27
Out of Plane Rotation: 27
Self Definition: 27

181

 Index
Set New CS Visible: 27
Toolpath References: 27

C-Style Post Processors: 52

Level 2 Interface: 21

Delete CS: 26
Depth Polarity: 10

Machining Coordinate System: 39, 43

D-Style Post Processors: 52

Main (top level) palette: 24

Master Clearance Plane: 18, 54
MDD (Machine Definition Document): 15

F
N

Flip Axis: 29, 32

Fourth & Fifth Axis Positioning: 43
New CS: 26
New CS from View: 26

G
O

G54: 25
Geometry, Reassign CS: 24

Operation Clearance Planes: 18

Graphics Preference: 22

Origin: 7
Change: 28

Origin of a plane, changing: 11

H and V Arrows: 21

Home View: 12, 21

Horizontal Axis Align: 29
Right Mouse Menu: 29

Plane Orientation: 10

HV Angle: 30, 32

Position (Process Option): 39

HV Point: 30, 32

Position of Axis of Rotation, 5-axis: 18

Post Processors: 51
3-axis: 52
B- & C-Style Output: 55

182

Index

Designations: 53
D-Style Output: 55
Types: 51
WFO: 51

Right Mouse Menu: 31

View Control palette: 21

W
R

Work Fixture Offset: 25, 121

Work fixture Offsets: 44

Red Intersecting Lines: 23

Reversed Rotary Limits, special MDD: 15

Workgroups: 7

Right Hand Rule: 11

Rotary: 16

Rotary Mill: 54
Rotary Milling (Process Option): 39
Rotary Setup: 1516, 44

XY Plane: 36
XZ Plane: 36

S
Show CS button: 21

Y
YZ Plane: 36

Simple Positioning: 54

T
Table Diagram, 4-axis: 16
Table Diagram, 5-axis: 17
Toggle Depth: 36
Tool Approach: 39
Toolpath Display: 40
Top Level palette: 24

V
Vertical Axis Align: 31

183

 Index

184